A high-strength buffer vehicle cable

Abstract

This utility model discloses a high-strength buffer vehicle cable, including a support body disposed within an insulation layer and tightly fitted to the cable core. A filler body fills the gap between the support body and the insulation layer. The filler body has an auxiliary structure that cooperates with the filler body to enhance the cable's buffering and bending resistance. This high-strength buffer vehicle cable, with its excellent buffering performance, bending resistance, and environmental adaptability, can meet the usage requirements of different scenarios and is suitable for various types of vehicles, including passenger cars, commercial vehicles, and new energy vehicles. It can effectively ensure the stable operation of the vehicle's electrical system and improve the vehicle's safety and reliability.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically a high-strength buffer vehicle cable. Background Technology

[0002] Vehicle-mounted cables are critical components inside automobiles used for transmitting electrical energy and signals. They typically consist of conductors, insulation layers, and sheathing layers, possessing good conductivity, insulation, and environmental resistance. With the continuous development of automotive technology, the application scenarios for vehicle-mounted cables are becoming increasingly complex, requiring not only to meet basic electrical performance requirements but also to possess higher mechanical properties, especially shock absorption capabilities.

[0003] During the use of vehicle-mounted cables, their working environment is complex and varied, and they are often threatened by various external impacts. For example, during vehicle operation, they may encounter road bumps, collisions, and other situations. If these external impacts act directly on the cable, they may cause damage to the internal structure of the cable, such as conductor breakage and insulation layer damage, thereby affecting the normal function of the cable. In addition, mechanical vibration inside the car will also generate continuous stress on the cable, reducing its service life. Therefore, it is crucial to improve the shock absorption and resistance of vehicle-mounted cables.

[0004] To address the aforementioned issues, improving the shock absorption capacity of vehicle cables can not only enhance their reliability and lifespan but also ensure the stable operation of automotive electronic systems, which is of great significance for improving the overall performance and safety of automobiles. Utility Model Content

[0005] This utility model addresses the problem that existing technical solutions are too simplistic by providing a high-strength buffer vehicle cable solution that is significantly different from existing technologies, thus solving the problems mentioned in the background.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a high-strength buffer vehicle-mounted cable, comprising a support body, the end of which is connected to an insulation layer, and several cable cores are disposed between the support body and the insulation layer. A filler is provided in the gap between the support body and the insulation layer to limit the cable cores. An auxiliary structure is also provided on the filler to enhance the cable's buffering performance and bending resistance. Furthermore, a braided layer and an outer sheath are sequentially wrapped around the outside of the insulation layer; these two layers protect the cable from external environmental corrosion.

[0007] Preferably, the support body is configured in a cross shape with good support capacity, and the support body is made of thermoplastic elastomer material. The TPE material can remain soft in an environment of -50℃ to 125℃, and will not harden or crack after repeated bending, and has good elasticity and fatigue resistance.

[0008] Preferably, the filler is made of granular or foamed polyurethane material and is used to fill the gap between the support and the insulation layer to absorb and disperse external impacts and enhance the buffering performance of the cable.

[0009] Preferably, the auxiliary structure includes grooves and auxiliary tubes. The filler has several grooves at equal angles, and each groove is embedded with an auxiliary tube to further disperse external impact, enhance the cable's bending resistance, and together with the filler, form a multi-layer buffer structure.

[0010] Preferably, the auxiliary tube is made of polyethylene material with good wear resistance, anti-aging properties and weather resistance, and basalt fiber is added to further enhance its bending resistance.

[0011] Preferably, the outer cladding layer is made of polyimide material with excellent properties such as high temperature resistance, chemical corrosion resistance, high strength and high modulus, while also exhibiting excellent elasticity, wear resistance and acid and alkali resistance.

[0012] Compared with the prior art, the beneficial effects of this utility model are: the high-strength buffer vehicle cable has excellent buffer performance, bending resistance and environmental adaptability, which enables it to meet the usage requirements in different scenarios. It is suitable for various types of vehicles, including passenger cars, commercial vehicles, new energy vehicles, etc., and can effectively ensure the stable operation of the vehicle's electrical system and improve the safety and reliability of the vehicle. By filling the space between the support and the insulation layer with granular or foamed polyurethane material, and in conjunction with the grooves and auxiliary tubes in the auxiliary structure, a multi-layer buffer structure is formed. This design can effectively absorb and disperse external impacts, significantly enhance the buffering performance of the cable, and reduce damage to the internal structure of the cable caused by external impacts. Compared with traditional cables, the buffering performance of this invention is improved by ≥50%, which can effectively prevent cable breakage or damage caused by external impacts such as bumps and collisions during vehicle operation.

[0013] The support structure features a cross-shaped design and is made of thermoplastic elastomer (TPE) material. TPE material remains flexible in environments ranging from -50℃ to 125℃, and does not harden or crack even after repeated bending, exhibiting excellent elasticity and fatigue resistance. This design not only provides stable support for the cable core but also enhances the overall bending resistance of the cable, enabling it to withstand ≥100,000 repeated bending cycles without damage.

[0014] The auxiliary tube is made of polyethylene and has added basalt fiber, which further enhances its wear resistance, anti-aging performance and weather resistance. The auxiliary tube is embedded in the groove of the filler and together with the filler, it forms a multi-layer buffer structure, which further disperses the impact of external forces and enhances the cable's bending resistance. The addition of the auxiliary tube improves the cable's bending resistance by ≥30% and wear resistance by ≥20%, which significantly improves the cable's service life under complex working conditions.

[0015] The outer sheath is made of polyimide, which possesses excellent high-temperature resistance, chemical corrosion resistance, high strength, and high modulus. This material maintains stable performance under high-temperature environments and exhibits good resistance to chemicals such as acids and alkalis. The outer sheath has a high-temperature resistance ≥200℃, a chemical corrosion resistance ≥90% (tested according to GB / T 2423 standard), and an abrasion resistance ≥1500 cycles (tested according to GB / T 2412 standard), significantly improving the cable's service life and reliability in harsh environments.

[0016] With the close fit between the support and the cable core, and the rational design of the filler and auxiliary structures, the overall cable structure of the present invention is more stable. This design not only improves the cable's resistance to bending and buffering performance, but also ensures the stability and reliability of the cable during long-term use. The overall structural stability of the cable is improved by ≥30%, the service life is extended by ≥50%, and the maintenance and replacement costs of the cable are significantly reduced. Attached Figure Description

[0017] Figure 1 This is a cross-sectional structural diagram of the present invention.

[0018] In the diagram: 1. Support body; 2. Cable core; 3. Filler; 4. Auxiliary structure; 401. Groove; 402. Auxiliary tube; 5. Insulation layer; 6. Braided layer; 7. Outer sheath. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0020] Please see Figure 1This utility model provides a technical solution: a high-strength buffer vehicle-mounted cable, comprising a support body 1, cable cores 2, a filler body 3, an auxiliary structure 4, a groove 401, an auxiliary tube 402, an insulation layer 5, a braided layer 6, and an outer sheath 7. The end of the support body 1 is connected to the insulation layer 5, and several cable cores 2 are disposed between them. These cable cores 2 are limited by the filler body 3, which fills the gap between the support body 1 and the insulation layer 5. An auxiliary structure 4 is provided on the filler body 3 to enhance the cable's buffering and bending resistance. Furthermore, the insulation layer 5 is sequentially covered by a braided layer 6 and an outer sheath 7, which together constitute the cable's external protective layer, protecting the cable from external environmental corrosion.

[0021] The support body 1 is designed in a cross shape with good support capacity, and the support body 1 is made of thermoplastic elastomer TPE material. TPE material can remain soft in an environment of -50℃ to 125℃, and will not harden or crack after repeated bending. It has good elasticity and fatigue resistance.

[0022] The filler 3 is made of granular or foamed polyurethane material and is used to fill the gap between the support 1 and the insulation layer 5 to absorb and disperse external impact and enhance the buffer performance of the cable. The tensile strength of the polyurethane material is ≥20MPa, the elongation at break is ≥500%, and the abrasion resistance is ≥1000 cycles (tested according to GB / T 2412 standard).

[0023] The auxiliary structure 4 includes a groove 401 and an auxiliary tube 402. The filler 3 has several grooves 401 at equal angles, and each groove 401 is embedded with an auxiliary tube 402 to further disperse the impact of external force, enhance the bending resistance of the cable, and together with the filler 3, form a multi-layer buffer structure.

[0024] The auxiliary tube 402 is made of polyethylene material with good wear resistance, anti-aging properties and weather resistance, and basalt fiber is added to further enhance its bending resistance. After adding basalt fiber to the polyethylene material, its bending resistance is improved by ≥30% and its wear resistance is improved by ≥20%.

[0025] The outer layer 7 is made of polyimide material with excellent high temperature resistance, chemical corrosion resistance, high strength and high modulus. It also performs well in terms of elasticity, wear resistance and acid and alkali resistance. The high temperature resistance of the polyimide material is ≥200℃, the chemical corrosion resistance is ≥90% (tested according to GB / T 2423 standard), and the wear resistance is ≥1500 cycles (tested according to GB / T 2412 standard).

[0026] Cable core preparation: It is made of multiple strands of copper wire to ensure that the cable core 2 has good conductivity and flexibility.

[0027] The twisted cable core 2 is shaped using a mold so that its outer diameter matches the inner diameter of the support body 1.

[0028] Support preparation: A cross-shaped support 1 is prepared by injection molding using thermoplastic elastomer (TPE) material.

[0029] Insert the cable core 2 into the center hole of the support body 1, ensuring that the two fit tightly together.

[0030] Filler filling: Granular or foamed polyurethane material is filled into the gap between the support 1 and the insulation layer 5 through injection molding or filling processes.

[0031] Ensure that the filler 3 is evenly distributed and fully filled to achieve good cushioning performance.

[0032] Auxiliary structure installation: Several grooves 401 are made at equal angles on the filler 3, and the size and position accuracy of the grooves are ensured by using a mold forming process.

[0033] An auxiliary tube 402, made of polyethylene with added basalt fiber, is embedded in the groove 401 to ensure that the auxiliary tube is tightly bonded to the filler 3.

[0034] Insulation layer coating: High-insulation polyethylene material is used, and the insulation layer 5 is uniformly wrapped around the outside of the cable core 2 and the filler 3 through an extrusion process.

[0035] Ensure that the thickness of insulation layer 5 is uniform and that its insulation performance meets the standard requirements.

[0036] Woven layer weaving: High-strength tin-plated copper wire is used, and the braided layer 6 is evenly braided on the outside of the insulation layer 5 by a braiding machine.

[0037] Ensure that the weaving density and strength of braided layer 6 meet the design requirements and provide good mechanical protection performance.

[0038] Outer layer coating: Polyimide material is used, and the outer layer 7 is uniformly wrapped around the outside of the braided layer 6 through an extrusion process.

[0039] Ensure that the thickness of the outer layer 7 is uniform and that its high temperature resistance and chemical corrosion resistance meet the standard requirements.

[0040] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high strength, cushioned, vehicle mounted cable comprising a support body (1) characterised in that: The support (1) is connected to an insulation layer (5) at its end, and a plurality of cable cores (2) are provided between the support (1) and the insulation layer (5). A filler (3) for limiting the cable cores (2) is filled between the support (1) and the insulation layer (5). An auxiliary structure (4) for enhancing the buffer and bending resistance of the cable is provided on the filler (3). A braided layer (6) and an outer sheath (7) are sequentially wrapped around the insulation layer (5). The auxiliary structure (4) includes a groove (401) and an auxiliary tube (402). The filler (3) has several grooves (401) at equal angles, and each groove (401) is embedded with an auxiliary tube (402) for further dispersing the impact of external forces. The auxiliary structure (4) and the filler (3) together constitute a multi-layer buffer structure.

2. The high-strength buffer vehicle-mounted cable according to claim 1, characterized in that: The support (1) is configured in a "+" shape and is made of thermoplastic elastomer material.

3. A high strength, buffered, vehicle mounted cable according to claim 1, wherein: The filler (3) is made of granular or foamed polyurethane material and is used to fill the gap between the support (1) and the insulation layer (5).

4. The high strength, buffered, vehicle cable of claim 1, wherein: The auxiliary tube (402) is made of polyethylene material.

5. A high strength, buffered, vehicle mounted cable according to claim 1, wherein: The outer layer (7) is made of polyimide material.

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