Compression and tension resistant automotive cable

Abstract

This utility model discloses a cable, aiming to provide a pressure-resistant and tensile-resistant automotive cable that can be used in multiple scenarios, has high structural resistance, and good performance. The key technical point is that the support layer of this application has multiple support members, which can rotate relative to each other within the support body. Combined with the interference fit between the intermediate filler and the injection molding area, the cable can disperse the corresponding force when subjected to pressure through the relative rotation between the support members, ensuring the strength of the cable structure. This allows the cable to maintain good integrity when used in various parts of the vehicle. During the casting process of this application, a staged injection molding process is adopted, allowing the support members to fully integrate with the injection molding layer, forming a high-strength protective layer that meets the requirements for cable use in automobiles. This utility model is applicable to the technical field of cables.

Description

Technical Field

[0001] This utility model relates to the technical field of cables, and more specifically, to a pressure- and tensile-resistant automotive cable. Background Technology

[0002] Cables are conductors covered with insulation, protective layers, and isolation layers used to transmit electrical or signal current and signal voltage. According to voltage, they can be divided into high-voltage cables and low-voltage cables. Although low-voltage cable lines are more expensive and more difficult to lay and maintain compared with low-voltage overhead lines and low-voltage overhead insulated lines, they are widely used in low-voltage power distribution systems (such as wiring in automobiles) because of their reliable operation, no need for poles, no land occupation, no obstruction of appearance, and less susceptibility to external influences.

[0003] However, the low-voltage cables currently used in the power industry are often damaged by compression during transportation and installation. This compression can lead to poor transmission and external cracking, reducing the protective function of the cable core and shortening its lifespan. This is especially true for cables used in special environments, such as wiring inside automobiles where multiple cables need to be laid in confined spaces. Therefore, to ensure that the cables have good structural resistance and more stable output in various scenarios inside automobiles, the cable structure needs to be adjusted. Utility Model Content

[0004] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a pressure-resistant and tensile-resistant automotive cable that can be used in multiple scenarios in automobiles, has high structural resistance, and has good performance.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a pressure-resistant and tensile-resistant automotive cable, comprising a conductive layer, an outer insulation layer, an inner insulation layer, an isolation layer, and a protective sleeve arranged sequentially from the inside out, characterized in that: the conductive layer is composed of several tin-plated copper conductors twisted together; the outer insulation layer is made of polyvinyl chloride or thermoplastic elastomer; the inner insulation layer is made of cross-linked polyethylene or polyvinyl chloride; the isolation layer is formed by combining aluminum foil shielding and copper braided mesh to form a multi-layer shield; the protective sleeve is made of PVC, PE, TPE, or LSZH material; and further comprising a support layer disposed between the protective sleeve and the isolation layer, the support layer comprising several support members spliced ​​together, the support members comprising: a support body, and two first connecting bodies extending from a first side of the support body along the axial direction of the support body in a first direction, the two first connecting bodies being arranged facing each other in the first diameter direction of the support body, and each of the two first connecting bodies having a hole perpendicular to the axial direction;

[0006] And two second connecting bodies extending from the second side of the support along the axial direction of the support and in a second direction opposite to the first direction, the two second connecting bodies being arranged facing each other in the second diameter direction of the support, and each of the two second connecting bodies having a protrusion perpendicular to the axial direction;

[0007] The first diameter direction where the two first connectors are located is perpendicular to the second diameter direction where the two second connectors are located;

[0008] In the plurality of support members, the connection between two adjacent support members is achieved by the mating connection between a hole on the first connecting body of one support member and a protrusion on the second connecting body of the other support member. The mating connection is a radial rotational mating connection, and the two adjacent support members can rotate relative to each other on the first connecting body or the second connecting body.

[0009] The protective sleeve is formed as follows: after each support component is placed outside the isolation layer, the protective sleeve is then wrapped around each support component by injection molding.

[0010] The present invention is further configured such that: an injection molding area is formed between the support member and the isolation layer, and an intermediate filler is provided in the injection molding area between two adjacent support members. The intermediate filler abuts against the two adjacent support members, and the intermediate filler and the injection molding area are interference fit.

[0011] The present invention is further configured such that: the intermediate filling component includes several main frame bodies in the shape of "U" and attached to the side support members and arranged radially in the injection molding area, a pair of inner extension bodies disposed on the longitudinal part of the main frame bodies, several concave connecting members disposed between the two inner extension bodies, and connecting ropes that connect each of the main frame bodies in sequence, the concave connecting members being connected in sequence to form a concave structure, and the included angle between two adjacent concave connecting members being between 163 degrees and 175 degrees.

[0012] The present invention is further configured such that: the support body includes an internal embedded frame and an injection-molded layer integrally formed with the embedded frame by injection molding, wherein the embedded frame is a circular metal structure.

[0013] The present invention is further configured such that the spacing between the support members is between 10mm and 30mm.

[0014] The present invention is further configured such that: the two first connecting bodies of the support member are flush with the outer circumferential surface of the support member, and the two second connecting bodies of the support member are flush with the inner circumferential surface of the support member.

[0015] By adopting the above technical solution, the beneficial effects are as follows: 1. In this utility model, by setting each layer to include a conductive layer composed of several stranded tin-plated copper conductors; an outer insulation layer made of polyvinyl chloride or thermoplastic elastomer; an inner insulation layer made of cross-linked polyethylene or polyvinyl chloride; an isolation layer composed of aluminum foil shielding and copper braided mesh forming a multi-layer shield; and a protective sleeve made of PVC, PE, TPE, or LSZH materials, the use of tin-plated copper conductors and a multi-layer insulation shielding structure can ensure conductivity and shielding effect while achieving high temperature resistance and corrosion resistance of the cable through the above materials. Furthermore, the supporting layer has multiple supporting members, which can rotate relative to each other within the supporting body. Combined with the interference fit between the intermediate filler and the injection molding area, the cable can distribute the corresponding force when subjected to pressure through the relative rotation between the supporting members, ensuring the strength of the cable structure. This allows the cable to maintain its structural integrity in different scenarios. In addition, during the casting process of this application, the use of a staged injection molding process allows the supporting members of this application to fully integrate with the injection molding layer, forming a high-strength protective layer that meets the usage requirements of the cable in various scenarios.

[0016] 2. Furthermore, the adjacent support members are connected by the mating of holes on the first connector of one support member with protrusions on the second connector of the other support member. Specifically, the support member has a first connector and a second connector, which are arranged in opposite directions. Specifically, the first connector is arranged along the axial direction of the support member and is flush with the support member, while the second connector extends along the other direction of the axial direction of the support member. The first connectors are arranged facing each other in the first diameter direction of the support surface, and the second connectors are arranged facing each other in the second diameter direction of the support member. The adjacent first and second connectors can rotate relative to each other, allowing the support member to adaptively adjust its angle under pressure. Furthermore, no internal stress occurs during rotation, avoiding stress concentration in the support member. In the production process of the support member, only a few identical support members need to be produced and connected, improving processing efficiency and reducing production costs. The length of the cable can be adjusted as needed by changing the number of support members, resulting in good performance.

[0017] 3. Simultaneously, an intermediate filler is provided between two adjacent support members. This intermediate filler is interference-fitted with the injection molding area. The intermediate filler comprises several U-shaped main frames arranged radially within the injection molding area, a pair of inner extensions on the longitudinal portion of the main frames, several concave connectors between the two inner extensions, and connecting ropes sequentially connecting each main frame. Specifically, the U-shaped main frames and the concave connectors cooperate to ensure that the intermediate filler... The filler undergoes progressive deformation under pressure, transforming the point load into a surface load. This results in more uniform pressure on the cable, preventing damage during use. Furthermore, the connecting ropes connect the main frame members in series, forming a mesh-like damping structure. This mesh-like structure, combined with the interference fit between the intermediate filler and the injection molding area, creates a preload between them. This ensures dynamic contact between the intermediate filler and the injection molding area, effectively buffering vibrations and preventing damage to the cable's protective sheath.

[0018] 4. Furthermore, in the production process of the aforementioned automotive cables, two layers of casting areas are set up. By casting the first and second casting areas twice, the cable blank after the intermediate filler is installed can be easily fixed and positioned after the first casting area is cast. After the first casting area is cured, the stability of the first casting area is ensured, and excessive casting at one time is prevented from reducing the overall processing efficiency. At the same time, the second casting area is set outside the first casting area. After curing, the second casting area forms a protective sleeve. By using the distributed casting method, the problem of poor bonding force between the various layers of the cable is effectively avoided. In addition, during the casting process, the intermediate filler is pre-installed in the injection area and interference fits with the injection area to ensure that each component is kept in a precise position during the injection process, preventing dimensional deviations of the finished product after injection molding. At the same time, the support can be assembled according to the required cable length before processing, which can meet the needs of cables of different lengths. The support is composed of multiple detachable support bodies, making the overall cable installation convenient, especially meeting the needs of rapid deployment in long-distance power transmission projects. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of a specific structure of an embodiment of the pressure-resistant and tensile-resistant automotive cable of this utility model;

[0020] The reference numerals in the figure are as follows: 1. Conductive layer; 2. Outer insulating layer; 3. Inner insulating layer; 4. Isolation layer; 5. Protective sleeve; 6. Support layer; 61. Support component; 611. Support body; 612. First connector; 613. Second connector; 7. Injection molding area; 8. Intermediate filler; 81. Main frame; 82. Inner extension; 83. Recessed connector; 84. Connecting rope; 9. Embedded frame. Detailed Implementation

[0021] Reference Figure 1 The present invention provides a further description of an embodiment of a pressure-resistant and tensile-resistant automotive cable.

[0022] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0023] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0024] A pressure-resistant and tensile-resistant automotive cable includes, from the inside out, a conductive layer 1, an outer insulation layer 2, an inner insulation layer 3, an isolation layer 4, and a protective sleeve 5. The conductive layer 1 is composed of several stranded tin-plated copper conductors; the outer insulation layer 2 is made of polyvinyl chloride or thermoplastic elastomer; the inner insulation layer is made of cross-linked polyethylene or polyvinyl chloride; the isolation layer 4 is a multi-layered shield formed by combining aluminum foil shielding and copper braided mesh; the protective sleeve 5 is made of PVC, PE, TPE, or LSZH material. The cable also includes a support layer 6 disposed between the protective sleeve 5 and the isolation layer 4. The support layer 6 is composed of several support members 61 spliced ​​together. Each support member 61 includes a support body 611 and two first connectors 612 extending from a first side of the support body 611 along the axial direction of the support body 611 in a first direction. The two first connectors 612 are arranged facing each other in the first diameter direction of the support body 611, and each of the two first connectors 612 has a hole perpendicular to the axial direction.

[0025] And two second connecting bodies 613 extending from the second side of the support body 611 along the axial direction of the support body 611 in a second direction opposite to the first direction. The two second connecting bodies 613 are arranged facing each other in the second diameter direction of the support body 611, and each of the two second connecting bodies 613 is provided with a protrusion perpendicular to the axial direction.

[0026] The first diameter direction where the two first connectors 612 are located is perpendicular to the second diameter direction where the two second connectors 613 are located;

[0027] Among the plurality of support members 61, the connection between two adjacent support members 61 is achieved by the mating connection between a hole on the first connecting body 612 of one support member 61 and a protrusion on the second connecting body 613 of the other support member 61. The mating connection is a radial rotational mating connection, and the two adjacent support members 61 can rotate relative to each other on the first connecting body 612 or the second connecting body 613.

[0028] The protective sleeve 5 is formed as follows: after each support member 61 is put on the outside of the isolation layer 4, the protective sleeve 5 is then wrapped around each support member 61 by injection molding.

[0029] An injection molding area 7 is formed between the support member 61 and the isolation layer 4. An intermediate filler 8 is provided in the injection molding area 7 between two adjacent support members 61. The intermediate filler 8 abuts against the two adjacent support members 61, and the intermediate filler 8 and the injection molding area 7 are interference fit.

[0030] The intermediate filler 8 includes several main frame bodies 81 that are U-shaped and attached to the two side support members 61 and arranged radially within the injection molding area 7, a pair of inner extensions 82 disposed on the longitudinal part of the main frame bodies 81, several concave connectors 83 disposed between the two inner extensions 82, and connecting ropes 84 that connect each of the main frame bodies 81 in sequence. The concave connectors 83 are connected in sequence to form a concave structure, and the included angle between two adjacent concave connectors 83 is between 163 degrees and 175 degrees.

[0031] The support 611 includes an internal embedded frame 9 and an injection-molded layer integrally formed with the embedded frame 9 by injection molding. The embedded frame 9 is a circular metal structure.

[0032] The spacing between the support members 61 is between 10mm and 30mm.

[0033] The two first connecting bodies 612 of the support member 61 are flush with the outer circumferential surface of the support member 611, while the two second connecting bodies 613 of the support member 61 are flush with the inner circumferential surface of the support member 611.

[0034] In this invention, by configuring each layer as follows: a conductive layer 1, composed of several stranded tin-plated copper conductors; an outer insulation layer made of polyvinyl chloride or thermoplastic elastomer; an inner insulation layer made of cross-linked polyethylene or polyvinyl chloride; an isolation layer 4, formed by a combination of aluminum foil shielding and copper braided mesh to form a multi-layer shield; and a protective sleeve 5, made of PVC, PE, TPE, or LSZH material, the use of tin-plated copper conductors and a multi-layer insulation shielding structure ensures both conductivity and shielding effectiveness. Furthermore, the aforementioned materials achieve high-temperature resistance and corrosion resistance for the cable. Simultaneously, the supporting layer 6... There are multiple support members 61, and the support members 61 can rotate relative to each other within the support body 611. Combined with the interference fit between the intermediate filler 8 and the injection molding area 7, the cable can disperse the corresponding force when subjected to pressure through the relative rotation between the support members 61, ensuring the strength of the cable structure. This allows the cable to maintain its structural integrity in different scenarios. At the same time, during the casting process of this application, the support members 61 can be fully integrated with the injection molding layer to form a high-strength protective layer, meeting the cable's usage requirements in various scenarios.

[0035] Furthermore, adjacent support members 61 are connected by a hole on the first connector 612 of one support member 61 engaging with a protrusion on the second connector 613 of the other support member 61. Specifically, the support member 611 is provided with a first connector 612 and a second connector 613, the first connector 612 and the second connector 613 being arranged in opposite directions. Specifically, the first connector 612 is arranged along the axial direction of the support member 611 and is flush with the support member 611, while the second connector 613 extends along the other direction of the axial direction of the support member 611, and the first connector 612 is arranged opposite to the first diameter direction of the support surface. The second connector 613 is arranged facing each other in the second diameter direction of the support 611, and the first connector 612 and the second connector 613 adjacent to each other can rotate relative to each other, so that the support 61 can achieve adaptive angle adjustment after being subjected to pressure, and no internal stress will occur during the rotation, avoiding the problem of stress concentration in the support 611. In addition, during the production process of the support 61, only a number of identical support bodies 611 need to be produced and connected, which improves the processing efficiency and reduces the production cost. Furthermore, the length of the cable can be adjusted as needed by changing the number of support bodies 611, resulting in good performance.

[0036] Meanwhile, an intermediate filler 8 is provided between two adjacent support members 61. The intermediate filler 8 is interference-fitted with the injection molding area 7. The intermediate filler 8 has several U-shaped main frame bodies 81 that are attached to the two side support members 61 and arranged radially within the injection molding area 7, a pair of inner extensions 82 provided on the longitudinal part of the main frame body 81, several concave connectors 83 provided between the two inner extensions 82, and connecting ropes 84 that connect each of the main frame bodies 81 in sequence. Specifically, the U-shaped main frame body 81 and the concave connectors cooperate to make the injection molding area 7 more flexible and flexible. The intermediate filler 8 undergoes progressive deformation under pressure, transforming the point load into a surface load, resulting in more uniform pressure on the cable and preventing damage during use. Furthermore, the connecting rope 84 connects each main frame 81 in series, forming a mesh-like damping structure between the connecting rope 84 and the main frame 81. This mesh-like structure, combined with the interference fit between the intermediate filler 8 and the injection molding area 7, generates a preload between them, ensuring dynamic contact and effectively buffering vibrations to prevent damage to the cable's protective sheath 5.

[0037] Furthermore, during the production of the aforementioned automotive cables, two layers of casting zones are incorporated. The first and second casting zones are cast twice. After casting the first zone, the cable blank after installing the intermediate filler 8 can be easily fixed and positioned. After the first zone cures, its stability is ensured, and excessive casting at one time is prevented from reducing overall processing efficiency. The second casting zone is located outside the first zone, and after curing, it forms a protective sleeve 5. This is achieved through the distributed casting process. This method effectively avoids the problem of poor bonding strength between different layers of the cable. Furthermore, during the casting process, by pre-installing the intermediate filler 8 within the injection molding area 7 and interfering with it, it ensures that each component remains in a precise position during injection molding, preventing dimensional deviations in the finished product after injection molding. At the same time, the support 61 can be assembled according to the required cable length before processing, meeting the needs of cables of different lengths. Moreover, the support 61 is composed of multiple detachably connected support bodies 611, making the overall cable installation convenient and particularly meeting the needs of rapid deployment in long-distance power transmission projects.

[0038] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A pressure- and tensile-resistant automotive cable, comprising, from the inside out, a conductive layer (1), an outer insulation layer (2), an inner insulation layer (3), an insulating layer (4), and a protective sheath (5), characterized in that, It also includes a support layer (6) disposed between the protective sleeve (5) and the isolation layer (4). The support layer (6) is composed of a number of support members (61) spliced ​​together. The protective sleeve (5) is formed as follows: after each support member (61) is put on the outside of the isolation layer (4), the protective sleeve (5) is wrapped around each support member (61) by injection molding.

2. The pressure- and tensile-resistant automotive cable according to claim 1, characterized in that, The support member (61) includes: a support body (611), and two first connecting bodies (612) extending from a first side of the support body (611) along the axial direction of the support body (611) in a first direction. The two first connecting bodies (612) are arranged facing each other in the first diameter direction of the support body (611), and each of the two first connecting bodies (612) is provided with a hole perpendicular to the axial direction. And two second connectors (613) extending from the second side of the support (611) along the axial direction of the support (611) in a second direction opposite to the first direction, the two second connectors (613) being arranged facing each other in the second diameter direction of the support (611), and each of the two second connectors (613) having a protrusion perpendicular to the axial direction; The first diameter direction where the two first connectors (612) are located is perpendicular to the second diameter direction where the two second connectors (613) are located.

3. The pressure- and tensile-resistant automotive cable according to claim 2, characterized in that, Among the plurality of support members (61), the connection between two adjacent support members (61) is achieved by the engagement of a hole on the first connecting body (612) of one support member (61) with a protrusion on the second connecting body (613) of the other support member (61). The engagement connection is a radial rotational engagement connection, and the two adjacent support members (61) can rotate relative to each other on the first connecting body (612) or the second connecting body (613).

4. The pressure- and tensile-resistant automotive cable according to claim 1, characterized in that, An injection molding area (7) is formed between the support member (61) and the isolation layer (4). An intermediate filler (8) is provided in the injection molding area (7) between two adjacent support members (61). The intermediate filler (8) abuts against the two adjacent support members (61), and the intermediate filler (8) and the injection molding area (7) are interference fit.

5. The compression- and tensile-resistant automotive cable according to claim 4, characterized in that, The intermediate filler (8) includes several main frame bodies (81) that are "U"-shaped and attached to the two side support members (61) and arranged radially in the injection molding area (7), a pair of inner extension bodies (82) disposed on the longitudinal part of the main frame body (81), several concave connectors (83) disposed between the two inner extension bodies (82), and connecting ropes (84) that connect each of the main frame bodies (81) in sequence. The concave connectors (83) are connected in sequence to form a concave structure, and the included angle between two adjacent concave connectors (83) is between 163 degrees and 175 degrees.

6. The pressure- and tensile-resistant automotive cable according to claim 2, characterized in that, The support (611) includes an internal embedded frame (9) and an injection-molded layer integrally formed with the embedded frame (9) by injection molding. The embedded frame (9) is a circular metal structure.

7. The pressure- and tensile-resistant automotive cable according to claim 1, characterized in that, The distance between the two support members (61) is between 10mm and 30mm.

8. The pressure- and tensile-resistant automotive cable according to claim 1, characterized in that, The two first connectors (612) of the support member (61) are flush with the outer circumferential surface of the support body (611), while the two second connectors (613) of the support member (61) are flush with the inner circumferential surface of the support body (611).

9. The pressure- and tensile-resistant automotive cable according to claim 1, characterized in that, The conductive layer (1) is composed of several tin-plated copper wires twisted together; the outer insulation layer is made of polyvinyl chloride or thermoplastic elastomer, and the inner insulation layer is made of cross-linked polyethylene or polyvinyl chloride; the isolation layer (4) is a multi-layer shield formed by combining aluminum foil shielding and copper braided mesh; the protective sleeve (5) is made of PVC, PE, TPE or LSZH material.

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