Cable, copper-aluminum stranded wire, and assembly thereof

Abstract

The present invention relates to the technical field of conductive wires, and in particular relates to a cable, a copper-aluminum stranded wire, and an assembly thereof. In the copper-aluminum stranded wire, stranded unit layers are layeredly arranged. Each stranded unit layer is provided with both aluminum wire stranded unit layers and copper wire stranded unit layers. Copper stranded units forming the copper wire stranded unit layers comprise at least two copper wires, and aluminum stranded units forming the aluminum wire stranded unit layers comprise at least two aluminum wires. In a copper-aluminum stranded wire formed in such a mode, copper wires and aluminum wires are twisted together, so that the weight of pure copper stranded wires can be reduced, and meanwhile, costs are reduced. In addition, since the stranded unit layers are composed of copper stranded wire units or aluminum stranded wire units, the outermost stranded unit layer is made of a single material, so that welding connection is facilitated when the copper-aluminum stranded wire is connected to a conductive component.

Description

Cable, copper-aluminum twisted wire and components thereof Technical Field

[0001] The present invention relates to the technical field of conductors, in particular to a cable, a copper-aluminum twisted wire and components thereof. Background Art

[0002] Copper and aluminum wires are widely used in power transmission, switching power supply magnetic components, and electromagnetic induction devices. As switching power supply magnetic components and electromagnetic induction devices increase in frequency and power, the skin effect reduces the effective area of ​​a single copper or aluminum wire, increasing losses and causing a rapid temperature rise. To increase the effective area, multiple thinner wires are often twisted together to form stranded wire. Currently, stranded wires are mostly made of a single copper wire. While copper metal has high conductivity, it also comes with high density, weight, and relatively high cost. Technical issues

[0003] The invention provides a copper-aluminum twisted wire, which is used to improve the technical problems of the current copper twisted wire being heavy and having high use cost. Technical Solutions

[0004] In addition, the present invention also aims to provide a cable using the above copper-aluminum twisted wire.

[0005] In addition, the present invention also aims to provide a copper-aluminum stranded wire assembly using the copper-aluminum stranded wire.

[0006] In a first aspect, an embodiment provides a copper-aluminum twisted wire, comprising at least two twisted unit layers, each of the twisted unit layers being arranged in layers from the center to the edge of the copper-aluminum twisted wire; of two adjacent twisted unit layers, the twisted unit layer on the outer side is twisted around the periphery of the twisted unit layer on the inner side; each of the twisted unit layers has twisted units, each of the twisted units being one of a copper wire twisted unit and an aluminum wire twisted unit; the copper wire twisted unit comprising at least two copper wires twisted together; and the aluminum wire twisted unit comprising at least two aluminum wires twisted together.

[0007] At least one of the twisted unit layers is an aluminum wire twisted unit layer, and at least one of the twisted unit layers is a copper wire twisted unit layer; the copper wire twisted unit layer is composed of at least one strand of the copper wire twisted unit, and the aluminum wire twisted unit layer is composed of at least one strand of the aluminum wire twisted unit.

[0008] Furthermore, in one embodiment, the copper wire twisting unit is formed by twisting copper wires, and the aluminum wire twisting unit is formed by twisting aluminum wires.

[0009] Furthermore, in one embodiment, the copper wire twisting unit includes an aluminum wire in the center and multiple copper wires at the periphery of the aluminum wire, and the adjacent copper wires at the periphery of the aluminum wire are in contact so that the multiple copper wires cover the aluminum wire in the center, and / or the aluminum wire twisting unit includes a copper wire in the center and multiple aluminum wires at the periphery of the copper wire, and the adjacent aluminum wires at the periphery of the copper wire are in contact so that the multiple aluminum wires cover the copper wire in the center.

[0010] Furthermore, in one embodiment, the twisted unit layer in the outermost layer has a plurality of twisted units, and adjacent twisted units are in contact, so that the twisted unit layer in the outermost layer covers the twisted unit layer in the second outermost layer.

[0011] Furthermore, in one embodiment, in the copper wire twisting unit, each of the copper wires has a copper wire insulation layer; in the aluminum wire twisting unit, each of the aluminum wires has an aluminum wire insulation layer.

[0012] Furthermore, in one embodiment, the twisted unit layer at the center of the copper-aluminum twisted wire is composed of a single strand of the twisted unit, and the remaining twisted unit layers each include at least two strands of the twisted units; the twisted units of the copper-aluminum twisted wire are arranged in a honeycomb shape.

[0013] Furthermore, in one embodiment, the copper wire twisted unit layers and the aluminum wire twisted unit layers are alternately arranged in layers.

[0014] Furthermore, in one embodiment, the copper-aluminum twisted wire further includes a twisted wire insulation layer, and the twisted wire insulation layer is located outside the outermost twisted unit layer.

[0015] In a second aspect, an embodiment provides a cable, characterized in that it includes a cable sheath and a cable core, the cable core includes a copper-aluminum stranded wire, and the copper-aluminum stranded wire is the copper-aluminum stranded wire described in any embodiment of the first aspect.

[0016] In a third aspect, an embodiment provides a copper-aluminum twisted wire assembly, comprising a copper-aluminum twisted wire and a conductive member conductively connected to the copper-aluminum twisted wire, wherein the copper-aluminum twisted wire is the copper-aluminum twisted wire described in any one of the embodiments of the first aspect; the twisted units in the outermost twisted unit layer are copper wire twisted units, and the conductive member is a copper conductive member, or the twisted units in the outermost twisted unit layer are aluminum wire twisted units, and the conductive member is an aluminum conductive member. Beneficial effects

[0017] According to the copper-aluminum twisted wire in the above embodiment, the twisted unit layers in the copper-aluminum twisted wire are arranged in layers, and each twisted unit layer includes both an aluminum wire twisted unit layer and a copper wire twisted unit layer. The copper twisted units that constitute the copper wire twisted unit layer include at least two copper wires, and the aluminum twisted units that constitute the aluminum wire twisted unit layer include at least two aluminum wires. In the copper-aluminum twisted wire composed in this way, the copper wires and the aluminum wires are twisted together, which can reduce the weight of the pure copper twisted wire and reduce the cost at the same time.

[0018] In addition, since the twisted unit layer is composed of copper twisted wire units or aluminum twisted wire units, the material of the outermost twisted unit layer is single, which facilitates welding connection when connecting the copper and aluminum twisted wires to the conductive parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG1 is a cross-sectional view of a copper-aluminum stranded wire according to an embodiment (the dotted line in the figure represents a stranded unit);

[0020] FIG2 is a cross-sectional view of the copper-aluminum stranded wire in FIG1 before the outermost stranded unit layer is wound during the production process (the dotted line in the figure represents a stranded unit);

[0021] FIG3 is a schematic structural diagram of the copper wire twisting unit in FIG1 (the dotted line in the figure represents a twisting unit);

[0022] FIG4 is a schematic structural diagram of the aluminum wire twisting unit in FIG1 (the dotted line in the figure represents one twisting unit).

[0023] List of feature names corresponding to the figure marks in the figure: 1, twisted unit layer; 1a, copper wire twisted unit layer; 1b, aluminum wire twisted unit layer; 11, twisted unit; 11a, copper wire twisted unit; 11b, aluminum wire twisted unit; 111, copper wire; 112, aluminum wire.

[0024] Explanation of the reference numerals in brackets in the accompanying drawings: In the reference numerals in brackets in the accompanying drawings, the features referred to by the reference numerals are both the features represented by the numbers in the brackets and the features represented by the numbers outside the brackets. Modes for Carrying Out the Invention

[0025] The present invention will be further described in detail below by means of specific embodiments in conjunction with the accompanying drawings. Similar elements in different embodiments are numbered with associated similar elements. In the following embodiments, many detailed descriptions are provided to enable the present application to be better understood. However, those skilled in the art will readily appreciate that some of the features may be omitted in different circumstances, or may be replaced by other elements, materials, or methods. In some cases, some operations related to the present application are not shown or described in the specification. This is to avoid the core portion of the present application being overwhelmed by excessive descriptions, and for those skilled in the art, it is not necessary to describe these related operations in detail. They will fully understand the related operations based on the description in the specification and the general technical knowledge in the art.

[0026] In addition, the features, operations, or characteristics described in the specification may be combined in any appropriate manner to form various embodiments. Furthermore, the steps or actions in the method description may be reordered or adjusted in a manner readily apparent to those skilled in the art. Therefore, the various sequences in the specification and drawings are provided solely for the purpose of clearly describing a particular embodiment and are not intended to be mandatory, unless otherwise specified.

[0027] Component numbers used herein, such as "first" and "second," are used solely to distinguish the components being described and do not convey any sequential or technical meaning. References to "connection" and "coupling" herein, unless otherwise specified, include both direct and indirect connections (couplings).

[0028] In one embodiment, referring to Figures 1 to 4 , a copper-aluminum stranded wire includes at least two stranded unit layers 1, each of which is arranged in layers from the center to the edge of the copper-aluminum stranded wire. Of two adjacent stranded unit layers 1, the outer stranded unit layer 1 is twisted around the inner stranded unit layer 1, i.e., each stranded unit layer 1 is arranged in an inner-outer layer. The number of stranded units can be two, three, four, or any other number.

[0029] Each stranded unit layer 1 comprises stranded units 11, each of which is either a copper wire stranded unit 11a or an aluminum wire stranded unit 11b. The copper wire stranded unit 11a comprises at least two twisted copper wires 111, while the aluminum wire stranded unit 11b comprises at least two twisted aluminum wires 112. At least one stranded unit layer 1 is an aluminum wire stranded unit layer 1b, and at least one stranded unit layer 1 is a copper wire stranded unit layer 1a. The copper wire stranded unit layer 1a consists of at least one copper wire stranded unit 11a, while the aluminum wire stranded unit layer 1b consists of at least one aluminum wire stranded unit 11b.

[0030] In the copper-aluminum twisted wire, the twisted unit layer 1 includes both copper wire twisted unit layer 1a and aluminum wire twisted unit layer 1b, so that the copper wire 111 and the aluminum wire 112 can be twisted. Compared with the pure copper wire 111, the copper-aluminum twisted wire of the present application has lower cost and lighter weight.

[0031] It should be understood that the twisting between two adjacent layers of twisted units 11 of copper-aluminum twisted wire is formed by a single twisting. Of course, if the process allows and the layering result can be guaranteed, three adjacent layers of twisted units 11 can also be formed by a single twisting.

[0032] In one embodiment, referring to FIG1 , the copper wire stranding unit 11a is formed by stranding copper wires 111, and the aluminum wire stranding unit 11b is formed by stranding aluminum wires 112. Such a stranding unit 11 is made of a single material, making processing easier and increasing production efficiency. In one embodiment, referring to FIG1 , the copper wires 111 in the copper stranding unit 11 have the same wire diameter, the aluminum wires 112 in the aluminum stranding unit 11 have the same wire diameter, and the copper wires 111 in the copper stranding unit 11 have the same wire diameter as the aluminum wires 112 in the aluminum stranding unit 11.

[0033] In addition to using a single material, in one embodiment, the copper wire twisted unit 11a includes an aluminum wire 112 in the center and multiple copper wires 111 on the periphery of the aluminum wire 112, and the adjacent copper wires 111 on the periphery of the aluminum wire 112 are in contact to cover the aluminum wire 112. In this way, the exposed portion of the copper wire twisted unit 11a can be made of copper, and when the copper wire twisted unit 11a is connected to the copper conductive member, it can be ensured that the same metal is in contact, and the stability is better. In one embodiment, the aluminum wire twisted unit 11b includes a copper wire 111 in the center and multiple aluminum wires 112 on the periphery of the copper wire 111, and the adjacent aluminum wires 112 on the periphery of the copper wire 111 are in contact to cover the copper wire 111. In this way, the exposed portion of the copper wire twisted unit 11a can be made of aluminum, and when the aluminum wire twisted unit 11b is connected to the aluminum conductive member, it can be ensured that the same metal is in contact, and the stability is better.

[0034] Since dissimilar metals are made of different materials and have different expansion coefficients, resistivity, and thermal conductivity, the welds of the dissimilar metals are prone to cracking after welding. When other conductive connection methods such as crimping are used, the contact resistance of the conductive interface between the dissimilar metals is large, gaps are easily formed, and the conductive reliability is poor. Since the copper-aluminum twisted wire needs to be conductively connected to the conductive part, in order to improve the connection reliability between the copper-aluminum twisted wire and the copper conductive part or the aluminum conductive part. Furthermore, in one embodiment, the twisted unit layer 1 in the outermost layer has multiple twisted units 11, and the adjacent twisted units 11 are in contact so that the twisted unit layer 1 in the outermost layer covers the twisted unit layer 1 in the second outermost layer. Since the twisted unit 11 is made of a single material, or the exposed part of the twisted unit 11 is made of a single material, the exposed part of the outermost twisted unit layer 1 is all made of a single material. The twisted unit layer 1 covering the inner layer described in this application means that the inner layer twisted unit layer is not exposed when viewed from the outside of the twisted unit layer on the outside.

[0035] The outermost twisted unit layer 1 is a copper wire twisted unit layer 1a or an aluminum wire twisted unit layer 1b. When the outermost twisted unit layer 1 is a copper wire twisted unit layer 1a, when the copper-aluminum twisted wire is connected to the copper conductive member, the outermost copper wire twisted unit layer 1a is in conductive contact with the copper conductive member. The copper wire 111 in the outermost copper wire twisted unit layer 1a and the copper conductive member are in conductive contact with each other, and the copper wire 111 in the outermost copper wire twisted unit layer 1a and the copper conductive member can be connected to each other by welding or crimping, which improves reliability. Similarly, when the outermost twisted unit layer 1 is an aluminum wire twisted unit layer 1b, the aluminum wire 112 in the outermost aluminum wire twisted unit layer 1b and the aluminum conductive member are in conductive contact with each other, using the same metal.

[0036] Because copper and aluminum are susceptible to corrosion upon contact, to improve the corrosion resistance of copper-aluminum stranded wire, in one embodiment, each copper wire 111 in the copper stranding unit 11a is provided with a copper wire insulation layer (not shown). Each aluminum wire 112 in the aluminum stranding unit 11b is provided with an aluminum wire insulation layer (not shown). Compared to providing insulation layers around the periphery of the stranding unit, the thickness of the aluminum and copper insulation layers can be reduced, minimizing the impact on the overall thickness.

[0037] Specifically, in one embodiment, referring to FIG. 1 , in any two adjacent twisted unit layers 1 , the outer twisted unit layer 1 has a plurality of twisted units 11 , and the adjacent twisted units 11 contact and cover the inner twisted unit layer 1 .

[0038] Specifically, in one embodiment, both copper wire 111 and aluminum wire 112 are enameled wire. When the copper-aluminum stranded wire is welded to a copper or aluminum conductor, the outer insulation layer of the enameled wire can fall off at high temperatures without affecting the weld. In one embodiment, the diameter of copper wire 111 and aluminum wire 112 ranges from 0.1 to 0.5 mm.

[0039] Regarding the arrangement of the twisted unit layer 1 , in one embodiment, please refer to FIG1 , the twisted unit layer 1 at the center of the copper-aluminum twisted wire is composed of a single-strand twisted unit 11 , and the remaining twisted unit layers 1 each include at least two-strand twisted units 11 .

[0040] Specifically, referring to FIG1 , there are three layers of twisted unit layers 1, wherein the central twisted unit layer 1 is composed of a single-strand twisted unit 11, the middle twisted unit layer 1 is composed of six-strand twisted units 11, and the outermost twisted unit layer 1 is composed of twelve-strand twisted units 11. In other embodiments, the number of twisted unit layers 1 can be adjusted as needed, for example, only two layers or four or more layers can be provided.

[0041] In one embodiment, in the Nth layer of twisted unit layer 1, the number of strands of the twisted unit 11 is 6 (N-1).

[0042] Furthermore, in one embodiment, the twisted units 11 are arranged in a honeycomb shape. In some other embodiments, the twisted units 11 can be arranged in any manner, for example, the twisted units 11 of each layer can be circular, triangular, or quadrilateral.

[0043] In one embodiment, referring to Figure 1 , the conductors within a stranded unit 11 are also arranged in a honeycomb pattern. For example, in copper stranded unit 11a, copper wires 111 are arranged in a honeycomb pattern, while in aluminum stranded unit 11b, aluminum wires 112 are arranged in a honeycomb pattern. This honeycomb arrangement allows stranded unit 11 to be closest to a circular shape, improving space utilization.

[0044] It should be noted that the honeycomb arrangement described in this application does not limit the shape of the wire to a hexagon. Please refer to Figure 1. The copper wire 111 and the aluminum wire 112 are both circular, but the distribution of the copper wire 111 in the copper wire twisting unit 11a adopts a honeycomb shape.

[0045] In some other embodiments, the central twisted unit layer 1 may be composed of three twisted units 11. In addition, in some other embodiments, the number of strands of the twisted units 11 in the central twisted unit layer 1 may also be four, five, or any other number.

[0046] Furthermore, in one embodiment, referring to FIG1 , copper wire stranded unit layers 1a and aluminum wire stranded unit layers 1b are arranged alternately in layers. This allows for a uniform distribution of parameters such as the overall conductivity and quality of the copper-aluminum stranded wire. In some other embodiments, the copper wire stranded unit layers 1a and the aluminum wire stranded unit layers 1b can be arranged in any feasible manner, such as two adjacent stranded unit layers 1 can both be copper wire stranded unit layers 1a or both be aluminum wire stranded unit layers 1b. In some other embodiments, the outermost stranded unit layer 1 and the second outermost stranded unit layer 1 can both be copper wire stranded unit layers 1a or aluminum wire stranded unit layers 1b. In this case, when the copper-aluminum stranded wire is welded to a conductive part, the different metals are less likely to come into contact. For example, when welding to a copper conductive part is required, in the copper-aluminum stranded wire used, the outermost stranded unit layer 1 and the second outermost stranded unit layer 1 are both copper wire stranded unit layers 1a. In this case, the aluminum wire 112 in the copper-aluminum stranded wire is less likely to come into contact with the copper conductive part. Similarly, when welding with aluminum conductive parts is required, the outermost twisted unit layer 1 and the second outermost twisted unit layer 1 of the copper-aluminum twisted wire used are both aluminum wire twisted unit layers 1b. At this time, the copper wire 111 in the copper-aluminum twisted wire is less likely to contact the copper conductive parts.

[0047] In one embodiment, in order to protect the copper-aluminum twisted wire, the copper-aluminum twisted wire further includes a twisted wire insulation layer (not shown in the figure), and the twisted wire insulation layer is located outside the outermost twisted unit layer 1.

[0048] In one embodiment, referring to FIG. 1 to FIG. 4 , the steps of forming the copper-aluminum stranded wire include:

[0049] It uses rare earth aluminum and copper materials with excellent conductivity, which are stretched and formed into a single thin wire with a diameter of 0.1-0.5mm.

[0050] Referring to FIG. 2 , seven formed single thin copper wires 111 are arranged according to a rule that their cross-sections are closest to a circle and are initially twisted together at a certain torque to form a copper wire twisted unit 11 a .

[0051] Referring to FIG. 3 , seven formed single thin aluminum wires 112 are arranged according to a rule that their cross-sections are closest to a circle and are initially twisted together at a certain torque to form an aluminum wire twisted unit 11 b .

[0052] 4 , a copper wire stranded unit 11 a and six aluminum wire stranded units 11 b are twisted for the second time according to a certain torque and a cross section closest to a circle, thereby obtaining two twisted unit layers 1 .

[0053] The formed secondary stranded wire and the twelve-strand copper wire stranded unit 11a are arranged according to the rule that the cross section is closest to a circle, and are stranded for the third time to obtain copper-aluminum stranded wires of three stranded unit layers 1.

[0054] The twisted wires are wrapped with polyimide tape as the insulation layer of the twisted wire (not shown in the figure), and the wrapping is performed at an overlap rate of 50%-70%.

[0055] The twisting spacing and twisting requirements are processed according to actual needs. In one embodiment, according to the above steps, twisting can be performed multiple times until the number of twisted unit layers 1 meets the actual needs.

[0056] In one embodiment, rare earth aluminum is used as the aluminum wire material. Although its electrical conductivity is only 61.7% of copper, its density is only 30% of copper. Because the new wire material utilizes a regular arrangement that approximates a circular shape, the area utilization rate is relatively improved for the same outer diameter, equivalent to a larger wire diameter compared to pure copper wire. To ensure that the conductivity of the copper-aluminum stranded wire is comparable to that of pure copper multi-strand wire, the final outer diameter of the copper-aluminum stranded wire is larger than that of pure copper wire. Under conditions of equal resistivity, the copper-aluminum stranded wire has a larger diameter, a smaller weight, and a lower cost than pure copper multi-strand wire.

[0057] In summary, the copper-aluminum stranded wire of this application offers high reliability and space utilization. Compared to stranded wire composed of pure copper wire, copper-aluminum stranded wire is lightweight and cost-effective. Furthermore, this copper-aluminum stranded wire of this application is easily automated for production, offering a high degree of freedom in wire arrangement design and customization.

[0058] In one embodiment, the copper-aluminum twisted wire can be used in cables or directly used as a conductor for electronic components.

[0059] In an embodiment of a cable, the cable includes a cable sheath and a cable core, the cable core includes a copper-aluminum stranded wire, and the copper-aluminum stranded wire is the copper-aluminum stranded wire described in any one of the above embodiments.

[0060] In an embodiment of a copper-aluminum stranded wire assembly, the copper-aluminum stranded wire assembly includes copper-aluminum stranded wire and a conductive member conductively connected to the copper-aluminum stranded wire. Referring to Figures 1 to 4 , the copper-aluminum stranded wire is the copper-aluminum stranded wire described in any of the above-described embodiments. In one embodiment, the stranded units 11 in the outermost stranded unit layer 1 are copper wire stranded units 11a, and the conductive member is a copper conductive member. In another embodiment, the stranded units 11 in the outermost stranded unit layer 1 are aluminum wire stranded units 11b, and the conductive member is an aluminum conductive member. The copper-aluminum stranded wire and the conductive member can be fixed by welding or crimping.

[0061] The above examples are used to illustrate the present invention, which are only used to help understand the present invention and are not intended to limit the present invention. Those skilled in the art can make several simple deductions, modifications or substitutions based on the concept of the present invention.

Claims

1. A copper-aluminum transition terminal, characterized in that, It includes a copper conductive part and an aluminum conductive part. The copper conductive part includes a first external connection part and a first connection part, and the aluminum conductive part includes a second external connection part and a second connection part. The first external connection part is used for electrically connecting with an external copper conductive part, and the second connection part is used for electrically connecting with an external aluminum conductive part; one of the first connection part and the second connection part has a socket, and the other has a plug inserted into the socket. After the socket and the plug are inserted into each other, they are crimped and fixed, and the plug and the socket are welded and fixed.

2. The copper-aluminum transition terminal according to claim 1, wherein The plug includes a plug crimping section and a plug welding section, and the plug crimping section and the plug welding section are arranged in the direction in which the plug is inserted into the socket.

3. The copper-aluminum transition terminal according to claim 2, characterized in that, The surfaces of the plug welding section are all welded to the socket.

4. The copper-aluminum transition terminal according to claim 2, wherein, The end of the plug for inserting into the socket is located on the plug welding section.

5. The copper-aluminum transition terminal according to claim 4, wherein, The cross-sectional area of the plug crimping section is larger than that of the plug welding section. The socket includes a socket welding section and a socket crimping section, and the wall thickness of the socket welding section is larger than that of the socket crimping section.

6. The copper-aluminum transition terminal according to claim 2, characterized in that, The outer peripheral surface of the plug crimping section is a polygonal cylindrical surface, and the inner hole of the socket includes a polygonal hole section adapted to the polygonal cylindrical surface.

7. The copper-aluminum transition terminal according to claim 2, wherein The second external connection part is a crimping hole located within the plug crimping section, and the crimping hole is used for crimping and fixing an external aluminum wire.

8. The copper-aluminum transition terminal according to claim 1, wherein The plug has a welding surface, and at least a part of the welding surface faces the direction in which the plug is inserted into the socket.

9. The copper-aluminum transition terminal according to any one of claims 1-8, characterized in that The first connection part has the socket, the second connection part has the plug, the second external connection part includes a crimping sleeve for crimping and fixing an external aluminum wire, and the crimping sleeve has an external connection hole for the external aluminum wire to be inserted.

10. An electronic device, characterized in that, It includes a conductive part and a copper-aluminum transition terminal connected to the conductive part, and the copper-aluminum transition terminal is the copper-aluminum transition terminal according to any one of claims 1-9.

Images