Small wire diameter low odor automotive wire

Abstract

This invention provides a small-diameter, low-odor automotive wire, comprising a conductor layer and an insulation layer arranged sequentially from the inside out. The conductor layer has either a type A structure with 7 stranded copper wires or a type B structure with 16 stranded copper wires. The insulation layer is made of QCJ-105A insulating material. The automotive wire of this invention meets the requirements for practical application conditions in current-carrying temperature rise and smoke emission curve tests. It is of high quality, has a long service life, and is odorless, making it suitable for widespread application.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a small-diameter, low-odor automotive wire. Background Technology

[0002] As the main network of automotive circuits, automotive wiring harnesses carry the transmission of vehicle power and signals, making them a crucial component of automobiles. The cost of their wires accounts for over 30% of the total cost of the wiring harness. However, existing automotive wiring harnesses suffer from problems such as high manufacturing costs and odor.

[0003] CN213400596U discloses an environmentally friendly, odorless, uniform electric field silicone rubber automotive cable, comprising a conductor, single copper wire, a semi-conductive shielding layer, and an insulation layer. The above design achieves the following effects: the silicone rubber automotive cable is environmentally friendly and healthy, containing no toxic or harmful substances and having no irritating odor; no toxic or harmful substances are generated during the production process, and there are no adverse effects on human health during production, installation, laying, or vehicle driving; the silicone rubber automotive cable has good heat resistance, a uniform electric field, can carry high currents, and possesses good mechanical properties.

[0004] CN208271641U discloses a cable for dual-motor driven new energy vehicles. The power cable and grounding cable are arranged coaxially in a straight line, with the two power cables symmetrically positioned in the middle and the two grounding cables symmetrically positioned on the outer sides. The sheaths of the two power cables are interconnected by a wide flat strip, and the sheaths of the power cables and the grounding cables are interconnected by a narrow flat strip. V-shaped notches are provided in the middle of the width of both the wide and narrow flat strips. A equilateral triangular star-shaped plastic core is located at the center of the power cable, securing three insulated phase wires and three circular pull ropes. The outer periphery is sequentially covered with an aluminum foil layer, a copper wire braided shielding layer, and a low-smoke halogen-free polyolefin sheath layer. Multiple raised plastic strips are evenly coiled around the outer wall of the power cable sheath layer, and length markings are evenly applied to the outer wall of the low-smoke halogen-free polyolefin sheath layer every meter. This cable has high strength, good shielding and heat dissipation, is safe, and is not easily damaged during construction.

[0005] CN205789160U discloses a low-odor, low-VOC thin-walled low-voltage automotive wire, comprising multi-strand wire conductors, a fixing layer covering the surface of the multi-strand wire conductors, and an insulating layer wrapping the surface of the fixing layer. The fixing layer is a mesh layer woven from polyurethane elastomer. An insulating rubber tube is provided between the insulating layer and the fixing layer. Capillaries connected to the internal channels of the insulating rubber tube are uniformly provided on the sidewall of the insulating rubber tube. A dry limestone particle filler is provided inside the insulating rubber tube. A V-shaped silicone skeleton is provided between adjacent wire conductors.

[0006] However, the aforementioned automotive stitching cannot reach 0.3mm. 2Small wire diameter makes it unsuitable for use in new energy vehicle seats, rearview mirrors, dashboards, doors, and windows. Utility Model Content

[0007] In view of the problems existing in the prior art, this utility model provides a small-diameter, low-odor automotive wire. Through a specific conductor structure design and a special insulation layer, the cost and odor of the automotive wire are reduced. The automotive wire has a small diameter and high quality, far exceeding the German standard of 0.35mm. 2 Require.

[0008] To achieve this objective, the present invention adopts the following technical solution:

[0009] This utility model provides a small-diameter, low-odor automotive wire, which includes a conductor layer and an insulation layer arranged sequentially from the inside out; the conductor layer has a structure including a type A 7-strand copper wire stranded structure or a type B 16-strand copper wire stranded structure; the insulation layer is an insulation layer formed of QCJ-105A insulation material.

[0010] The small-diameter, low-odor automotive wire described in this invention refers to a conductor layer with a cross-sectional area of ​​0.3 mm². 2 The conductor layer structure includes either a type A structure with 7 stranded copper wires or a type B structure with 16 stranded copper wires. The copper wires can be annealed soft copper monofilaments. The type A structure with 7 stranded copper wires improves the concentricity of the cable insulation extrusion, overcomes the conductor damage caused by "fine wire" cutting in wire harness factories, improves the stability of cable current or signal control transmission under vibration conditions, and extends the service life of automotive wiring harnesses. The type B structure with 16 stranded copper wires enhances the flexibility and durability of automotive wiring harnesses. The insulation layer consists of an insulation layer formed from QCJ-105A insulation material. After being tested at 80℃ for 2 hours and then at 60℃, the odor test result is no greater than level 3.5, solving the odor problem of automotive wiring harnesses. Furthermore, the low-odor automotive wiring harness in this utility model can achieve a thickness of 0.3mm. 2 The small-diameter, low-odor automotive wire meets practical application requirements through current-carrying temperature rise and smoke curve testing, filling a gap in the German standard automotive wire specifications. This reduces cable procurement costs by over 20%, providing users with the best cost-performance solution. The small-diameter, low-odor automotive wire described in this invention has a current-carrying capacity of no less than 11A at 0℃ and no less than 5A at 85℃, meeting practical application conditions. The conductor layer, after ultrasonic welding, has a tear strength greater than 25N, far exceeding the German standard of 0.35mm. 2 Require.

[0011] Preferably, the outer diameter of the small-diameter, low-odor automotive wire is 1.29 to 1.35 mm, for example, it can be 1.29 mm, 1.295 mm, 1.3 mm, 1.31 mm, 13.2 mm, 13.4 mm or 1.35 mm, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0012] The small-diameter, low-odor automotive wire of this invention has an outer diameter of 1.29–1.35 mm, which can meet the airtightness and waterproofness test requirements of various wire harness manufacturers in the market without changing their existing wire harness cutting equipment, matching metal terminals, and waterproof sealing accessories.

[0013] Both the Type A (7-wire stranded) and Type B (16-wire stranded) structures of this invention utilize a multi-hole threading layering tooling mold for stranding, improving the tightness and roundness of the conductor layer stranding. The maximum production line speed is 1650 m / min, with no single wire breakage during insulation extrusion. The inner wall of the multi-hole threading layering tooling mold is made of ceramic material, reducing the coefficient of friction. The conductor layer stranding equipment can use a Niehoff 630 wire bundling machine, with an active wire feeding mechanism. The production efficiency of the Type A (7-wire stranded) structure can reach up to 75 m / min, and the production efficiency of the Type B (16-wire stranded) structure can reach up to 80 m / min.

[0014] Preferably, the type A 7-copper-wire stranded structure includes a 1+6 layered stranded structure, which improves the insulation concentricity to 95.6%.

[0015] Preferably, the diameter of a single wire in the type A seven-wire twisted structure is 0.20 to 0.25 mm, for example, it can be 0.20 mm, 0.21 mm, 0.22 mm, 0.23 mm, 0.235 mm, 0.24 mm or 0.25 mm, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0016] Preferably, the wiring pitch in the type A 7-copper-wire stranded structure is 3.0 to 4.0 mm, for example, it can be 3.0 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.7 mm or 4.0 mm, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0017] The air pressure for feeding the A-type 7-copper-wire stranded structure described in this utility model is 0.09 to 0.15 MPa, for example, it can be 0.09 MPa, 0.095 MPa, 0.1 MPa, 0.12 MPa, 0.14 MPa, 0.145 MPa or 0.15 MPa, etc., but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0018] The twisting method is left-handed, and the winding tension is 14-18N, for example, it can be 14N, 15N, 16N, 16.5N, 17N, 17.5N or 18N, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0019] The engagement torque is 2700 to 2900 N / min, for example, it can be 2700 N / min, 2710 N / min, 2730 N / min, 2800 N / min, 2850 N / min, 2880 N / min or 2900 N / min, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0020] Preferably, the type B 16-wire stranded copper wire structure includes a 5+11 layered stranded structure, which has a flexural dynamic life cycle that is superior to the German standard 0.35mm. 2 The improvement of 22% enhances the stability of cable current or signal control transmission under vibration conditions and extends the service life of automotive wiring harnesses.

[0021] Preferably, the diameter of a single wire in the type B 16-wire stranded structure is 0.14 to 0.16 mm, for example, it can be 0.14 mm, 0.145 mm, 0.148 mm, 0.15 mm, 0.155 mm, 0.157 mm or 0.16 mm, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0022] The tear strength of the Type A (7-wire stranded copper wire) and Type B (16-wire stranded copper wire) structures in this invention is greater than 25N, which is far higher than that used to replace the German standard 0.35mm. 2 The minimum required 12N.

[0023] Preferably, the wiring pitch in the type B 16-copper-wire stranded structure is 3.0 to 4.0 mm, for example, it can be 3.0 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.7 mm or 4.0 mm, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable, with 3.0 mm being the preferred value.

[0024] In this invention, the preferred B-type 16-copper-wire stranded structure has a wiring pitch of 3.0–4.0 mm to balance the flexibility of the automotive wiring harness with structural stability. An excessively large wiring pitch will increase the internal gaps of the stranded conductors, reduce the overall flexibility of the cable, and increase the risk of breakage. An excessively small wiring pitch will compress the internal gaps of the conductors, increase the friction between the stranded wires, which may lead to the breakage of a single conductor, and also increase the difficulty of stranding, affecting production efficiency and finished product quality.

[0025] The air pressure for feeding the B-type 16-copper-wire stranded structure described in this utility model is 0.07 to 0.13 MPa. For example, it can be 0.07 MPa, 0.075 MPa, 0.08 MPa, 0.09 MPa, 0.1 MPa, 0.12 MPa, or 0.13 MPa, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0026] The twisting method is left-handed, and the take-up tension is 12-16N, such as 12N, 13N, 14N, 15N, 15.5N or 16N, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0027] The engagement torque is 4500 to 4700 N / min, for example, it can be 4500 N / min, 4550 N / min, 4570 N / min, 4600 N / min, 4640 N / min, 4680 N / min or 4700 N / min, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0028] Preferably, the thickness of the insulating layer is 0.25 to 0.35 mm, for example, it can be 0.25 mm, 0.26 mm, 0.27 mm, 0.28 mm, 0.29 mm, 0.30 mm or 0.35 mm, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0029] The insulating layer of this invention is extruded onto the outside of the conductor layer using a Rosenthal 60+30+30 extruder. The extruder body plasticizing temperatures are 165℃, 175℃, 180℃, 180℃, 180℃, 180℃, 180℃, 180℃, 180℃, 180℃, and 180℃, while the auxiliary machine body plasticizing temperatures are 165℃, 175℃, 180℃, 180℃, and 180℃. The conductor is fed using a spool-type unloading method, meeting the high-speed requirements of a 1650m / min high-speed extrusion production line.

[0030] The insulating layer described in this utility model comprises an insulating layer formed of QCJ-105A insulating material. The substrate of this insulating material includes PVC resin, calcium-zinc stabilizer, trioctyl trimellitate TOTM plasticizer, diisodecyl phthalate plasticizer, polyester plasticizer, antioxidant, and lubricant; the ester content of trioctyl trimellitate TOTM plasticizer is increased from 99% to 99.5%. The insulating hardness of this insulating material is 92–96A, for example, it can be 92A, 92.5A, 93A, 94A, 94.5A, 95A, or 96A, but is not limited to the listed values; other unlisted values ​​within this range are also applicable.

[0031] The twin-screw extrusion and granulation drying temperature is controlled at 80-90℃, for example, it can be 80℃, 81℃, 83℃, 85℃, 87℃ or 90℃, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0032] The time should be no less than 85 minutes, such as 85 minutes, 86 minutes, 87 minutes, 88 minutes, 89 minutes, 90 minutes or 95 minutes, but it is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0033] Vacuum degree ≥ 0.05MPa, for example, it can be 0.05MPa, 0.055MPa, 0.06MPa, 0.07MPa, 0.08MPa, 0.09MPa or 0.1MPa, etc., but is not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0034] Before granulation and packaging, add a vibrating screen with a length of not less than 8m, such as 8m, 8.2m, 8.4m, 8.5m, 8.7m or 9m, but not limited to the listed values. Other unlisted values ​​within this range are also applicable.

[0035] The device vibrates fully to release odors, reducing odors and VOCs during the production process. The odor test result is 3.5, which is better than the industry standard of 4.0, thus solving the odor problem in the automotive industry.

[0036] The small-diameter, low-odor automotive wire provided by this utility model can meet the current-carrying requirements of different parts of new energy vehicles such as seats, rearview mirrors, instruments, doors and windows, improve cable life, and reduce cable procurement costs by more than 20%.

[0037] Compared with the prior art, the present invention has at least the following beneficial effects:

[0038] (1) The small-diameter, low-odor automotive wire provided by this utility model is between 0.22 and 0.35 mm. 2 The automotive wiring harness products meet the actual application conditions in terms of current-carrying temperature rise and smoke curve testing, filling the gap in the specifications of the German standard automotive wiring harness, and reducing cable procurement costs by more than 20%.

[0039] (2) The small-diameter, low-odor automotive wire provided by this utility model has a current-carrying capacity of not less than 11A at an ambient temperature of 0℃ and not less than 5A at an ambient temperature of 85℃, which meets the actual application conditions. The tensile strength of the conductor after ultrasonic welding is greater than 25N, which is far higher than the German standard of 0.35mm. 2 The requirements are met; moreover, the odor test score is 3.5, which is better than the industry standard of 4.0, thus solving the odor problem in the automotive industry. Attached Figure Description

[0040] Figure 1 This is a schematic cross-sectional view of the small-diameter, low-odor automotive wire provided in Embodiment 1 of this utility model.

[0041] Figure 2 This is a schematic diagram of the A-type 7-copper-wire twisted structure in Embodiment 1 of this utility model.

[0042] Figure 3 This is a schematic diagram of the B-type 16-copper-wire stranded structure in Embodiment 2 of this utility model.

[0043] In the diagram: 1-Conductor layer; 2-Insulating layer; 3-Copper wire; 4-Mold hole. Detailed Implementation

[0044] The technical solution of this utility model will be further described below with reference to the accompanying drawings and specific embodiments.

[0045] The present invention will now be described in further detail. However, the examples described below are merely simplified examples of the present invention and do not represent or limit the scope of protection of the present invention. The scope of protection of the present invention shall be determined by the claims.

[0046] Example 1

[0047] This embodiment provides a small-diameter, low-odor automotive wire, the structural schematic of which is shown below. Figure 1 As shown.

[0048] The low-odor automotive wire with small diameter includes a conductor layer 1 and an insulation layer 2 arranged sequentially from the inside out; the conductor layer 1 has a structure of 7 stranded copper wires of type A; the insulation layer 2 is an insulation layer formed of QCJ-105A insulation material.

[0049] The outer diameter of the small-diameter, low-odor automotive wire is 1.30 mm.

[0050] The type A seven-copper-wire stranded structure is stranded using a multi-hole threading layered tooling mold, forming a 1+6 layered stranded structure, as shown in the schematic diagram. Figure 2 As shown in the diagram. The black dots represent copper wire 3, and the white dots represent mold holes 4.

[0051] The diameter of a single wire in the type A seven-wire stranded structure is 0.22 mm. The pitch of the wires in the type A seven-wire stranded structure is 3.6 mm.

[0052] The feed pressure during the preparation of the type A 7-copper-wire stranded structure is 0.1MPa, the stranding method is left-handed, the take-up tension is 16N, and the bundle twist is 2800 twists / minute.

[0053] The thickness of the insulating layer is 0.28 mm.

[0054] Example 2

[0055] This embodiment provides a small-diameter, low-odor automotive wire, which includes a conductor layer and an insulation layer arranged sequentially from the inside out; the conductor layer has a B-type structure with 16 stranded copper wires; and the insulation layer is formed of QCJ-105A insulation material.

[0056] The outer diameter of the small-diameter, low-odor automotive wire is 1.35 mm.

[0057] The type B 16-copper-wire stranded structure is stranded using a multi-hole threading layered tooling mold, and is a 5+11 layered stranded structure, as shown in the schematic diagram. Figure 3 As shown in the diagram. The black dots represent copper wire 3, and the white dots represent mold holes 4.

[0058] The diameter of a single wire in the type B 16-wire stranded structure is 0.16 mm. The pitch of the wiring in the type B 16-wire stranded structure is 3.0 mm.

[0059] The feed pressure during the preparation of the type B 16 copper wire stranded structure is 0.09 MPa, the stranding method is left-handed, the take-up tension is 15 N, and the bundle twist is 4600 twists / min.

[0060] The thickness of the insulating layer is 0.35 mm.

[0061] Example 3

[0062] This embodiment provides a small-diameter, low-odor automotive wire, which includes a conductor layer and an insulation layer arranged sequentially from the inside out; the conductor layer has a B-type structure with 16 stranded copper wires; and the insulation layer is formed of QCJ-105A insulation material.

[0063] The outer diameter of the small-diameter, low-odor automotive wire is 1.29 mm.

[0064] The type B 16 copper wire stranded structure is stranded using a multi-hole threading layered tooling mold, and is a 5+11 layered stranded structure.

[0065] The diameter of a single wire in the type B 16-stranded copper wire structure is 0.14 mm. The pitch of the wiring in the type B 16-stranded copper wire structure is 4.0 mm.

[0066] The feed pressure during the preparation of the type B 16-wire stranded structure is 0.13 MPa, the stranding method is left-handed, the take-up tension is 16 N, and the bundle twist is 4500 twists / minute.

[0067] The thickness of the insulating layer is 0.25 mm.

[0068] Example 4

[0069] This embodiment provides a small-diameter, low-odor automotive wire, which includes a conductor layer and an insulation layer arranged sequentially from the inside out; the conductor layer has a structure of 7 stranded copper wires of type A; the insulation layer is an insulation layer formed of QCJ-105A insulation material.

[0070] The outer diameter of the small-diameter, low-odor automotive wire is 1.35 mm.

[0071] The type A seven-wire stranded structure is stranded using a multi-hole threading layered tooling mold, forming a 1+6 layered stranded structure; the diameter of each wire in the type A seven-wire stranded structure is 0.20mm. The wire pitch in the type A seven-wire stranded structure is 3.0mm.

[0072] The feed pressure during the preparation of the type A 7-copper-wire stranded structure is 0.09MPa, the stranding method is left-handed, the take-up tension is 14N, and the bundle twist is 2900 twists / minute.

[0073] The thickness of the insulating layer is 0.35 mm.

[0074] As can be seen from Examples 1 to 4, the small-diameter, low-odor automotive wire conductor layer design provided by this utility model is reasonable. The current-carrying temperature rise and smoke curve tests meet the actual application conditions. The cable procurement cost is low, the cable quality is high, the service life is long and there is no odor. It is suitable for use in new energy vehicle seats, rearview mirrors, instruments, doors and windows and other parts.

[0075] Comparative Example 1

[0076] This comparative example provides a small-diameter automotive wire, which is identical to Example 1 except that the insulation layer is formed by irradiation of cross-linked XLPE insulating material at 125°C.

[0077] Because the insulation layer material in this comparative example is 125℃ irradiated cross-linked XLPE insulation material, the resulting automotive wiring still has an odor problem.

[0078] The applicant declares that the above description is only a specific embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present utility model fall within the protection and disclosure scope of the present utility model.

Claims

1. A small-diameter, low-odor automotive wire, characterized in that, The low-odor automotive wire with small diameter includes a conductor layer and an insulation layer arranged sequentially from the inside out; the conductor layer has a structure of either a type A structure with 7 stranded copper wires or a type B structure with 16 stranded copper wires; the insulation layer is formed of QCJ-105A insulation material.

2. The small-diameter, low-odor automotive wire according to claim 1, characterized in that, The outer diameter of the small-diameter, low-odor automotive wire is 1.29–1.35 mm.

3. The small-diameter, low-odor automotive wire according to claim 1, characterized in that, The type A seven-copper-wire stranded structure includes a 1+6 layered stranded structure.

4. The small-diameter, low-odor automotive wire according to claim 1, characterized in that, In the type A structure with 7 stranded copper wires, the diameter of each wire is 0.20 to 0.25 mm.

5. The small-diameter, low-odor automotive wire according to claim 1, characterized in that, The wiring pitch in the type A 7-wire stranded structure is 3.0–4.0 mm.

6. The small-diameter, low-odor automotive wire according to claim 1, characterized in that, The type B 16-copper-wire stranded structure includes a 5+11 layered stranded structure.

7. The small-diameter, low-odor automotive wire according to claim 1, characterized in that, The diameter of a single wire in the type B 16-strand copper wire structure is 0.14–0.16 mm.

8. The small-diameter, low-odor automotive wire according to claim 1, characterized in that, The wire pitch in the type B 16-wire stranded structure is 3.0–4.0 mm.

9. The small-diameter, low-odor automotive wire according to claim 8, characterized in that, The wiring pitch in the type B 16-wire stranded structure is 3.0mm.

10. The small-diameter, low-odor automotive wire according to claim 1, characterized in that, The thickness of the insulating layer is 0.25 to 0.35 mm.

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