New energy vehicle copper-clad aluminum braided shielding high-voltage cable

Abstract

The utility model discloses a new energy automobile copper clad aluminum braided shield high voltage cable in the technical field of high voltage cable, including stranded copper conductor, the fixed extrusion of insulating layer has on the outer wall of stranded copper conductor, the insulating layer is cross -linked polyethylene or cross -linked polyolefin insulating layer, the insulating layer outside fixedly set semiconductive inner layer, fill in the PP filling strip between semiconductive inner layer with insulating layer, the outer wall of semiconductive layer extrudes and has copper clad aluminum braided shield layer, copper clad aluminum braided shield layer is 0.1~0.2 tinned copper clad aluminum wire, and with semiconductive inner layer is 360 degree ring pressure contact, the outer wall of copper clad aluminum braided shield layer fixed extrusion has aluminum foil layer, the outer wall of aluminum foil layer fixed extrusion has semiconductive outer layer, the outer wall of semiconductive outer layer fixed extrusion has cross -linked polyolefin sheath, the utility model discloses can reduce the shielding layer direct current resistance, guarantees the continuity of grounding, promotes high -frequency shielding efficiency, strengthens in 100kHz~30MHz frequency band shielding attenuation.

Description

Technical Field

[0001] This utility model relates to the field of high-voltage cable technology, and in particular to a copper-clad aluminum braided shielded high-voltage cable for new energy vehicles. Background Technology

[0002] New energy vehicle drive systems generally use 400V / 800V high-voltage platforms, and the cables need to withstand large currents (≥200A) and have good shielding performance.

[0003] Existing technologies mostly use bare copper or tin-plated copper wire braided shielding, resulting in heavy wiring harnesses and high copper material costs, which contradicts the vehicle's "lightweight and cost reduction" requirements.

[0004] Copper-clad aluminum (CCA) wire has been used in communication and control cables, but it has the following drawbacks under high voltage, high current, vibration, and thermal cycling conditions: the aluminum core has high resistance and is prone to oxidation, which leads to an increase in the DC resistance of the shielding layer and affects the grounding continuity; when the copper layer thickness is insufficient, the high-frequency shielding effectiveness is reduced; the traditional single-layer braided structure has insufficient shielding attenuation (<60dB) in the 100kHz to 30MHz frequency band, which can easily interfere with CAN and LVDS signals.

[0005] Based on this, this utility model designs a copper-clad aluminum braided shielded high-voltage cable for new energy vehicles to solve the above problems. Utility Model Content

[0006] The purpose of this utility model is to provide a copper-clad aluminum braided shielded high-voltage cable for new energy vehicles, which can reduce the DC resistance of the shielding layer, ensure grounding continuity, improve high-frequency shielding effectiveness, and enhance shielding attenuation in the 100kHz to 30MHz frequency band.

[0007] This utility model is implemented as follows: A copper-clad aluminum braided shielded high-voltage cable for new energy vehicles includes: a stranded copper conductor, an insulation layer fixedly extruded on the outer wall of the stranded copper conductor, the insulation layer being a cross-linked polyethylene or cross-linked polyolefin insulation layer; a semi-conductive inner layer fixedly disposed on the outer side of the insulation layer, with a PP filler strip filling the space between the semi-conductive inner layer and the insulation layer; a copper-clad aluminum braided shielding layer extruded on the outer wall of the semi-conductive layer, the copper-clad aluminum braided shielding layer being 0.1-0.2mm tin-plated copper-clad aluminum wire, forming a 360° circumferential contact with the semi-conductive inner layer; an aluminum foil layer fixedly extruded on the outer wall of the copper-clad aluminum braided shielding layer; a semi-conductive outer layer fixedly extruded on the outer wall of the aluminum foil layer; and a cross-linked polyolefin sheath fixedly extruded on the outer wall of the semi-conductive outer layer.

[0008] Furthermore, the stranded copper conductors are in two sets.

[0009] Furthermore, 2% to 4% graphene microsheets are added to the cross-linked polyolefin sheath.

[0010] Furthermore, the PP filler strip is a PP filler rope, and the PP filler rope is arranged along the length direction of the cable, and reinforcing ribs are nested in the PP filler rope.

[0011] Furthermore, the outer wall of the cross-linked polyolefin sheath is coated with a wear-resistant layer.

[0012] Furthermore, the semiconductive outer layer is an ethylene-vinyl acetate copolymer-based semiconductive material.

[0013] Furthermore, the semiconductive inner layer is an ethylene-vinyl acetate copolymer-based semiconductive material.

[0014] The beneficial effects of this utility model are: it combines lightweight, low cost and excellent electromagnetic compatibility performance. Attached Figure Description

[0015] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0017] 1-Stranded copper conductor, 2-Insulation layer, 3-PP filler strip, 4-Semi-conductive inner layer, 5-Copper-clad aluminum braided shielding layer, 6-Aluminum foil layer, 7-Semi-conductive outer layer, 8-Cross-linked polyolefin sheath. Detailed Implementation

[0018] Please see Figure 1 As shown, this utility model provides a copper-clad aluminum braided shielded high-voltage cable for new energy vehicles. To better understand the above technical solution, the following will describe the above technical solution in detail with reference to the accompanying drawings and specific embodiments.

[0019] In a specific embodiment of the technical solution of this utility model:

[0020] The invention comprises a stranded copper conductor 1, with an insulating layer 2 fixedly extruded onto the outer wall of the stranded copper conductor 1. The insulating layer 2 is a cross-linked polyethylene or cross-linked polyolefin insulating layer. A semi-conductive inner layer 4 is fixedly disposed on the outer side of the insulating layer 2, and a PP filler strip 3 is filled between the semi-conductive inner layer 4 and the insulating layer 2. A copper-clad aluminum braided shielding layer 5 is extruded onto the outer wall of the semi-conductive inner layer 4. The copper-clad aluminum braided shielding layer 5 is made of 0.1-0.2mm tin-plated copper-clad aluminum wire and makes 360° circumferential contact with the semi-conductive inner layer 4. An aluminum foil layer 6 is fixedly extruded onto the outer wall of the copper-clad aluminum braided shielding layer 5. A semi-conductive outer layer 7 is fixedly extruded onto the outer wall of the aluminum foil layer 6. A cross-linked polyolefin sheath 8 is fixedly extruded onto the outer wall of the semi-conductive outer layer 7. This invention combines lightweight, low cost, and excellent electromagnetic compatibility performance. This invention achieves a transfer impedance Zt ≤ 10mΩ / m@1MHz and a shielding attenuation ≥ 75dB@30MHz, which is superior to the 65dB level of traditional single-layer copper braiding. The thickness of the copper and the sandwich structure work together to suppress aluminum oxidation, resulting in a DC resistance increase of less than 5% after 1000 hours of salt spray testing. The cross-linked polyolefin sheath 8 significantly improves the cable's insulation, flame retardancy, and fire resistance. The insulation layer 2 ensures good electrical insulation properties for the stranded copper conductor 1 while preventing current leakage and reducing losses. The PP filler strip 3 increases the cable's roundness. The aluminum core reduces weight by 30%, resulting in a comprehensive weight reduction of 3kg to 5kg for the entire vehicle wiring harness. The copper-clad aluminum braided shielding layer 5 is made of 0.1 to 0.2mm tin-plated copper-clad aluminum wire, which forms a 360° circumferential contact with the semi-conductive inner layer 4, achieving a low grounding resistance of ≤5mΩ / m.

[0021] The stranded copper conductor 1 consists of two sets. The two sets of stranded copper conductor 1 can accelerate the electron transport rate.

[0022] The cross-linked polyolefin sheath 7 contains 2% to 4% graphene microflakes. The addition of graphene thermally conductive sheath can reduce hot spot temperatures and increase the long-term aging life of the cable by more than 20%.

[0023] The PP filler strip 3 is a PP filler rope, which is arranged along the length of the cable and has reinforcing ribs nested within it. This can improve the tensile strength of the cable.

[0024] The outer wall of the cross-linked polyolefin sheath 7 is coated with a wear-resistant layer; this design can improve the wear resistance of the cross-linked polyolefin sheath 7.

[0025] The semiconductive outer layer 7 is an ethylene-vinyl acetate copolymer-based semiconductive material with a volume resistivity of 10¹ to 10¹⁰. 3 Ω·cm is used to create a uniform electric field and prevent partial discharge.

[0026] The semiconductive inner layer 4 is an ethylene-vinyl acetate copolymer-based semiconductive material with a volume resistivity of 10¹ to 10¹⁰.3 Ω·cm is used to create a uniform electric field and prevent partial discharge.

[0027] The semi-conductive double-layer interface controls the electric field, resulting in a partial discharge extinction voltage ≥2kV, which meets the requirements of the 1500V platform.

[0028] While specific embodiments of the present invention have been described above, those skilled in the art should understand that the specific embodiments described are merely illustrative and not intended to limit the scope of the present invention. Equivalent modifications and variations made by those skilled in the art in accordance with the spirit of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A new energy vehicle copper-clad aluminum braided shielding high-voltage cable, characterized in that, include: A stranded copper conductor, wherein an insulating layer is fixedly extruded on the outer wall of the stranded copper conductor, and the insulating layer is a cross-linked polyethylene or cross-linked polyolefin insulating layer; A semi-conductive inner layer is fixedly disposed on the outside of the insulating layer, and a PP filler strip is filled between the semi-conductive inner layer and the insulating layer; A copper-clad aluminum braided shielding layer is extruded onto the outer wall of the semiconductive inner layer. The copper-clad aluminum braided shielding layer is made of 0.1-0.2 tin-plated copper-clad aluminum wire and is in 360° circumferential contact with the semiconductive inner layer. An aluminum foil layer is fixedly extruded onto the outer wall of the copper-clad aluminum braided shielding layer; A semi-conductive outer layer is fixedly extruded onto the outer wall of the aluminum foil layer; A cross-linked polyolefin sheath is fixedly extruded onto the outer wall of the semiconductive outer layer.

2. The new energy vehicle copper-clad aluminum braided shielding high-voltage cable according to claim 1, characterized in that: The stranded copper conductors are in two sets.

3. The new energy vehicle copper-clad aluminum braided shielding high-voltage cable according to claim 1, characterized in that: The cross-linked polyolefin sheath contains 2% to 4% graphene microflakes.

4. The new energy vehicle copper-clad aluminum braided shielding high-voltage cable according to claim 1, characterized in that: The PP filler strip is a PP filler rope, and the PP filler rope is set along the length of the cable, and reinforcing ribs are nested in the PP filler rope.

5. The new energy vehicle copper-clad aluminum braided shielding high-voltage cable according to claim 1, characterized in that: The outer wall of the cross-linked polyolefin sheath is coated with a wear-resistant layer.

6. The new energy vehicle copper-clad aluminum braided shielding high-voltage cable according to claim 1, characterized in that: The semiconductive outer layer is an ethylene-vinyl acetate copolymer-based semiconductive material.

7. The new energy vehicle copper-clad aluminum braided shielding high-voltage cable according to claim 1, characterized in that: The semiconductive inner layer is an ethylene-vinyl acetate copolymer-based semiconductive material.

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