CN213958619U - Flat automobile cable - Google Patents

Abstract

A flat automobile cable belongs to the technical field of automobile wire harnesses and comprises a conductive wire core, a semi-conductive layer and an insulating layer, wherein the conductive wire core is in a structure that more than three single cores with outer walls covering the semi-conductive layer are arranged in parallel on the same plane; semi-conducting layers are arranged between two adjacent single cores and outside the conducting wire core; the single core is of a multi-monofilament bundle-twisted structure; the insulating layer is sleeved outside the semi-conducting layer. The utility model discloses use many monofilaments to adopt compound hank technology to restraint the hank and become single core as soft conductor, increase conductor compliance. A plurality of conductors are arranged in a cable in parallel according to production requirements, and a high-quality semi-conducting layer is used as a parallel conductor coating layer, so that the current-carrying capacity of each conductor is ensured to be the same in a transmission environment. The flexible high-performance insulating material is used as the insulating layer, so that the safe use of the wire is met, the bending performance is ensured, a special crimping terminal is not needed, and the cost is low.

Description

Flat automobile cable

Technical Field

The utility model belongs to the technical field of the car wiring harness, especially relate to a flattening car cable.

Background

The automobile has high popularity in the current society, is deeply embedded into the families of people and becomes an indispensable part of life. In the family of motor vehicles, the time in the vehicle is very long each day, and the motor vehicle is equivalent to a second home. Therefore, not only the automobile is a vehicle, but also people are more and more concerned about the comfort and the safety of the automobile, and the application of various configurations related to the comfort and the safety in the automobile is increased year by year. Automobile wires still mainly use round wires or sheathed wires at present, and as automobile functions are increased, wiring space is increasingly tense. The cab of the commercial truck is a living area of a driver and passengers, the space is short, the phenomenon that floor wiring harnesses are arranged in the cab to protrude is caused, and the attractiveness and the safety are affected.

In a flat aluminum wire or copper wire cable used in the prior art, an aluminum plate or copper plate is used as a power transmission conductor, and an insulating layer is extruded on the outer layer. Because the aluminum plate or the copper plate has high hardness and poor flexibility, the aluminum plate or the copper plate is difficult to lay in a vehicle, can only be pressed in advance according to the wiring environment, needs a special connector, has high cost and poor universality.

A round wire, a copper rod or an aluminum rod used in the prior art are used as conductors, a layer of high-performance insulating material is prepared on the outer layer, the conductors and electric wires are round, the outer diameter of a large-section product is large, the flexibility is poor, and laying and using of customers are affected.

Therefore, there is a need in the art for a new solution to solve this problem.

SUMMERY OF THE UTILITY MODEL

The utility model discloses the technical problem that will solve is: the utility model provides a flattening car cable, flattening car cable have big cross-section, and the current-carrying capacity is big, can be at narrow space along with advantages such as the crooked change of environment for solve circular wire or sheath line compliance poor, influence pleasing to the eye and safe technical problem.

A flat automobile cable comprises a conductive wire core, a semi-conductive layer and an insulating layer, wherein the conductive wire core is in a structure that more than three single cores with outer walls covering the semi-conductive layer are arranged on the same plane in parallel, and the semi-conductive layer is arranged between every two adjacent single cores and outside the conductive wire core; the single core is of a multi-monofilament bundle-twisted structure; the insulating layer is sleeved outside the semi-conducting layer.

The single core is bare copper with the purity of more than 99.99 percent.

The semi-conducting layer is a polyolefin semi-conducting layer added with carbon black.

The semi-conductive layer is a polyvinyl chloride semi-conductive layer added with carbon black.

The insulating layer is a polyolefin insulating layer.

Through the above design scheme, the utility model discloses following beneficial effect can be brought:

the utility model discloses use many monofilaments to adopt compound hank technology to restraint the hank and become single core as soft conductor, increase conductor compliance. A plurality of conductors are arranged in a cable in parallel according to production requirements, and a high-quality semi-conducting layer is used as a parallel conductor coating layer, so that the current-carrying capacity of each conductor is ensured to be the same in a transmission environment. The insulating material who uses soft high performance has both satisfied the wire and has used safely as the insulating layer, guarantees bending property simultaneously, has improved the poor problem of current flat cable bending property, has improved current flat cable and need use special crimping terminal problem with high costs.

The utility model discloses cable strong adaptability of production can adjust parallelly connected conductor quantity according to customer's high reduction demand, and is nimble convenient, highly can reduce below 50% even. The wiring height of the wire is greatly reduced, the phenomenon of wiring protrusion of a cab in a commercial vehicle can be avoided, the attractiveness and safety of the vehicle are improved, and the brand image is improved.

Drawings

The invention is further described with reference to the following drawings and detailed description:

fig. 1 is a schematic structural diagram of a cable with an aluminum plate or a copper plate as a core in the prior art.

Fig. 2 is a schematic structural diagram of a cable with a round copper wire as a core in the prior art.

Fig. 3 is a schematic structural view of the flat automobile cable of the present invention.

In the figure, 1-conductive wire core, 2-semi-conductive layer, 3-insulating layer and 4-single core.

Detailed Description

As shown in the figure, the flat automobile cable comprises a conductive wire core 1, a semi-conductive layer 2 and an insulating layer 3, wherein the conductive wire core 1 is in a structure that more than three single cores 4 with outer walls covering the semi-conductive layer 2 are arranged in parallel on the same plane, and the semi-conductive layer 2 is arranged between every two adjacent single cores 4 and outside the conductive wire core 1; the single core 4 is of a multi-monofilament bundle-twisted structure; the insulating layer 3 is arranged outside the semiconducting layer 2.

The single core 4 is bare copper with the purity of more than 99.99 percent.

The semi-conductive layer 2 is a polyolefin semi-conductive layer added with carbon black.

The semi-conductive layer 2 is a polyvinyl chloride semi-conductive layer added with carbon black.

The insulating layer 3 is a polyolefin insulating layer.

A manufacturing method of a flattened automobile cable is used for manufacturing the flattened automobile cable and comprises the following steps which are sequentially carried out,

step one, drawing 14/0.31 doubling by using a multi-head wire drawing machine, wherein the requirement of the doubling elongation is more than or equal to 20%, and stranding into a flexible conductor 70/0.31 which is a single core 4 by using a 5-shaft 14/0.31 doubling high-speed double-twisted wire bundling machine and a double-shaft pay-off stand, wherein the doubling drawing speed is 10m/s, and the stranding speed of the stranding is 1500 rpm;

step two, coating the single core 4 with the semiconductive material in an extruder, and cooling to obtain a single extrudate I, wherein the density of the semiconductive material is 1.3 +/-0.05 kg/cm 3; in the extrusion process, the extrusion speed is 300 m/min-700 m/min, the equipment adopts active traction and passive traction, and the tension is controlled by 10 horizontal wire storage frames;

and step three, discharging a specified number of single extrudates I by a pay-off rack, simultaneously passing the extrudates I through an extruder, coating the semi-conductive materials again to form a semi-conductive layer 2, cooling to obtain a flat extrudate II, wherein in the extrusion process, the extrusion speed is 20-100 m/min, the equipment is active traction and passive traction, and the tension is controlled by 10 horizontal wire storage racks.

And step four, coating an insulating material on the outer part of the flat extrudate II by using an extruder to form an insulating layer 3, cooling to obtain the flat automobile cable, wherein in the extrusion process, the extrusion speed is 20-100 m/min, the equipment adopts active traction and passive traction, and the tension is controlled by 10 horizontal wire storage frames.

The parameters of the extruder in the second step and the third step are set as follows in the working process:

the temperature of one section of a main machine of the extruder is increased to the set temperature of a machine head in sequence, and the set temperature is as follows: the drying temperature of the material is 60-80 ℃; the primary temperature of the main machine is 160-170 ℃; the second section of the host is 170-180 ℃; the three sections of the main machine are 175-185 ℃; the four sections of the main machine are 180-190 ℃; the temperature of the machine head is 185-195 ℃;

the extruder adopts a pipe extruding type mold core and a pipe extruding type mold sleeve in the coating process, the angle of the pipe extruding type mold core is 30-45 degrees, the angle of the pipe extruding type mold sleeve is 35-50 degrees, the angle of the pipe extruding type mold sleeve in the coating process is not smaller than that of the pipe extruding type mold core, and the angle of an extruding mold is 60 degrees;

the length of the diameter of the extruded tube type mold core is 10-15 mm, the length of the diameter of the extruded tube type mold sleeve is 1-3 mm, the thickness of the diameter of the extruded tube type mold core is 0.4-0.7 mm, and the size of an outlet of the extruded tube type mold sleeve is larger than the outer diameter of a cold end of the cable.

The specific cooling method in the second step, the third step and the fourth step comprises the following steps: each extrudate sequentially passes through two cooling zones, wherein the first cooling zone is a natural air cooling zone and is arranged between the die sleeve outlet and the water cooling zone; the second cooling area is a water cooling area, and the temperature is 5-35 ℃.

The present invention is further described in detail by the following specific examples:

for example, the maximum outer diameter of the original wire is FLRY 25196/0.41 and 9.4mm, I can be QI-B5 x 5350/0.31 and 5.5mm, and the height is reduced by more than or equal to 41 percent.

1. Example 1

1.1 cable model specification: QI-B5 × 5350/0.31.

1.2 the minimum thickness of the cable sheath layer is 0.52mm, and the maximum outer diameter is 5.5 mm.

1.3 the cable sheath material is a thermoplastic PVC material independently developed by Shanghai Fuao plastic products Limited, and the material is the material brand PVC-8105; the semiconductive material is a thermoplastic semiconductive PVC material which is independently developed by Shanghai Fuao plastic products Limited and has the material mark of XQV.

1.4 the conductive wire core is discharged by five single cores and QB-B5 mm2 single wires which cover the semi-conductive layer on the outer surface of the insulation layer through a single-shaft pay-off rack, and the pay-off tension is kept consistent.

1.5 extruding the first semiconductive layer through a flat die in a 90-extruder using a single-flight screw. The paying-off mode of the movable disc is controlled by air pressure, and the paying-off tension is controlled by air pressure. The traction adopts active traction and passive traction.

1.6 extruding a second layer of insulation through a flat die in a 90 extruder using a single flight screw. The paying-off mode of the movable disc is controlled by air pressure, and the paying-off tension is controlled by air pressure. The traction adopts active traction and passive traction.

1.7 Table 1: example 1 sheath procedure extrusion temperature

1.8 in the process of extruding the wire core, the angle of the extrusion die sleeve is 35 degrees, and the angle of the extrusion die core is 35 degrees; the bearing diameter length of the die sleeve is 2mm, and the bearing diameter length of the die core is 10 mm.

1.9 of a cooling system, wherein the temperature of a cooling area at the first section of the near mold is 27 ℃; the water temperature of a far mold cooling area is 13 ℃.

1.10 the extrusion speed was 55 m/min.

2. Example 2

2.1 cable model specification: QI-B4 4224/0.31.

2.2 the minimum thickness of the cable sheath layer is 0.52mm, and the maximum outer diameter is 5.1 mm.

2.3 the cable sheath material is a thermoplastic PVC material independently developed by Shanghai Fuao plastic products Limited, and the material is the material brand PVC-8105; the semiconductive material is a thermoplastic semiconductive PVC material which is independently developed by Shanghai Fuao plastic products Limited and has the material mark of XQV.

2.4 the conductive wire core is discharged by 4 single cores and QB-B4 mm2 single wires which cover the semi-conductive layer on the outer surface of the insulation layer through a single-shaft pay-off rack, and the pay-off tension keeps consistent.

2.5 extrusion of the first semiconductive layer through a flat die in a 90-extruder, using a single-flight screw. The paying-off mode of the movable disc is controlled by air pressure, and the paying-off tension is controlled by air pressure. The traction adopts active traction and passive traction.

2.6 extruding the second layer of insulation through a flat die in a 90 extruder using a single flight screw. The paying-off mode of the movable disc is controlled by air pressure, and the paying-off tension is controlled by air pressure. The traction adopts active traction and passive traction.

2.7 Table 2: example 2 sheath procedure extrusion temperature

2.8 in the process of extruding the wire core, the angle of the extrusion die sleeve is 35 degrees, and the angle of the extrusion die core is 35 degrees; the bearing diameter length of the die sleeve is 2mm, and the bearing diameter length of the die core is 10 mm.

2.9 cooling system, the temperature of the cooling area of the first section of the near mould is 27 ℃; the water temperature of a far mold cooling area is 13 ℃.

2.10 the extrusion speed was 55 m/min.

3. Example 3

3.1 cable model specification: QI-B4 2.580/0.41.

3.2 the minimum thickness of the cable sheath layer is 0.48mm, and the maximum outer diameter is 3.4 mm.

3.3 the cable sheath material is a thermoplastic PVC material independently developed by Shanghai Fuao plastic products Limited, and the material is the material brand PVC-8105;

3.4 the conductive core is by 4 ply 20/0.41 doubling, and pay off side by side through the unipolar pay off rack, and unwrapping wire tension keeps unanimous.

3.5 extrusion of the insulation through a flat die in a 90 extruder, using a single-flight screw. The paying-off mode of the movable disc is controlled by air pressure, and the paying-off tension is controlled by air pressure. The traction adopts active traction and passive traction.

3.6 Table 3: example 3 sheath procedure extrusion temperature

3.7 in the process of extruding the wire core, the angle of the extrusion die sleeve is 35 degrees, and the angle of the extrusion die core is 35 degrees; the bearing diameter length of the die sleeve is 2mm, and the bearing diameter length of the die core is 10 mm.

3.8 manufacturing failed because of the small tolerances in the die design and the inability of the doubled yarn to pass out of the die core. After the size of the wire core is adjusted, the wire can penetrate out of the die core, but the rubber material extrudes the doubled wires together after coming out of the die head, and the conductor cannot be flat.

4. Example 4

4.1 Cable model specification: QI-B1080/0.41.

4.2 the minimum thickness of the cable sheath layer is 0.48mm, and the maximum outer diameter is 3.4 mm.

4.3 the cable sheath material is a thermoplastic PVC material independently developed by Shanghai Fuao plastic products Limited company, and the material is the material brand PVC-8105.

4.4 the conductor core is 80/0.41 wire stranded by cage, and the flat conductor is formed by a flat cage-stranded die.

4.5 extrusion of the insulation through a flat die in a 90 extruder, using a single-flight screw. The paying-off mode of the movable disc is controlled by air pressure, and the paying-off tension is controlled by air pressure. The traction adopts active traction and passive traction.

4.6 Table 4: example 4 sheath procedure extrusion temperature

4.7 in the process of extruding the wire core, the angle of the extrusion die sleeve is 35 degrees, and the angle of the extrusion die core is 35 degrees; the bearing diameter length of the die sleeve is 2mm, and the bearing diameter length of the die core is 10 mm.

4.8 the manufacture fails, after the conductor is coated with the insulating layer, the phenomenon of axial rotation appears in the water tank, and the conductor returns to the original round shape after coming out of the machine head, and the flat shape cannot be kept.

5. Example 5

5.1 cable model specification: QI-B4 2.580/0.41.

5.2 the minimum thickness of the cable sheath layer is 0.48mm, and the maximum outer diameter is 3.4 mm.

5.3 the cable sheath material is a thermoplastic PVC material independently developed by Shanghai Fuao plastic products Limited, and the material is the material brand PVC-8105.

5.4 the conductive core is by 4 ply 20/0.41 wires, and pay off side by side through the unipolar pay off rack, and unwrapping wire tension keeps unanimous.

5.5 extrusion of the insulation through a flat die in a 90 extruder, using a single-flight screw. The paying-off mode of the movable disc is controlled by air pressure, and the paying-off tension is controlled by air pressure. The traction adopts active traction and passive traction.

5.6 Table 5: example 5 sheath procedure extrusion temperature

5.7 in the process of extruding the wire core, the angle of the extrusion die sleeve is 35 degrees, and the angle of the extrusion die core is 35 degrees; the bearing diameter length of the die sleeve is 2mm, and the bearing diameter length of the die core is 10 mm.

5.8 manufacturing failure due to too little peel force between the conductor and the insulation, insufficient securement between the insulation and the conductor, and play.

Claims (5)

1. The utility model provides a flattening car cable, characterized by: the cable comprises a conductive cable core (1), a semi-conductive layer (2) and an insulating layer (3), wherein the conductive cable core (1) is of a structure that more than three single cores (4) with outer walls coating the semi-conductive layer (2) are arranged in parallel on the same plane, and the semi-conductive layer (2) is arranged between every two adjacent single cores (4) and outside the conductive cable core (1); the single core (4) is of a multi-monofilament bundle-twisted structure; the insulating layer (3) is sleeved outside the semi-conducting layer (2).

2. The flattened automotive cable of claim 1, wherein: the single core (4) is bare copper with the purity of more than 99.99 percent.

3. The flattened automotive cable of claim 1, wherein: the semi-conductive layer (2) is a polyolefin semi-conductive layer added with carbon black.

4. The flattened automotive cable of claim 1, wherein: the semi-conductive layer (2) is a polyvinyl chloride semi-conductive layer added with carbon black.

5. The flattened automotive cable of claim 1, wherein: the insulating layer (3) is a polyolefin insulating layer.

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