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CN-122025231-A - Flat laminated composite aluminum row and application thereof in large-current transmission of new energy automobile

CN122025231ACN 122025231 ACN122025231 ACN 122025231ACN-122025231-A

Abstract

The invention discloses a flat laminated composite aluminum row and application thereof in high-current transmission of a new energy automobile, and belongs to the technical field of wires and cables. The flat laminated composite aluminum bar and the application thereof in the heavy-current transmission of the new energy automobile comprise a laminated conductor assembly, an intermediate insulating isolation layer and an outer layer coating insulating layer, wherein the laminated conductor assembly is formed by vertically and parallelly overlapping two groups of flat aluminum conductors with identical specifications, the intermediate insulating isolation layer is clamped between the joint surfaces of the two groups of flat aluminum conductors, the outer layer coating insulating layer is tightly coated on the integral outer side formed by the laminated conductor assembly and the intermediate insulating isolation layer to form an integrated flat laminated structure, the flat aluminum conductors are made of AL6101-T64 aluminum alloy materials, the thickness of the flat aluminum conductors is 6.3mm, the width of the flat aluminum conductors is 35mm, and the surfaces of the flat aluminum conductors are subjected to electrochemical polishing treatment.

Inventors

  • YANG YONG
  • LV ZHIQIAN
  • DENG QINGYUN

Assignees

  • 广东三睿超导科技有限公司

Dates

Publication Date
20260512
Application Date
20260323

Claims (8)

  1. 1. The utility model provides a flat lamination composite aluminum row, its characterized in that includes lamination conductor subassembly, middle insulating isolation layer (2) and outer cladding insulating layer (3), lamination conductor subassembly comprises the parallel coincide from top to bottom of two sets of flat aluminum conductors (1) that the specification is unanimous, middle insulating isolation layer (2) clamp is located between the faying face of two sets of flat aluminum conductors (1), outer cladding insulating layer (3) closely cladding is in lamination conductor subassembly and the whole outside that middle insulating isolation layer (2) formed, constitutes the flat lamination structure of integration.
  2. 2. The flat laminated composite aluminum busbar according to claim 1, wherein the flat aluminum conductor (1) is made of an Al6101-T64 aluminum alloy material, the thickness of the flat aluminum conductor (1) is 6.3mm, the width of the flat aluminum conductor (1) is 35mm, and the surface of the flat aluminum conductor (1) is subjected to electrochemical polishing treatment.
  3. 3. The flat laminated composite aluminum busbar of claim 1, wherein the intermediate insulating isolation layer (2) is made of high-temperature ceramic silica gel, and the thickness of the intermediate insulating isolation layer (2) is 1.5-2.0 mm.
  4. 4. The flat laminated composite aluminum busbar according to claim 1, wherein the rated heat resistant temperature of the intermediate insulating isolation layer (2) is equal to or higher than 200 ℃, and the instantaneous heat resistant temperature of the intermediate insulating isolation layer (2) is equal to or higher than 250 ℃.
  5. 5. The flat laminated composite aluminum busbar of claim 1, wherein the outer cladding insulating layer (3) is made of PA12 nylon, and the thickness of the outer cladding insulating layer (3) is 2.0-2.5 mm.
  6. 6. The flat laminated composite aluminum busbar according to claim 1, wherein the rated heat-resistant temperature of the outer layer cladding insulating layer (3) is more than or equal to 125 ℃, the instant heat-resistant temperature of the outer layer cladding insulating layer (3) is more than or equal to 175 ℃, and the bending radius of the outer layer cladding insulating layer (3) is less than or equal to 2 times the width of the aluminum busbar.
  7. 7. A process for forming a flat laminated composite aluminium busbar according to any one of claims 1 to 6, comprising the steps of: S1, preparing an aluminum conductor, namely selecting Al6101-T64 aluminum alloy raw materials to carry out aluminum extrusion processing to prepare a flat aluminum conductor (1) with the thickness of 6.3mm and the width of 35mm, carrying out electrochemical polishing treatment on the surface of the aluminum conductor, and preparing two groups of flat aluminum conductors (1) with consistent specifications for later use; S2, forming and compounding an intermediate insulating isolation layer, namely extruding a high-temperature ceramic silica gel raw material by adopting a 90 extruder to form an intermediate insulating isolation layer (2) with the thickness of 1.0-1.5 mm, clamping the intermediate insulating isolation layer (2) between the joint surfaces of two groups of flat aluminum conductors (1), performing high-temperature vulcanization treatment on the clamped structure, and then cooling and fixing the structure through a cooling water tank to form a composite blank of a laminated conductor assembly and the intermediate insulating isolation layer (2); S3, extruding the outer layer cladding insulating layer by using a 120-speed special extruder, extruding PA12 nylon raw materials with a pressurizing die, forming the outer layer cladding insulating layer (3) with the thickness of 0.8-1.2 mm on the outer side of the composite green body in a tight cladding mode, cooling the outer layer cladding insulating layer again through a water tank after cladding, and shaping the outer layer insulating layer to form an aluminum row semi-finished product with an integrated flat laminated structure; S4, carrying out subsequent finish machining treatment, namely sequentially cutting, 3D bending and peeling on the semi-finished product of the aluminum bar, punching the aluminum conductor part, attaching a product label after finishing, and finally packaging the finished product to obtain the final flat laminated composite aluminum bar.
  8. 8. Use of a flat laminated composite aluminium busbar according to any one of claims 1 to 6 for high current transmission between a charging interface and a battery pack of a new energy electric vehicle.

Description

Flat laminated composite aluminum row and application thereof in large-current transmission of new energy automobile Technical Field The invention relates to the technical field of wires and cables, in particular to a flat laminated composite aluminum row and application thereof in high-current transmission of new energy automobiles. Background Along with the rapid development of social economy and the popularization of the green low-carbon concept, the new energy automobile industry is exploded, meanwhile, the requirements of people on the automobile riding experience are continuously improved, and the new energy automobile is promoted to be iteratively upgraded in the light weight, high endurance and high integration directions. The development trend brings stringent requirements to structural design, volume control and weight optimization of the core components in the vehicle, and particularly in a heavy current transmission link, the performance of a connecting cable directly influences the cruising ability, spatial layout and running stability of the whole vehicle. Based on the above, the inventor finds that the conventional new energy automobile adopts round cables for large current transmission, the manufacturing process of the cables is mature and the cost is lower, but the conventional round cables adopt a stranded structure of stranded copper wires, so that the sectional area of the cables needs to be increased to meet the large current transmission requirement, the cables are huge and heavier, a large amount of laying space in the automobile is occupied, the airtight and compact automobile layout cannot be adapted, the weight of the whole automobile can be increased, the endurance mileage is further reduced, a large amount of gaps exist between adjacent cables when the round cables are laid due to the round section of the round cables, the space utilization rate is low, the bending radius is larger, the cables are difficult to flexibly lay in a narrow and complex automobile space, and the tight equipment layout requirement cannot be adapted. Accordingly, in view of the above, research and improvement are made on the existing structure and the existing defects, and a flat laminated composite aluminum row and an application thereof in large current transmission of new energy automobiles are provided, so that the purpose of higher practical value is achieved. Disclosure of Invention The invention aims to provide a flat laminated composite aluminum row and application thereof in large-current transmission of new energy automobiles, so as to solve the problems of huge volume, heavy weight, occupied laying space, low space utilization rate and larger bending radius of the traditional round cable in the background art. In view of the above problems, the technical scheme provided by the invention is as follows: The utility model provides a flat lamination compound aluminium row, includes lamination conductor subassembly, middle insulating isolation layer and outer cladding insulating layer, lamination conductor subassembly comprises parallel coincide from top to bottom by two sets of flat aluminium conductors of specification unanimity, middle insulating isolation layer presss from both sides between the faying face of locating two sets of flat aluminium conductors, outer cladding insulating layer closely wraps in lamination conductor subassembly and middle insulating isolation layer formed whole outside, constitutes the flat lamination structure of integration. Further, the flat aluminum conductor is made of an AL6101-T64 aluminum alloy material, the thickness of the flat aluminum conductor is 6.3mm, the width of the flat aluminum conductor is 35mm, and the surface of the flat aluminum conductor is subjected to electrochemical polishing treatment. The technical scheme has the advantages that the flat aluminum conductor made of the AL6101-T64 aluminum alloy material has excellent conductivity and mechanical strength, can meet the requirement of large current transmission of a new energy automobile, is remarkable in light-weight effect, can reduce the overall weight of the automobile, is matched with the specification of 35mm in width by 6.3mm in thickness, can ensure enough current carrying capacity, can also be compact in structure, can remove surface oxide layers and impurities by surface electrochemical polishing treatment, reduces contact resistance, improves conductivity efficiency, enhances surface corrosion resistance and prolongs the service life of aluminum bars. Furthermore, the middle insulating isolation layer is made of high-temperature ceramic silica gel, and the thickness of the middle insulating isolation layer is 1.5-2.0 mm. The high-temperature ceramic silica gel insulating layer has the advantages that the insulating performance of the middle insulating isolation layer made of the high-temperature ceramic silica gel material is excellent, two groups of flat aluminum conductors can be e