Transcription of HEV/EV用高柔軟耐熱アルミケーブルと接続技術
1 HEV/EV . 1 3 4 5.. 2.. Highly Flexible Heat - resistant Aluminum Cable and Connection Technology for HEV/EV. H. Saita, R. Watanabe, M. Nishimura, S. Zouraku, and M. Mochizuki HEV . EV .. The hybrid electric vehicle (HEV) and electric vehicle (EV) market is expected to expand as a result of the recent growing interest in environmental protection and tighter environmental regulations in each country. The newer the power supply systems of these vehicles are, the higher their output power becomes. To carry high current, the cables of the power supply systems also tend to be larger in size and weight and less flexible. Against this background, there are growing demands for weight reduction and more flexibility of the cables.
2 To respond to this requirement, we have developed a more flexible cable. This cable is also lighter in weight than a conventional copper cable by the use of an aluminum conductor. In addition, we also have developed a connection method that replaced the conventional crimp method to secure the connection between the aluminum conductor and the copper terminal.. 1 .. CO2 HEV . HEV/EV .. 45.. 40. 1 . 35. Cable size mm2 .. 30.. 25.. 20.. 15.. 10.. 5. 0. 1 1995 2000 2005 2010 2015 2020 2025. 2 Year 3 . 4 1 . 5 Fig. 1. Cable size trend. 16. HEV/EV . 2 2 .. TPE TPE . XLPE .. 2 .. 2 3 TPE . TPE 2 . 150 . 2 . A D. TPE . TPE Thermoplastic Elastomer C 3 .. 1 2 . 2 1 100.. 90.. 80 100 mm . 70 .. E .. Bending force N . P.
3 15% 3 60.. 50.. 40 .. 30 . 1 .. Table 1. Comparison of specifications of conventional 20. products and developed products.. 10.. mm2 20 35. 0. Cu Al 0 20 40 60 80 100 120. / / . 19 / 13 / 19 / 24 / Cable size mm2 . mm . mm 3 . m /m Fig. 3. Cable flexibility. - XLPE TPE. mm mm . N 34 28 2 .. 125 150. Table 2. Shore hardness. g/m 215 155 TPE . A 50 70 A 75 90 A 95 .. 3 . Table 3. Formulation type. A B C D.. 2 . Fig. 2. Cable structure.. 17. 2018 131 . 2 4 3 1 . 4 3 . 4 6 .. mm2 mm 2 . HEV/EV .. 3 .. 5 .. 7 . 5 .. 4 35sq . Table 4. Test result of prototype cable A part of all . the tests . 1083 660 .. 1 34 N .. 28 N.. ISO 6722 . 150 x 3000 . 150 x 4 . 6 . JASO D 624 . Table 6. Connection method. 30 .. 100 mm/.
4 R5. 20. oxide lm is not destroyed . Number of strands that 150 mm 15. 100 mm 10. 5.. 0. 4 Fig. 4. Test method of flexibility. Conductor size 1 5 18 . 5 . Table 5. Test result.. 500 N 100 mm/min 542 N. m 5 . m . m . Fig. 5. Number of strands that oxide film is not 40 150 X 3000 destroyed. 18. HEV/EV . 3 2 .. 7 . Table 7. Contact resistance Terminal - Conductor layer.. 1 2 3 1083 660 232 . m 5 30 60 500 1000.. R R R 8 .. 8 . Table 8. Ultrasonic bonding test result.. 6 .. J . 1 .. 8500 .. 7 . 23000.. 6 7 . Fig. 6. Energy input from conductor side. Fig. 7. Energy input from top and bottom. 19. 2018 131 .. Sn A A. 200 m Sn L.. Cu AL .. A - A ( ). 200 m Cu K 200 m Al K. 8 .. Fig. 8. Cross section photo of connection.
5 10 EDS. Fig. 10. Magnified photo and EDS.. Thermal Shock 40 150 .. Resistace m-ohm .. 0 500 1000 1500 2000 2500 3000 3500. Cycle 9 11 . Fig. 9. Photo of Bonding area. Fig. 11. Thermal shock test result. 3 3 . 4 . 8 . HEV/EV TPE .. 2 .. 9 10 . EDS .. 11 1 . 47 3 . 20.
