High-voltage cable in new energy electric automobile and preparation method thereof
阅读说明：本技术 一种新能源电动汽车车内高压电缆及其制备方法 (High-voltage cable in new energy electric automobile and preparation method thereof ) 是由 刘家朝 于 2019-12-16 设计创作，主要内容包括：本发明公开了一种新能源电动汽车车内高压电缆及其制备方法，包括设置在电缆内部的导体，该导体由多层股线复绞而成，所述的股线由多根镀锡铜丝束合而成，束丝方向与股线复绞方向相反，束丝节径比控制在20?25倍之内；在导体外挤包耐高温180℃高抗撕型混炼硅橡胶绝缘层，在耐高温180℃高抗撕型混炼硅橡胶绝缘层外绕包第一耐高温隔离层，在第一耐高温隔离层外以疏绕的方式缠绕可兼做负极线芯的屏蔽层，在屏蔽层外绕包第二耐高温隔离层，第二耐高温隔离层外挤包耐高温180℃高抗撕型混炼硅橡胶护套层。该电缆具有传输容量大、耐高温、柔韧抗撕、抗弯曲、抗开裂、耐溶剂腐蚀性能好的优点。(The invention discloses a high-voltage cable in a new energy electric vehicle and a preparation method thereof, and the high-voltage cable comprises a conductor arranged in the cable, wherein the conductor is formed by compound twisting of multiple layers of folded yarns, the folded yarns are formed by bundling a plurality of tinned copper wires, the stranding direction is opposite to the compound twisting direction of the folded yarns, and the pitch-diameter ratio of the stranding is controlled within 20-25 times; the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber insulating layer is wrapped outside the conductor, a first high-temperature-resistant isolating layer is wrapped outside the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber insulating layer, a shielding layer which can be used as a negative wire core is wound outside the first high-temperature-resistant isolating layer in a sparse winding mode, a second high-temperature-resistant isolating layer is wrapped outside the shielding layer, and the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber sheath layer is wrapped outside the second high-temperature-resistant isolating layer in an extruded mode. The cable has the advantages of large transmission capacity, high temperature resistance, flexibility, tearing resistance, bending resistance, cracking resistance and good solvent corrosion resistance.)
1. The high-voltage cable in the new energy electric automobile is characterized by comprising a conductor arranged in the cable, wherein the conductor is formed by compound twisting of multiple layers of folded yarns, the folded yarns are formed by bundling a plurality of tinned copper wires, the stranding direction is opposite to the compound twisting direction of the folded yarns, and the pitch-diameter ratio of the stranded wires is controlled within 20-25 times;
the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber insulating layer is wrapped outside the conductor, a first high-temperature-resistant isolating layer is wrapped outside the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber insulating layer, a shielding layer which can be used as a negative wire core is wound outside the first high-temperature-resistant isolating layer in a sparse winding mode, a second high-temperature-resistant isolating layer is wrapped outside the shielding layer, and the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber sheath layer is wrapped outside the second high-temperature-resistant isolating layer in an extruded mode.
2. The high-voltage cable in the new energy electric vehicle as claimed in claim 1, wherein the conductor is formed by multi-layer strand wires in a complex twisting mode, the twisting direction of each layer of strand wires is opposite to the wire bundling direction of the layer of strand wires, the pitch diameter ratio of the outermost layer is controlled to be 10-14 times, and the pitch diameter ratio of the inner layer is controlled to be 14-22 times.
3. The in-vehicle high-voltage cable for the new energy electric vehicle according to claim 1, wherein the first high-temperature-resistant isolation layer and the second high-temperature-resistant isolation layer are both ceramic silicon rubber belts.
4. The in-vehicle high-voltage cable for the new energy electric vehicle as claimed in claim 1, wherein the shielding layer is formed by loosely winding a plurality of stranded soft copper strands, gaps between the plurality of stranded soft copper strands are not more than 3mm, a winding pitch-diameter ratio is controlled to be 10-12 times, and a winding direction is a left direction.
5. The high-voltage cable in the new energy electric vehicle as claimed in claim 4, wherein the soft copper stranded wire is formed by stranding tinned soft copper wires with a diameter of 0.2-0.5 mm, the pitch-diameter ratio of the stranded wires is controlled to be 15-20 times, and the direction is the right direction.
6. The preparation method of the high-voltage cable in the new energy electric vehicle according to claims 1 to 5, characterized by comprising the following steps:
1) firstly, a conductor adopts a category 6 soft tinned conductor specified by ultra GB/T3956-2008, the diameter of a single wire is not more than 0.16mm, the conductor is produced through the stages of wire drawing, annealing, tinning, wire bundling and multiple twisting, a thicker copper wire is drawn into a required superfine copper wire through a wire drawing machine, then the surface of the copper is tinned through a tinning process, and the copper wire is annealed while tinning; then the tinned copper wire is bundled by a wire bundling machine, the wire bundling direction is opposite to the complex twisting direction of the layer of complex twisted conductor, if the complex twisting direction of the layer of complex twisted conductor is the right direction, the wire bundling is the left direction, and meanwhile, the pitch-diameter ratio of the wire bundling is controlled to be within 20-25 times; finally, performing multi-layer complex twisting on the bundled compound wires to form a conductor, keeping the twisting direction of each layer of the complex twisted conductor opposite to the wire bundling direction of the layer of compound wires, controlling the pitch-diameter ratio of the outermost layer to be between 10 and 14 times, and controlling the pitch-diameter ratio of the inner layer to be between 14 and 22 times;
2) extruding an insulating layer, namely firstly, adding 1.2 percent of 2, 5-dimethyl-2, 5-di (tert-butylperoxy) hexane as a vulcanizing agent into silicon rubber virgin rubber, mixing on an open mill to ensure that the vulcanizing agent and the silicon rubber are uniformly mixed, keeping the temperature of a roller not more than 50 ℃ in the process, introducing cooling water to cool down in time, then uniformly extruding the mixed rubber on a conductor through an extruding machine, and continuously vulcanizing through a high-temperature high-pressure steam pipeline; the temperature of the charging barrel is controlled in the extrusion process, cooling water is introduced in time for cooling, when the wire core passes through a vulcanization pipeline, a valve is opened in time for introducing water vapor, the air pressure is controlled to be 0.8-1.2 MPa, the linear speed is controlled to be 11-17 m/min, and proper adjustment is carried out according to the insulation thickness to ensure full vulcanization;
3) tightly winding a ceramic silicon rubber belt on the insulating wire core in a wrapping mode to form a first high-temperature-resistant isolation layer;
4) bundling and twisting the tinned soft copper wire with the diameter of 0.2-0.5 mm into a folded wire by using a wire bundling machine, wherein the specific number of each strand can be determined according to the section design of a negative conductor, the pitch-diameter ratio of the wire bundling is controlled to be 15-20 times, and the direction is the right direction; uniformly winding the bundled strands on the isolating layer through a metal wire armoring machine, wherein the strands are uniformly distributed, the gaps are not more than 3mm, the winding pitch-diameter ratio is controlled to be 10-12, and the winding direction is the left direction, so that a shielding layer is formed;
5) overlapping and wrapping a ceramic silicon rubber belt outside the shielding layer, wherein the covering rate is controlled to be 10-20%, the wrapping direction is the right direction and is opposite to the winding direction of the shielded copper wire, and a second high-temperature-resistant isolation layer is formed;
6) and 3) extruding and wrapping the high-temperature-resistant 180-DEG C high-tearing-resistant mixed silicone rubber sheath layer on the second high-temperature-resistant isolation layer, wherein the specific production process is the same as the process for extruding and wrapping the insulation layer in the step 2).
Technical Field
The invention relates to a novel high-voltage cable in a new energy electric automobile and a preparation method thereof, which are mainly applied to a connecting wire of a high-voltage power system in the new energy electric automobile with the rated voltage DC1500V/AC1000 and below.
Background
With the rapid development of economy in China and the improvement of the living standard of people, automobiles gradually become common products and enter thousands of households, and it can be expected that more and more families with automobiles, even more than 2 automobiles are owned by some families in the near future. Because the traditional gasoline automobiles are increased rapidly, the problem of air pollution caused by exhaust emission is more and more serious, and the new energy electric automobile is developed rapidly due to energy conservation and environmental protection. In recent years, with the breakthrough of the technical bottleneck of new energy automobiles and the subsidy of national policies, the market of the new energy automobiles is rapidly developed. The high-voltage cable in the new energy electric automobile is an important matched product, and although the development is fast in recent years, the performance is also perfect, and the problems of heavy weight, poor flexibility and bending performance, cracking, no high temperature resistance and the like of a cable body still exist.
Disclosure of Invention
The invention aims to solve the technical problem of providing a new energy electric automobile in-car high-voltage cable which is large in transmission capacity, high-temperature resistant, flexible, tear-resistant, bending-resistant, cracking-resistant and solvent corrosion-resistant.
The invention also discloses a preparation method of the novel high-voltage cable in the new energy electric automobile.
In order to achieve the above purpose, the invention adopts the following technical scheme: a high-voltage cable in a new energy electric vehicle comprises a conductor arranged in the cable, wherein the conductor is formed by compound twisting of multiple layers of folded yarns, the folded yarns are formed by bundling a plurality of tinned copper wires, the bundling wire direction is opposite to the compound twisting direction of the folded yarns, and the knot diameter ratio of the bundling wire is controlled within 20-25 times; the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber insulating layer is wrapped outside the conductor, a first high-temperature-resistant isolating layer is wrapped outside the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber insulating layer, a shielding layer which can be used as a negative wire core is wound outside the first high-temperature-resistant isolating layer in a sparse winding mode, a second high-temperature-resistant isolating layer is wrapped outside the shielding layer, and the high-temperature-resistant 180-DEG C high-tear-resistance mixing silicone rubber sheath layer is wrapped outside the second high-temperature-resistant isolating layer in an extruded mode.
In a further improvement, the conductor adopts a
The conductor is further improved, the conductor is formed by twisting three layers of folded yarns in a complex manner, the twisting direction of each layer of folded yarns is opposite to the yarn-bundling direction of the layer of folded yarns, the pitch-diameter ratio of the outermost layer is controlled to be 10-14 times, and the pitch-diameter ratio of the inner layer is controlled to be 14-22 times.
In a further improvement, the first high-temperature-resistant isolation layer and the second high-temperature-resistant isolation layer are both ceramic silicon rubber belts.
The shielding layer is formed by combining a plurality of bundle-twisted soft copper strand loose windings, the gap between the plurality of bundle-twisted soft copper strand loose windings is not more than 3mm, the winding pitch-diameter ratio is controlled to be 10-12 times, and the winding direction is the left direction.
The soft copper compound yarn is further improved, the soft copper compound yarn is formed by twisting tinned soft copper wires with the diameter of 0.2-0.5 mm in a bundling mode, the pitch-diameter ratio of the bundled wires is controlled to be 15-20 times, and the direction is the right direction.
A preparation method of a high-voltage cable in a new energy electric automobile comprises the following steps:
1) firstly, a conductor adopts a
2) extruding an insulating layer, namely firstly, adding 1.2 percent of 2, 5-dimethyl-2, 5-di (tert-butylperoxy) hexane as a vulcanizing agent into silicon rubber virgin rubber, mixing on an open mill to ensure that the vulcanizing agent and the silicon rubber are uniformly mixed, keeping the temperature of a roller not more than 50 ℃ in the process, introducing cooling water to cool down in time, then uniformly extruding the mixed rubber on a conductor through an extruding machine, and continuously vulcanizing through a high-temperature high-pressure steam pipeline; the temperature of the charging barrel is controlled in the extrusion process, cooling water is introduced in time for cooling, when the wire core passes through a vulcanization pipeline, a valve is opened in time for introducing water vapor, the air pressure is controlled to be 0.8-1.2 MPa, the linear speed is controlled to be 11-17 m/min, and proper adjustment is carried out according to the insulation thickness to ensure full vulcanization;
3) tightly winding a ceramic silicon rubber belt on the insulating wire core in a wrapping mode to form a first high-temperature-resistant isolation layer;
4) bundling and twisting the tinned soft copper wire with the diameter of 0.2-0.5 mm into a folded wire by using a wire bundling machine, wherein the specific number of each strand can be determined according to the section design of a negative conductor, the pitch-diameter ratio of the wire bundling is controlled to be 15-20 times, and the direction is the right direction; uniformly winding the bundled strands on the isolating layer through a metal wire armoring machine, wherein the strands are uniformly distributed, the gaps are not more than 3mm, the winding pitch-diameter ratio is controlled to be 10-12, and the winding direction is the left direction, so that a shielding layer is formed;
5) overlapping and wrapping a ceramic silicon rubber belt outside the shielding layer, wherein the covering rate is controlled to be 10-20%, the wrapping direction is the right direction and is opposite to the winding direction of the shielded copper wire, and a second high-temperature-resistant isolation layer is formed;
6) and 3) extruding and wrapping the high-temperature-resistant 180-DEG C high-tearing-resistant mixed silicone rubber sheath layer on the second high-temperature-resistant isolation layer, wherein the specific production process is the same as the process for extruding and wrapping the insulation layer in the step 2).
The invention has the beneficial effects that:
the conductor adopts the 6 th soft conductor specified in the super GB/T3956-2008, and simultaneously, because the strand direction of each layer of the strands is opposite to the complex twisting direction, the flexibility of the conductor is ensured on one hand, the stability of the conductor is ensured on the other hand, the conductor is not easy to flatten and deform, and the cable roundness is maintained;
the high-temperature 180 ℃ high-tear-resistance mixed silicone rubber is adopted for insulation, firstly, the long-term working temperature of the material reaches 180 ℃, compared with a cable which is generally made of a thermoplastic elastomer and has the long-term working temperature of 70 ℃ or 90 ℃, the working temperature is increased by more than 110 ℃, the same current is transmitted, only a smaller cable section is needed, the weight of the cable can be effectively reduced, and the weight of the whole automobile is reduced. Meanwhile, the silicone rubber material has high tearing resistance and flexibility, and can meet the requirement of long-term bending use without cracking; generally, the heat resistance and the long-term working safety and reliability of the cable are greatly improved compared with those of the conventional thermoplastic elastomer cable. The production of the cable insulation and sheath adopts a high-temperature high-pressure water vapor continuous vulcanization process, and compared with the conventional hot drying tunnel or water boiling process, the quality of the cable insulation and sheath is ensured;
the isolation layer of the cable is made of high-temperature-resistant ceramic silicon rubber material, the material has good insulating property and plays a role in isolation, meanwhile, the heat-resistant temperature also reaches over 180 ℃, the temperature is kept consistent with the working temperature of the cable, and the material also has a fireproof function;
the traditional braided shielding mode is changed by the shielding of the cable, and a strand winding mode is adopted; firstly, adopt the shielding mode of strand winding, not only have the same shielding effect of braided shield, satisfy cable electromagnetic compatibility's needs, this shielding layer adopts strand bundle hank simultaneously, rethread strand winding more, can design bigger cross-section, its shielding effective cross-section can be close to or reach the conductor cross-section, can regard as negative pole or zero line to use, the use of reducible cable like this, make a cable can reach the effect of two cables, can effectively practice thrift car inner space, further reduce cable weight, from reaching the design weight that reduces whole car, realize the lightweight design mesh of car.
Drawings
FIG. 1 is a schematic structural diagram of the present invention.
Detailed Description
As shown in fig. 1, the high-voltage cable in the new energy electric vehicle comprises a conductor arranged in the cable, wherein the
the high-temperature-resistant 180 ℃ high-tearing-resistance mixing silicon rubber insulating layer 2 is extruded outside the conductor, a first high-temperature-resistant isolating layer 3 is wound outside the high-temperature-resistant 180 ℃ high-tearing-resistance mixing silicon rubber insulating layer, a shielding layer 4 which can be used as a negative wire core is wound outside the first high-temperature-resistant isolating layer in a sparse winding mode, a second high-temperature-resistant isolating layer 5 is wound outside the shielding layer, and a high-temperature-resistant 180 ℃ high-tearing-resistance mixing silicon
A preparation method of a track traffic direct current traction combined flexible cable comprises the following specific steps:
1) firstly, a conductor adopts a
2) extruding an insulating layer, namely firstly, adding 1.2 percent of 2, 5-dimethyl-2, 5-di (tert-butylperoxy) hexane as a vulcanizing agent into silicon rubber virgin rubber, mixing on an open mill to ensure that the vulcanizing agent and the silicon rubber are uniformly mixed, keeping the temperature of a roller not more than 50 ℃ in the process, introducing cooling water to cool down in time, then uniformly extruding the mixed rubber on a conductor through an extruding machine, and continuously vulcanizing through a high-temperature high-pressure steam pipeline; the control of feed cylinder temperature should be noted at the process of extruding, in time leads to the cooling water and cools down, treats that the sinle silk passes through the vulcanization pipeline, in time opens the valve and leads to steam, and atmospheric pressure control is between 0.8~1.2 MPa, and the linear speed control is between 11~17m/min, carries out appropriate adjustment according to insulation thickness, for example: the insulation thickness is 1.5mm, the steam pressure is controlled at 0.9MPa, the linear speed is controlled at 13m/min, and the full vulcanization is ensured;
3) tightly winding a ceramic silicon rubber belt on the insulating wire core in a wrapping mode to form a first high-temperature-resistant isolation layer;
4) the method comprises the following steps of (1) bundling and stranding tin-plated soft copper wires with the diameters of 0.2-0.5 mm into folded wires through a wire bundling machine, wherein the specific number of each folded wire can be determined according to the section design of a negative conductor, for example: the main line conductor is 50mm2The insulation outer diameter is 13.0mm, the wrapping outer diameter is 13.5mm, and the negative electrode conductor is required to be 50mm2Then, the design structure of the negative conductor is as follows: 19 x 21 x 0.4mm, i.e. 19 strands, 21 filaments per strand, calculated cross-section 50.1mm2The strand winding gap is 0.47mm, the yarn bundle pitch-diameter ratio is controlled to be 15-20 times, and the direction is the right direction; uniformly winding the bundled strands on the isolating layer through a metal wire armoring machine, wherein the strands are uniformly distributed, the gaps are not more than 3mm, the winding pitch-diameter ratio is controlled to be 10-12, and the winding direction is the left direction, so that a shielding layer is formed;
5) overlapping and wrapping a ceramic silicon rubber belt outside the shielding layer, wherein the covering rate is controlled to be 10-20%, the wrapping direction is the right direction and is opposite to the winding direction of the shielded copper wire, and a second high-temperature-resistant isolation layer is formed;
6) and 3) extruding and wrapping the high-temperature-resistant 180-DEG C high-tearing-resistant mixed silicone rubber sheath layer on the second high-temperature-resistant isolation layer, wherein the specific production process is the same as the process for extruding and wrapping the insulation layer in the step 2).
While the invention has been described in terms of its preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
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