阅读说明：本技术 电动汽车充电用抗曲挠铝合金电缆及其制备方法 (Anti-bending aluminum alloy cable for charging electric automobile and preparation method thereof ) 是由 惠小兵 李军 王华俊 瞿其勇 严忠岐 于 2021-08-23 设计创作，主要内容包括：本发明涉及电线电缆制造技术领域,且公开了电动汽车充电用抗曲挠铝合金电缆及其制备方法,包括导体、绝缘层、屏蔽层、隔离层和外护层；电动汽车充电用抗曲挠铝合金电缆的制备方法,步骤一：导体材料制备；步骤二：铸造铝合金杆；步骤三：拉丝绞合处理；步骤四：高温热化处理；步骤五：包裹处理；步骤六：降温冷却成形。该电动汽车充电用抗曲挠铝合金电缆及其制备方法,韧性更好,弯曲性更强,不具有反弹性,同时电缆轻巧灵便,便携使用方便,特别适用狭小空间布局,整体耐油,耐腐蚀,耐磨,抗弯折。使用温度范围广,高温可达125度,对电缆柔韧性及载流量有较大提升。(The invention relates to the technical field of wire and cable manufacturing, and discloses an anti-bending aluminum alloy cable for charging an electric automobile and a preparation method thereof, wherein the anti-bending aluminum alloy cable comprises a conductor, an insulating layer, a shielding layer, an isolating layer and an outer protecting layer; the preparation method of the anti-bending aluminum alloy cable for charging the electric automobile comprises the following steps: preparing a conductor material; step two: casting an aluminum alloy rod; step three: carrying out wire drawing and stranding treatment; step four: carrying out high-temperature thermalization; step five: packaging treatment; step six: cooling and forming. The anti-bending aluminum alloy cable for charging the electric automobile and the preparation method thereof have the advantages of better toughness, stronger bending property, no rebound, lightness, flexibility, portability and convenient use, are particularly suitable for narrow space layout, and are integrally oil-resistant, corrosion-resistant, wear-resistant and bending-resistant. The service temperature range is wide, the high temperature can reach 125 ℃, and the flexibility and the current-carrying capacity of the cable are greatly improved.)

1. Anti-bending aluminum alloy cable for charging electric automobile comprises a conductor (1), an insulating layer (2), a shielding layer (3), an isolating layer (4) and an outer protecting layer (5), and is characterized in that the insulating layer (2) is arranged outside the conductor (1), the isolating layer (4) and the outer protecting layer (5) are arranged outside a plurality of conductors (1), the conductor (1) contains rare earth (lanthanum, scandium, yttrium), iron and boron elements, the mass percent of the rare earth (lanthanum, scandium and yttrium) is 0.1-0.8 wt%, the mass percent of the iron is 0.04-0.1 wt%, and the mass percent of the boron is 0.06-0.2 wt%.

2. The preparation method of the anti-bending aluminum alloy cable for charging the electric automobile according to claim 1, which is characterized by comprising the following steps:

the method comprises the following steps: preparing a conductor (1), selecting an aluminum-based material, melting the aluminum-based material, adding rare earth (lanthanum, scandium and yttrium), iron and boron elements into the melted aluminum-based material, adjusting the proportion of the aluminum-based material, the rare earth (lanthanum, scandium and yttrium), the iron and the boron elements by proportioning, and finally stirring and mixing the aluminum-based material, the rare earth (lanthanum, scandium and yttrium), the iron and the boron elements uniformly to obtain a molten conductor material;

step two: casting an aluminum alloy rod, casting the molten conductor material obtained in the step one into a trapezoid, and cold-drawing the trapezoid into an aluminum alloy rod material with a certain cross-sectional area through a die by a rolling mill;

step three: wire drawing and stranding, namely performing a plurality of wire drawing treatments on the aluminum alloy rod with a certain cross section area in the step two to draw the aluminum alloy rod into 0.1-0.5 mm wire diameter filaments, and stranding the aluminum alloy filaments to form an aluminum alloy wire harness;

step four: high-temperature thermalization, namely putting the aluminum alloy wire harness obtained in the third step into a heating furnace, uniformly thermalizing the aluminum alloy wire harness by the heating furnace, and cooling the aluminum alloy wire harness to lose efficacy after the high-temperature thermalization;

step five: wrapping, namely wrapping the outer walls of the aluminum alloy wire harnesses prepared in the fourth step with an insulating layer (2) and a shielding layer (3), wrapping the outer parts of the aluminum alloy wire harnesses with an isolating layer (4) and an outer protecting layer (5), arranging the outer protecting layer (5) outside the isolating layer (4), and arranging a filler (6) inside the isolating layer (4);

step six: and (5) cooling and forming, namely cooling the aluminum alloy wire harness wrapped in the step five, and rolling and packaging after cooling.

3. The preparation method of the anti-bending aluminum alloy cable for charging the electric automobile according to claim 2, characterized by comprising the following steps: and in the third step, the aluminum alloy filaments are bundled after wire drawing is finished, and the multi-strand stranded aluminum alloy filaments are stranded into the anti-elastic high-temperature-resistant filamentary material so as to be effectively integrated with the aluminum alloy conductor material.

4. The preparation method of the anti-bending aluminum alloy cable for charging the electric automobile according to claim 2, characterized by comprising the following steps: the heating time of the heating furnace in the fourth step is divided into three stages, the temperature of the heating furnace in the first stage is 230 ℃, the heating time is 50-60 minutes, the temperature of the heating furnace in the second stage is 350 ℃, the heating time is 70-80 minutes, the temperature of the heating furnace in the third stage is 420 ℃, the heating time is 40-50 minutes, the cooling treatment mode adopts natural cooling, and the heating furnace naturally fails for 72 hours.

5. The preparation method of the anti-bending aluminum alloy cable for charging the electric automobile according to claim 2, characterized by comprising the following steps: and in the fifth step, when the insulating layer (2), the shielding layer (3), the isolating layer (4) and the outer protective layer (5) are wrapped outside the aluminum alloy wire harness, plasticizing treatment needs to be carried out in a heating mode, so that the insulating layer (2), the shielding layer (3), the isolating layer (4) and the outer protective layer (5) are effectively attached to the outer wall of the aluminum alloy wire harness.

6. The preparation method of the anti-bending aluminum alloy cable for charging the electric automobile according to claim 2, characterized by comprising the following steps: and cooling in the sixth step is carried out in a water cooling mode, the wrapped aluminum alloy wire harness is fused into the water cooling box, so that the aluminum alloy wire harness passes through cooling water in the water cooling box, and the cooling water rapidly cools the surface temperature of the aluminum alloy wire harness.

Technical Field

The invention relates to the technical field of wire and cable manufacturing, in particular to an anti-bending aluminum alloy cable for charging an electric automobile and a preparation method thereof.

Background

At present, more than 90% of cables applied to the market are copper-core cables, copper resources in China are deficient, a large amount of copper is imported, statistics is carried out that copper used on the cables accounts for more than 65% of the total consumption every year, and aluminum resources in China are relatively rich. Copper is expensive, has high specific gravity and large rebound elasticity, is inconvenient to construct and apply, and is particularly a cable for charging an electric automobile. At present, the insulated wire cable conductor core adopts aluminium system material to replace copper at present, and most adopt the duralumin wire, and the application range along with the aluminum alloy material becomes wide, according to the use in different areas, can be used in line, communication line for the coal mine, line, car electric wire for the high-speed railway to and electromagnetic wire etc. according to the difference of use scene, need different performance, satisfy the demand of using.

The aluminum alloy wire for charging the automobile not only needs to ensure that the aluminum alloy wire has good stretchability, but also needs to have good flexibility and conductivity, is not easy to realize by common aluminum alloy, and has poor fatigue resistance and bending resistance. Therefore, the invention provides an anti-bending aluminum alloy cable for charging an electric automobile and a preparation method thereof.

Disclosure of Invention

Technical problem to be solved

Aiming at the defects of the prior art, the invention provides the anti-bending aluminum alloy cable for charging the electric automobile and the preparation method thereof, the anti-bending aluminum alloy cable has better toughness, stronger bending property and no rebound elasticity, and meanwhile, the cable is light, flexible and convenient, is portable and convenient to use, is particularly suitable for narrow space layout, and is integrally oil-resistant, corrosion-resistant, wear-resistant and bending-resistant. The service temperature range is wide, the high temperature can reach 125 ℃, the flexibility and the current-carrying capacity of the cable are greatly improved, and the problems of poor fatigue resistance and poor bending performance of the conventional aluminum alloy cable are solved.

(II) technical scheme

In order to achieve the purpose, the invention provides the following technical scheme: the anti-bending aluminum alloy cable for charging the electric automobile comprises a conductor, an insulating layer, a shielding layer, an isolating layer and an outer protecting layer, wherein the insulating layer is arranged outside the conductor, the isolating layer and the outer protecting layer are arranged outside the conductors, rare earth (lanthanum, scandium and yttrium), iron and boron elements are contained in the conductor, the mass percent of the rare earth (lanthanum, scandium and yttrium) is 0.1-0.8 wt%, the mass percent of the iron is 0.04-0.1 wt%, and the mass percent of the boron is 0.06-0.2 wt%.

The preparation method of the anti-bending aluminum alloy cable for charging the electric automobile comprises the following specific steps:

the method comprises the following steps: preparing a conductor, namely selecting an aluminum-based material, melting the aluminum-based material, adding rare earth (lanthanum, scandium and yttrium), iron and boron elements into the melted aluminum-based material, adjusting the proportion of the aluminum-based material, the rare earth (lanthanum, scandium and yttrium), the iron and the boron elements according to the proportion, and stirring and uniformly mixing the aluminum-based material, the rare earth (lanthanum, scandium and yttrium), the iron and the boron elements to obtain a molten conductor material;

step two: casting an aluminum alloy rod, casting the molten conductor material obtained in the step one into a trapezoid, and cold-drawing the trapezoid into an aluminum alloy rod material with a certain cross-sectional area through a die by a rolling mill;

step three: wire drawing and stranding, namely performing a plurality of wire drawing treatments on the aluminum alloy rod with a certain cross section area in the step two to draw the aluminum alloy rod into 0.1-0.5 mm wire diameter filaments, and stranding the aluminum alloy filaments to form an aluminum alloy wire harness;

step four: high-temperature thermalization, namely putting the aluminum alloy wire harness obtained in the third step into a heating furnace, uniformly thermalizing the aluminum alloy wire harness by the heating furnace, and cooling the aluminum alloy wire harness to lose efficacy after the high-temperature thermalization;

step five: wrapping, namely wrapping an insulating layer and a shielding layer on the outer wall of the aluminum alloy wire harness prepared in the fourth step, wrapping an isolating layer and an outer protective layer outside the aluminum alloy wire harness, wherein the outer protective layer is arranged outside the isolating layer, and meanwhile, filling materials are arranged inside the isolating layer;

step six: and (5) cooling and forming, namely cooling the aluminum alloy wire harness wrapped in the step five, and rolling and packaging after cooling.

Preferably, the aluminum alloy filaments are bundled after the wire drawing in the third step, and the multiple strands of stranded wires are stranded into the anti-elastic high-temperature-resistant wire-shaped material, so that the multi-strand stranded wires are effectively integrated with the aluminum alloy conductor material.

Preferably, the heating time of the heating furnace in the fourth step is divided into three stages, the temperature of the heating furnace in the first stage is 230 ℃, the heating time is 50-60 minutes, the temperature of the heating furnace in the second stage is 350 ℃, the heating time is 70-80 minutes, the temperature of the heating furnace in the third stage is 420 ℃, and the heating time is 40-50 minutes. The cooling treatment mode adopts natural cooling, and the natural failure lasts for 72 hours.

Preferably, when the insulating layer, the shielding layer, the isolating layer and the outer protective layer are wrapped outside the aluminum alloy wire harness in the fifth step, plasticizing treatment needs to be carried out in a heating mode, so that the insulating layer, the shielding layer, the isolating layer and the outer protective layer are effectively attached to the outer wall of the aluminum alloy wire harness.

Preferably, the cooling in the sixth step adopts a water cooling mode, and the wrapped aluminum alloy wire harness is melted into the water cooling box, so that the aluminum alloy wire harness passes through cooling water in the water cooling box, and the cooling water quickly cools the surface temperature of the aluminum alloy wire harness.

(III) advantageous effects

Compared with the prior art, the invention provides the anti-bending aluminum alloy cable for charging the electric automobile and the preparation method thereof, and the anti-bending aluminum alloy cable has the following beneficial effects:

1. the conductor prepared by the anti-bending aluminum alloy cable for charging the electric automobile and the preparation method thereof improves the conductivity of the conductor, and compared with copper, the resistivity of the copper conductor is 0.017241 (omega. mm) at the standard temperature of 20 DEG C²M) of a conductive aluminum alloy having a resistivity of 0.0279(Ω. mm)²M), comparing the two, the IACS is different due to the difference of the resistivity, the aluminum alloy is 61.8% of the copper, and the electrical performance is consistent when we increase the sectional area of the aluminum alloy conductor to 150% of the sectional area of the copper conductor; and because the density of the aluminum alloy conductor is about 1/3 of the density of the copper conductor, the weight of the finished cable is about 45-65% of that of the copper core cable, and the cable is more convenient to use during charging.

2. The anti-bending aluminum alloy cable for charging the electric automobile and the conductor prepared by the preparation method have the advantages that the elongation of the rare earth aluminum alloy is basically the same as that of a copper conductor (25%), and the rare earth aluminum alloy conductor subjected to high-temperature treatment has smaller rebound resilience, so that the anti-bending aluminum alloy cable is suitable for being used as a 5-class conductor for the electric automobile charging cable.

3. Through the anti-bending aluminum alloy cable for charging the electric automobile and the conductor prepared by the preparation method, iron added to the aluminum alloy conductor during high-temperature treatment generates high-strength creep resistance, and the added rare earth elements further improve the creep resistance under high-temperature operation and are equivalent to the yield strength of a copper conductor, so that the creep resistance of the aluminum alloy conductor is equivalent to that of the copper conductor, and the requirement of ensuring the connection stability during long-time overheating is met.

4. Through the anti-bending aluminum alloy cable for charging the electric automobile and the conductor prepared by the preparation method thereof, the rare earth aluminum alloy cable subjected to high-temperature treatment has strong flexibility and bending performance, and through a 90-degree repeated bending test on a bending test machine, the aluminum alloy single wire can be bent for more than 30 times and is equivalent to copper.

5. Through the anti-bending aluminum alloy cable for charging the electric automobile and the conductor prepared by the preparation method, the metal loss of the rare earth aluminum alloy in the air is far smaller than that of the copper in the air, the added rare metals are all suitable metal pairs, lanthanum and yttrium can improve the oxidation resistance and conductivity of nonferrous metals, scandium can improve the strength and heat resistance, the contact corrosion caused by potential difference is reduced, and the corrosion of the cable is improved.

Drawings

Fig. 1 is a schematic structural diagram of the anti-bending aluminum alloy cable for charging an electric vehicle according to the present invention.

In the figure: 1 conductor, 2 insulating layers, 3 shielding layers, 4 isolating layers, 5 outer protecting layers and 6 filling materials.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Referring to fig. 1, the anti-bending aluminum alloy cable for charging an electric vehicle includes a conductor 1, an insulating layer 2, a shielding layer 3, an insulating layer 4, and an outer sheath 5, the insulating layer 2 is disposed outside the conductor 1, the insulating layer 4 and the outer sheath 5 are both disposed outside the plurality of conductors 1, the conductor 1 contains rare earth ((lanthanum, scandium, yttrium)), iron, and boron elements, the rare earth (lanthanum, scandium, yttrium) is 0.1-0.8 wt%, the iron is 0.04-0.1 wt%, and the boron is 0.06-0.2 wt%.

The method comprises the following steps: preparing a conductor 1, namely selecting an aluminum-based material, melting the aluminum-based material, adding rare earth (lanthanum, scandium and yttrium), iron and boron elements into the melted aluminum-based material, adjusting the proportion of the aluminum-based material, the rare earth (lanthanum, scandium and yttrium), the iron and the boron elements according to the proportion, and stirring and mixing the aluminum-based material, the rare earth (lanthanum, scandium and yttrium), the iron and the boron elements uniformly to obtain a molten conductor material;

step two: casting an aluminum alloy rod, casting the molten conductor material obtained in the step one into a trapezoid, and cold-drawing the trapezoid into an aluminum alloy rod material with a certain section through a mold by a rolling mill;

step three: wire drawing and stranding, namely performing a plurality of wire drawing treatments on the aluminum alloy rod with a certain cross section area in the second step to enable the aluminum alloy rod to be drawn into 0.1-0.5 mm wire diameter filaments, bundling the aluminum alloy filaments, and performing multi-strand stranding to form aluminum alloy wire bundles, wherein the aluminum alloy wire bundles are divided into 5 th type and 6 th type, and the 6 th type is an ultra-soft conductor;

step four: high-temperature thermalization, namely putting the aluminum alloy wire harness obtained in the third step into a heating furnace, uniformly thermalizing the aluminum alloy wire harness by the heating furnace, and cooling the aluminum alloy wire harness to lose efficacy after the high-temperature thermalization;

step five: wrapping, namely wrapping the outer walls of the prepared aluminum alloy wire harnesses in the fourth step with an insulating layer 2 and a shielding layer 3, wrapping the outer parts of the aluminum alloy wire harnesses with an isolating layer 4 and an outer protective layer 5, arranging the outer protective layer 5 outside the isolating layer 4, arranging a filler 6 inside the isolating layer 4, and selecting the materials of the insulating layer 2 and the outer protective layer 5 strictly according to the requirements of GB/T33594-2017 Cable for charging electric vehicles, wherein the aluminum alloy wire harnesses have high and low temperature resistance, aging resistance, chemical resistance, solvent resistance and oil resistance;

step six: and (5) cooling, namely cooling the aluminum alloy wire harness wrapped in the step five, and rolling and packaging after cooling.

And step three, the aluminum alloy filaments are bundled after wire drawing is finished, and when a plurality of strands are twisted, the strands need to be twisted into the anti-elastic high-temperature-resistant wire-shaped material, so that the anti-elastic high-temperature-resistant wire-shaped material and the aluminum alloy conductor material are effectively integrated.

The heating time of the heating furnace in the fourth step is divided into three stages, the temperature of the heating furnace in the first stage is 230 ℃, the heating time is 50-60 minutes, the temperature of the heating furnace in the second stage is 350 ℃, the heating time is 70-80 minutes, the temperature of the heating furnace in the third stage is 420 ℃, the heating time is 40-50 minutes, the cooling treatment mode adopts natural cooling, and the heating furnace naturally fails for 72 hours. The rare earth aluminum alloy cable subjected to high-temperature treatment after multi-strand stranding has strong flexibility and bending property, and can meet the requirements of 5000 cycles and smaller bending property in 11.5.7.3 swing tests in GB/T33594-2017 Cable for charging electric vehicles.

In the fifth step, when the insulating layer 2, the shielding layer 3, the isolating layer 4 and the outer protection layer 5 are wrapped outside the aluminum alloy wire harness, the aluminum alloy wire harness needs to be baked in a heating mode, so that the insulating layer 2, the shielding layer 3, the isolating layer 4 and the outer protection layer 5 are effectively attached to the outer wall of the aluminum alloy wire harness.

And cooling in the sixth step is carried out in a water cooling mode, the wrapped aluminum alloy wire harness is fused into the water cooling box, so that the aluminum alloy wire harness passes through cooling water in the water cooling box, and the cooling water rapidly cools the surface temperature of the aluminum alloy wire harness.

It is to be noted that the term "comprises," "comprising," or any other variation thereof is intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.

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