Aluminum alloy small-section wire for anti-vibration automobile

Abstract

The utility model discloses an anti-vibration aluminium alloy small section conductor for automobile, including aluminium alloy conductor, the aluminium alloy conductor is covered with graphene deposition layer, PE foamed insulating layer, bamboo joint bionical anti-vibration layer and elastomer sheath outward gradually, bamboo joint bionical anti-vibration layer is annular convex that is spaced apart and arranged in the outer surface of PE foamed insulating layer, is equipped with hollow cavity in annular convex, fills with flexible damping material in hollow cavity. The utility model discloses an anti-vibration aluminium alloy small section conductor for automobile, can improve the long -term reliability, signal integrity and service life of automobile conductor under complex working condition significantly while realizing the light weight and miniaturization of utmost.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a vibration-resistant aluminum alloy small-section conductor for automobiles. Background Technology

[0002] In the automotive wiring harness field, especially in vibration-sensitive areas of both new energy vehicles and traditional vehicles, wires are constantly subjected to complex mechanical vibration environments. Traditional small-section wires mostly use copper conductors and ordinary insulation sheaths, which suffer from problems such as heavy weight, susceptibility to fatigue, and insufficient vibration resistance. Although aluminum alloy conductors can reduce weight and cost, their tensile and bending fatigue resistance still needs to be improved. In addition, continuous vibration can easily lead to insulation wear, cracking, and even short-circuit faults. Existing vibration-resistant designs often use thickened sheaths or external wrapping, which increases the diameter and weight of the wiring harness, making it unsuitable for wiring and lightweight design within the compact automotive space. Therefore, there is an urgent need for a small-section wire solution that integrates lightweight, high conductivity, and excellent vibration resistance. Utility Model Content

[0003] The purpose of this invention is to provide a vibration-resistant aluminum alloy small-section conductor for automobiles, in order to solve the problems existing in the prior art.

[0004] The purpose of this utility model is achieved as follows: a vibration-resistant aluminum alloy small cross-section wire for automobiles, comprising an aluminum alloy conductor, the aluminum alloy conductor being sequentially covered with a graphene deposition layer, a PE foam insulation layer, a bamboo-like bionic vibration-damping layer and an elastomer sheath, the bamboo-like bionic vibration-damping layer being annular protrusions spaced apart on the outer surface of the PE foam insulation layer, the annular protrusions having a hollow cavity inside, the hollow cavity being filled with a flexible damping material.

[0005] This invention relates to a vibration-resistant aluminum alloy small-section wire for automobiles. Through a composite and synergistic design from the inside out, consisting of an aluminum alloy conductor, a graphene deposition layer, a PE foam insulation layer, a bamboo-inspired vibration-damping layer, and an elastomer sheath, it achieves extreme lightweighting and miniaturization while systematically solving a series of core problems such as conductor fatigue and oxidation, stress cracking of the insulation layer, absorption and dissipation of vibration energy, and environmental tolerance under high-frequency vibration environments. This significantly improves the long-term reliability, signal integrity, and service life of automotive wires under complex operating conditions.

[0006] As a further improvement of this invention, the height of the annular protrusion is 0.3mm, and the interval between adjacent annular protrusions is 5mm. This parameter is compatible with micro-injection molding technology, which precisely changes the stress transmission path through the bamboo-like node design with a 5mm interval to avoid resonance effects, and ensures the vibration energy dispersion effect without increasing the overall diameter of the conductor with the 0.3mm protrusion height, thus ensuring small cross-section characteristics and wiring flexibility.

[0007] As a further improvement of this invention, the PE foam insulation layer has a uniformly distributed micron-level closed-cell structure. The micron-level closed-cell structure formed by the precision physical foaming process of the PE foam insulation layer not only absorbs vibration energy through the elastic deformation of independent micropores and dissipates resonance energy through cell friction and gas damping effects, achieving the dual functions of "vibration reduction + noise reduction," but also endows the insulation layer with excellent flexibility due to its low modulus characteristics, avoiding stress cracking under high-frequency vibration, while simultaneously reducing the insulation layer density, further contributing to the lightweighting of the conductor.

[0008] As a further improvement of this utility model, the annular protrusion is integrally formed with the PE foam insulation layer, which completely eliminates the interlayer interface, avoids the potential risk of delamination, and ensures that vibration energy is efficiently and smoothly transmitted and dissipated in the overall structure.

[0009] As a further improvement of this utility model, the cross-section of the aluminum alloy conductor is no more than 6 mm², which can accurately adapt to the wiring needs of the narrow space of the car. At the same time, combined with the lightweight characteristics of the aluminum alloy conductor, the weight of the whole vehicle electrical system is further reduced. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the structure of the vibration-resistant aluminum alloy small-section conductor for automobiles according to this utility model.

[0011] The structure consists of 1 aluminum alloy conductor, 2 graphene deposition layer, 3 PE foam insulation layer, 4 bamboo-inspired biomimetic vibration-damping layer, and 5 elastomer sheath. Detailed Implementation

[0012] like Figure 1 The vibration-resistant aluminum alloy small cross-section wire for automobiles shown includes an aluminum alloy conductor 1, which is covered with a graphene deposition layer 2, a PE foam insulation layer 3, a bamboo-like bionic vibration-damping layer 4, and an elastomer sheath 5 in sequence. The bamboo-like bionic vibration-damping layer 4 consists of annular protrusions spaced on the outer surface of the PE foam insulation layer 3. The annular protrusions have a hollow cavity inside, which is filled with a flexible damping material.

[0013] Among them, the aluminum alloy conductor 1 is the lightweight backbone of data transmission. Incorporating rare earth elements and an optimized formula, it maintains excellent conductivity while achieving a density only one-third that of copper conductors, thus creating a core advantage in lightweight transmission. Innovative grain refinement technology results in a uniform and dense conductor structure, and the surface features a nano-level anti-oxidation coating that effectively reduces contact resistance, controlling signal attenuation at industry-leading levels and ensuring the stability of high-speed data transmission over long distances. The cross-section of the aluminum alloy conductor 1 is no greater than 6 mm², precisely adapting to the wiring requirements of confined automotive spaces. Furthermore, combined with the lightweight characteristics of the aluminum alloy conductor 1, it further reduces the weight of the entire vehicle's electrical system.

[0014] The graphene deposition layer 2, using atomically thin graphene as the core material, precisely constructs a nanoscale protective barrier on the surface of the aluminum alloy conductor 1 using chemical vapor deposition technology. When subjected to vibration, it can rapidly disperse stress, preventing structural damage caused by stress concentration. Its unique van der Waals forces between layers allow the multilayer graphene to dissipate energy through interlayer slippage during vibration, effectively reducing the vibration frequency and amplitude. Furthermore, its superior conductivity reduces the cross-sectional area of ​​the conductor for the same current carrying capacity, providing a solid guarantee for the miniaturization and integration design of automotive wiring harnesses.

[0015] The PE foam insulation layer 3, through a precision physical foaming process, transforms the polyethylene matrix into a uniformly distributed micron-sized closed-cell structure, creating an efficient vibration buffer system for the cable. These densely packed, independent micropores act like countless miniature springs; when encountering vibration, the pore walls absorb and disperse energy through elastic deformation, effectively attenuating the transmission of vibration waves. When the external vibration frequency resonates with the natural frequency of the pore structure, the friction between the pores and the gas damping effect further dissipate energy, allowing the cable to maintain stable operation even under vibration. Simultaneously, the low modulus of PE foam material endows the insulation layer with excellent flexibility, preventing cracking or damage caused by stress concentration even in high-frequency, high-amplitude vibration scenarios, ensuring a tight fit between the cable's internal conductor and insulation layer. Furthermore, its closed-cell structure blocks the propagation of mechanical noise generated by vibration, achieving a dual function of "vibration reduction and noise reduction."

[0016] The bamboo-joint biomimetic vibration-damping layer 4 utilizes micro-injection molding technology to create annular protrusions with a height of 0.3mm at 5mm intervals around the PE foam insulation layer 3, forming a node design similar to bamboo joints. This effectively alters the stress transmission path, disperses the energy generated by vibration, and significantly reduces the impact of resonance on the cable. Furthermore, the annular protrusions are integrally molded with the PE foam insulation layer 3, completely eliminating the interlayer interface, avoiding potential delamination risks, and ensuring efficient and smooth transmission and dissipation of vibration energy within the overall structure. The hollow cavity inside the bamboo-joint biomimetic vibration-damping layer 4 is filled with flexible damping material, which absorbs vibration while reducing its own weight. Even in high-frequency, high-intensity vibration environments, the bamboo-joint biomimetic vibration-damping layer 4, with its unique structure and excellent buffering performance, ensures the stability of the cable's internal conductors, guarantees accurate and continuous signal transmission, and provides a reliable protective barrier for the stable operation of equipment.

[0017] The elastomer sheath 5, serving as the cable's terminal protection layer, is made of a composite material with high elastic modulus and high damping characteristics, exhibiting excellent weather resistance, abrasion resistance, and chemical corrosion resistance. Its unique elastic network structure enables the cable to construct an efficient vibration buffer system through the dynamic response mechanism of its molecular chains. Upon encountering vibration, the molecular chains can reversibly stretch and curl, converting vibrational energy into intramolecular frictional heat dissipation, effectively reducing vibration. Even under harsh environmental conditions, it maintains softness and elasticity, avoiding vibration-resistant failure caused by low-temperature hardening or high-temperature softening.

[0018] In summary, the vibration-resistant automotive aluminum alloy small-section wire of this embodiment, through a composite collaborative design from the inside out of "aluminum alloy conductor 1 - graphene deposition layer 2 - PE foam insulation layer 3 - bamboo-like biomimetic vibration-damping layer 4 - elastomer sheath 5", achieves extreme lightweighting and miniaturization while systematically solving a series of core problems such as conductor fatigue and oxidation, insulation layer stress cracking, vibration energy absorption and dissipation, and environmental tolerance under high-frequency vibration environment. It significantly improves the long-term reliability, signal integrity, and service life of automotive wires under complex working conditions.

[0019] 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. An anti-vibration aluminum alloy small cross-section wire for an automobile, characterized by: The device includes an aluminum alloy conductor, which is sequentially covered with a graphene deposition layer, a PE foam insulation layer, a bamboo-like bionic vibration damping layer, and an elastomer sheath. The bamboo-like bionic vibration damping layer consists of annular protrusions spaced apart on the outer surface of the PE foam insulation layer. Each annular protrusion has a hollow cavity filled with a flexible damping material.

2. The vibration-resistant aluminum alloy small-section conductor for automobiles according to claim 1, characterized in that: The height of the annular protrusion is 0.3 mm, and the interval between adjacent annular protrusions is 5 mm.

3. The vibration-resistant aluminum alloy small-section conductor for automobiles according to claim 1, characterized in that: The PE foam insulation layer has a uniformly distributed micron-sized closed-cell structure.

4. The vibration-resistant aluminum alloy small-section conductor for automobiles according to claim 1, characterized in that: The annular protrusion is integrally formed with the PE foam insulation layer.

5. The vibration-resistant aluminum alloy small-section conductor for automobiles according to any one of claims 1-4, characterized in that: The cross-section of the aluminum alloy conductor is no greater than 6 mm².

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