A composite automotive wire resistant to deformation and fatigue fracture

Abstract

The utility model discloses a kind of deformation-resistant anti-fatigue fracture composite automobile electric wire, including copper-clad aluminium conductor, the irradiation crosslinking polyvinyl chloride insulating layer covered in copper-clad aluminium conductor outside, the tinned copper wire braiding layer being set in the irradiation crosslinking polyvinyl chloride insulating layer outside, the aluminium foil wrapping shielding layer being wrapped in tinned copper wire braiding layer outside, the honeycomb non-woven fabric filling layer being set in the aluminium foil wrapping shielding layer outside and the irradiation crosslinking polyvinyl chloride sheath being extruded in honeycomb non-woven fabric filling layer outside.The utility model's deformation-resistant anti-fatigue fracture composite automobile electric wire, each layer structure is from material property to process design depth cooperation, make electric wire in complex working condition with super strong deformation resistance and anti-fatigue fracture performance, significantly improve the mechanical stability, signal integrity and durability of automobile electric wire in vibration, bending, harsh working condition such as high-low temperature cycle.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a composite automotive wire that is resistant to deformation and fatigue fracture. Background Technology

[0002] With the development of the automotive industry, especially the popularization of electric vehicles and intelligent connected vehicles, the working environment of automotive wiring harnesses is becoming increasingly complex, and the performance requirements for wires are also becoming higher. Automotive wires not only need to transmit electrical energy and signals, but also need to withstand dynamic stresses such as vibration, bending, temperature changes, and mechanical extrusion over long periods, which can easily lead to problems such as conductor fatigue fracture, insulation wear, shielding failure, and overall deformation. Traditional automotive wires mostly use pure copper conductors and ordinary PVC insulation sheaths, which have disadvantages such as heavy weight, insufficient fatigue resistance, and susceptibility to permanent deformation. Although copper-clad aluminum conductors can achieve weight reduction to some extent, their fatigue resistance and structural stability under dynamic stress still need improvement; ordinary insulation and sheath materials are prone to molecular chain slippage under long-term stress, leading to permanent deformation or cracking; the shielding and filler layers lack deformation resistance design and are prone to fatigue damage under repeated bending. Therefore, there is an urgent need for a new type of composite automotive wire that can simultaneously meet the requirements of lightweight, deformation resistance, fatigue fracture resistance, and adaptability to complex automotive environments. Utility Model Content

[0003] The purpose of this invention is to provide a composite automotive wire that is resistant to deformation and fatigue fracture, in order to solve the problems existing in the prior art.

[0004] The purpose of this utility model is achieved as follows: a composite automotive wire resistant to deformation and fatigue fracture, comprising a copper-clad aluminum conductor, an irradiated cross-linked polyvinyl chloride insulation layer covering the copper-clad aluminum conductor, a tinned copper wire braided layer disposed outside the irradiated cross-linked polyvinyl chloride insulation layer, an aluminum foil wrapping shielding layer wrapped around the tinned copper wire braided layer, a honeycomb nonwoven fabric filling layer disposed outside the aluminum foil wrapping shielding layer, and an irradiated cross-linked polyvinyl chloride sheath extruded outside the honeycomb nonwoven fabric filling layer.

[0005] This invention relates to a composite automotive wire that is resistant to deformation and fatigue fracture. The copper-clad aluminum conductor composite structure achieves a balance of rigidity and flexibility, and the difference in thermal expansion coefficients between aluminum and copper creates a "buffer gap" to disperse stress. The irradiated cross-linked polyvinyl chloride insulation layer, with its three-dimensional network molecular structure, evenly disperses external forces and reduces deformation. The tin-plated copper wire braided layer, with its tight network structure and tin plating, enhances toughness and alleviates fatigue accumulation. The aluminum foil-wrapped shielding layer, through its spiral-wrapped continuous tubular structure, deforms synchronously with the wire, delaying fatigue cracking. The honeycomb non-woven fabric filling layer, with its honeycomb grid structure, disperses stress and absorbs vibration energy. The irradiated cross-linked polyvinyl chloride sheath is made of the same material as the insulation layer, reducing interlayer stress conflict. The deep synergy of material properties and process design among these components gives the wire superior deformation resistance and fatigue fracture resistance under complex operating conditions, significantly improving the mechanical stability, signal integrity, and durability of automotive wires under harsh conditions such as vibration, bending, and high / low temperature cycling.

[0006] As a further improvement of this invention, the copper-clad aluminum conductor consists of an aluminum core and a copper outer layer covering the aluminum core. The aluminum core provides the conductor with appropriate rigidity to avoid excessive deformation during bending and pulling, while the copper outer layer ensures good conductivity and ductility, and can withstand a certain degree of plastic deformation without easily cracking. At the same time, the "buffer gap" formed between the aluminum and copper due to the difference in their coefficients of thermal expansion can disperse localized stress concentration points under dynamic stress, further improving the reliability of the conductor in complex wiring environments.

[0007] As a further improvement of this utility model, the polyvinyl chloride molecular chains inside the irradiated cross-linked polyvinyl chloride insulation layer have a three-dimensional network cross-linked structure, which gives it excellent resistance to deformation and elastic recovery rate, effectively resisting permanent deformation and maintaining insulation integrity.

[0008] As a further improvement of this invention, the tin-plated copper wire braided layer has an interwoven mesh structure, and the surface of the copper wire is plated with a tin layer. The tight mesh structure can effectively disperse external impacts such as compression and torsion, avoiding permanent deformation. The tin plating layer can enhance the toughness of the copper wire and reduce the risk of embrittlement during deformation. At the same time, its excellent elastic recovery performance can alleviate fatigue accumulation and delay fracture during repeated bending and stretching, providing solid structural support for the wire. In summary, the tin-plated copper wire braided layer, with its interwoven mesh structure and the protection of the tin layer, provides excellent electromagnetic shielding effectiveness and mechanical toughness, significantly improving the overall bending fatigue life of the cable.

[0009] As a further improvement of this utility model, the aluminum foil wrapping shielding layer is a continuous tubular structure formed by a spiral wrapping process using high-ductility aluminum foil, with overlapping areas between the aluminum foil layers. The high-ductility aluminum foil allows the wrapping layer to change synchronously with the bending, extrusion, and stretching of the wire, making it less prone to cracking and falling off. The overlapping structure can disperse repeated stress damage, delay the generation and propagation of fatigue cracks, and the wrapping layer has good adhesion to the internal structure, reducing interlayer friction and extending the service life of the wire.

[0010] As a further improvement of this utility model, the honeycomb nonwoven fabric filling layer is a continuous tubular structure formed by longitudinal wrapping and thermal stitching of a high-strength nonwoven fabric material with a honeycomb mesh structure. The honeycomb mesh can form a uniform three-dimensional support system, disperse external compression and bending stress, maintain the relative position stability of the internal conductor and insulation layer, and the porous elastic properties can also absorb vibration energy and reduce stress accumulation. At the same time, it is lightweight and flexible, adaptable to various laying requirements, and the thermal stitching process also ensures the continuity and structural strength of the filling layer.

[0011] As a further improvement of this utility model, the number of copper-clad aluminum conductors is three, which can simultaneously meet the needs of multi-circuit signal or energy transmission in automotive electrical systems, greatly saving wiring space. Moreover, each copper-clad aluminum conductor has the advantages of combining rigidity and flexibility and dispersing stress, which can ensure that the overall wire still maintains excellent resistance to deformation and fatigue fracture when transmitting multiple circuits. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of the deformation-resistant and fatigue-resistant composite automotive wire of this utility model.

[0013] The structure consists of: 1. Copper-clad aluminum conductor; 2. Irradiated cross-linked polyvinyl chloride insulation layer; 3. Tinned copper wire braided layer; 4. Aluminum foil wrapped shielding layer; 5. Honeycomb non-woven fabric filling layer; and 6. Irradiated cross-linked polyvinyl chloride sheath. Detailed Implementation

[0014] like Figure 1 The deformation-resistant and fatigue-resistant composite automotive wire shown includes a copper-clad aluminum conductor 1, an irradiated cross-linked polyvinyl chloride insulation layer 2 covering the copper-clad aluminum conductor 1, a tinned copper wire braided layer 3 disposed outside the irradiated cross-linked polyvinyl chloride insulation layer 2, an aluminum foil wrapped shielding layer 4 wrapped outside the tinned copper wire braided layer 3, a honeycomb nonwoven fabric filling layer 5 disposed outside the aluminum foil wrapped shielding layer 4, and an irradiated cross-linked polyvinyl chloride sheath 6 extruded outside the honeycomb nonwoven fabric filling layer 5.

[0015] Among them, the copper-clad aluminum conductor 1, as a superior alternative to pure copper conductors, exhibits multiple significant advantages due to its unique composite structure. Its core uses aluminum as the substrate, with an outer layer of high-purity copper. While ensuring basic conductivity, it achieves a balance of rigidity and flexibility—the aluminum substrate provides the conductor with appropriate rigidity, preventing excessive deformation during bending and stretching; the outer copper layer maintains the ductility of the metal, capable of withstanding a certain degree of plastic deformation without easily cracking. Simultaneously, when the conductor is subjected to dynamic stress environments such as vibration and temperature cycling for extended periods, the difference in thermal expansion coefficients between aluminum and copper creates a small "buffer gap," which can disperse local stress concentration points, making it a reliable choice in complex wiring environments. In this embodiment, three copper-clad aluminum conductors 1 are used, simultaneously meeting the multi-circuit signal or energy transmission needs of the automotive electrical system, significantly saving wiring space. Each copper-clad aluminum conductor 1 possesses the advantages of a balance of rigidity and flexibility and stress dispersion, ensuring that the overall wire maintains excellent resistance to deformation and fatigue fracture during multi-circuit transmission.

[0016] The irradiated cross-linked polyvinyl chloride (PVC) insulation layer 2 has a three-dimensional network cross-linked structure of PVC molecular chains, which is more tightly and firmly bonded to molecules compared to the linear molecular structure of ordinary PVC. When subjected to external forces such as compression, stretching, long-term vibration, or load, its network molecular structure can evenly distribute stress throughout the entire molecular system, preventing stress concentration in local areas and effectively restraining the movement of molecular chains. Under the same external force, the deformation amplitude is significantly reduced, and it can quickly rebound to its original shape after the external force disappears. Even in long-term stress environments, it can stably maintain the integrity of the insulation structure, ensuring that the insulation performance is not affected.

[0017] The tin-plated copper wire braided layer 3 has an interwoven mesh structure, and the surface of the copper wires is plated with a tin layer. The tin-plated copper wire braided layer 3, with its tightly interwoven mesh structure and the composite material properties of copper and tin, significantly improves the cable's resistance to deformation and fatigue fracture. The tight braiding disperses external impacts, preventing permanent deformation even under compression or torsion, thus maintaining structural integrity. The tin plating enhances the toughness of the copper wires, reducing the risk of embrittlement during deformation. Furthermore, the tin-plated copper wire braided layer 3 exhibits excellent elastic recovery performance, effectively mitigating fatigue accumulation and delaying fracture under repeated bending and stretching dynamic stresses, providing robust structural support for the long-term use of the cable in complex operating conditions.

[0018] The aluminum foil-wrapped shielding layer 4 is a crucial support for maintaining the structural stability of the cable under complex operating conditions. Utilizing high-ductility aluminum foil, a continuous tubular three-dimensional protective structure is formed through a spiral wrapping process. This effectively resists deformation caused by external forces. Even under bending, compression, or tension, the wrapping layer adapts to the cable's shape, preventing cracking or detachment and maintaining the integrity of the shield. Simultaneously, the overlapping structure created by the wrapping process disperses damage caused by repeated stress. In long-term dynamic bending and vibration environments, it significantly delays the initiation and propagation of fatigue cracks, improving fatigue fracture resistance. Furthermore, the excellent fit between the aluminum foil wrapping layer and the cable's internal structure reduces interlayer friction during deformation, further extending the cable's service life.

[0019] The honeycomb nonwoven filling layer 5 is a continuous tubular structure formed by longitudinal wrapping and heat-sealing of high-strength nonwoven fabric with a honeycomb mesh structure. The honeycomb nonwoven filling layer 5 uses a special molding process to create a honeycomb mesh structure from high-strength nonwoven fabric, forming a uniformly distributed three-dimensional support system. This effectively disperses stress generated by external compression and bending, preventing cable deformation due to excessive local stress. Even under continuous external force in complex laying environments, it maintains the relative positional stability of the internal conductor and insulation layer. Simultaneously, the porous elastic properties of the honeycomb structure buffer fatigue damage caused by repeated bending and vibration. Under long-term dynamic stress, it absorbs energy through its own deformation, reducing stress accumulation within the material and significantly improving the overall fatigue fracture resistance of the cable. Furthermore, the honeycomb nonwoven filling layer is lightweight, does not add excessive weight to the cable, and has good flexibility, adapting to various cable laying requirements.

[0020] The irradiated cross-linked polyvinyl chloride sheath 6, made of the same material as the insulation layer 2, enhances overall synergistic performance. This ensures consistent thermal expansion coefficients and deformation trends under temperature changes and external forces, effectively reducing stress conflicts between layers caused by material differences. It also prevents peeling and cracking during alternating heating and cooling or repeated bending, thus strengthening the cable's overall resistance to deformation. Furthermore, it simplifies the production process, reduces the cost of procuring different materials and adjusting processes, and eliminates the need for complex separation during recycling, making it more environmentally friendly and providing convenience and stability throughout the cable's entire lifecycle.

[0021] In summary, the deformation-resistant and fatigue-resistant composite automotive wire of this embodiment features a deep synergy between the material properties and process design of each layer, enabling the wire to possess superior deformation resistance and fatigue fracture resistance under complex working conditions. This significantly improves the mechanical stability, signal integrity, and durability of automotive wires under harsh conditions such as vibration, bending, and high and low temperature cycling.

[0022] This utility model is not limited to the above embodiments. Based on the technical solutions disclosed in this utility model, those skilled in the art can make some substitutions and modifications to some of the technical features without creative labor, and these substitutions and modifications are all within the protection scope of this utility model.

Claims

1. A kink resistant, fatigue resistant, composite automotive wire, characterized by: It includes a copper-clad aluminum conductor, an irradiated cross-linked polyvinyl chloride (PVC) insulation layer covering the copper-clad aluminum conductor, a tin-plated copper wire braided layer disposed outside the irradiated PVC insulation layer, an aluminum foil wrapping shielding layer wrapped around the tin-plated copper wire braided layer, a honeycomb nonwoven fabric filling layer disposed outside the aluminum foil wrapping shielding layer, and an irradiated PVC sheath extruded outside the honeycomb nonwoven fabric filling layer.

2. The resistance to deformation, fatigue resistant, fracture resistant composite automotive wire of claim 1, wherein: The copper-clad aluminum conductor consists of an aluminum core and a copper outer layer covering the aluminum core.

3. The kink resistant, fatigue fracture resistant composite automotive wire of claim 1, wherein: The irradiated cross-linked polyvinyl chloride insulation layer has a three-dimensional network cross-linked structure of polyvinyl chloride molecular chains inside.

4. The kink resistant, fatigue fracture resistant composite automotive wire of claim 1, wherein: The tin-plated copper wire braided layer has an interwoven mesh structure, and the surface of the copper wire is plated with a tin layer.

5. The resistance to deformation, fatigue resistant, fracture resistant composite automotive wire of claim 1, wherein: The aluminum foil wrapping shielding layer is a continuous tubular structure formed by a spiral wrapping process using high-ductility aluminum foil, with overlapping areas between the aluminum foil layers.

6. The resistance to deformation, fatigue resistant, fracture resistant composite automotive wire of claim 1, wherein: The honeycomb nonwoven filling layer is a continuous tubular structure formed by longitudinal wrapping and heat-sealing of a high-strength nonwoven material with a honeycomb grid structure.

7. The kink resistant, fatigue fracture resistant composite automotive wire of any of claims 1-6, wherein: The number of copper-clad aluminum conductors is 3.

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