CN211907700U

CN211907700U - Injection molding's pencil

Info

Publication number: CN211907700U
Application number: CN202020527671.4U
Authority: CN
Inventors: 王超
Original assignee: Changchun Jetty Automotive Parts Co Ltd
Current assignee: Changchun Jetty Automotive Parts Co Ltd
Priority date: 2020-04-10
Filing date: 2020-04-10
Publication date: 2020-11-10
Anticipated expiration: 2030-04-10

Abstract

The invention relates to an injection-molded wire harness, which comprises a terminal and at least one conductor, wherein one end of the terminal is connected with an electric circuit of an electric device, the other end of the terminal is connected with the conductor, and the wire harness is provided with a protective layer which is formed by injection molding and covers the conductor, and at least one positioning device which is formed by injection molding and used for fixing the position of the wire harness or/and a sealing device which is used for water proofing. The wire harness fixing device can reduce manual operation, improve the consistency of wire harness products, reduce the production cost of the wire harness products and prolong the service life of the wire harness.

Description

Injection molding's pencil

Technical Field

The invention relates to the technical field of wire harnesses, in particular to an injection-molded wire harness.

Background

In the field of electrical connection, a wire harness is used as a bridge for connecting an electrical loop, is communicated between a power supply and electrical appliances and between the electrical appliances for data exchange, and is an essential important part in automobiles, airplanes, ships, various household electrical appliances and equipment.

The wire harness is composed of various types and materials, but the main structure is composed of a cable, a terminal, a sheath, a fixing device, a waterproof device and the like, wherein the cable is composed of a conductor and an insulating layer coated around the conductor. At present, the processing technology of the wire harness is complex, and comprises the procedures of cutting, peeling, pressing a terminal, welding, pipe penetrating, blind plugging, plugging a terminal, plugging a sheath, split charging, wiring, rubber coating, branch fixing, mounting and positioning devices, mounting parts, conducting, appearance inspection, packaging and the like, wherein the split charging, wiring, rubber coating, branch fixing, mounting and positioning devices and the mounting parts occupy the main working hours of wire harness production, automatic production equipment does not exist at present, all the wire harness is operated manually, the qualification rate is high, the production cost is high, the product consistency cannot be guaranteed, and the wire harness processing technology becomes the bottleneck for limiting the development of the wire harness industry. In the traditional wire harness processing technology, two mounting modes of a positioning device of a wire harness are adopted, namely adhesive tape fixing and ribbon fixing are adopted, but the two methods have the defects of inaccurate mounting size, easy falling of the positioning device and the like. In the traditional wire harness processing technology, the sealing device of the wire harness is made of rubber, the wire harness needs to be stretched in advance during installation to ensure that the wire harness can penetrate through a cable and is fixed, and in order to ensure the sealing performance, daub and sealant need to be added between the sealing device and the cable, so that the technology is complex, the sealing device is easy to damage, and the sealing function is ineffective.

In addition, each part on traditional pencil, all not the inseparable combination, including the cable and protective case above that, the cable passes through the terminal and is connected with the sheath, positioner passes through adhesive tape or ribbon fixed, watertight fittings passes through the attached pencil of elasticity of rubber spare on, in long-time use, each part is connected and can be progressively become invalid, lead to cable and protective case wearing and tearing, the cable breaks away from with the sheath, positioner position is inaccurate or drop and watertight fittings damages or drops, the function of each part has been lost, thereby lead to the pencil to become invalid, can cause the accident when serious.

Therefore, a new method capable of simplifying the assembly production process of the wire harness is urgently needed in the wire harness industry at present, so that manual operation can be reduced, the consistency of products is improved, and the production cost of the products is reduced.

Therefore, the chinese patent application CN 104149770 a discloses an injection molding type anti-lock brake system sensor harness, which adds an injection molding positioning piece on the original signal transmission cable, but the invention only aims at the anti-lock brake system sensor harness, and has limitation in use. The invention still needs to purchase the finished cable and then process the cable into the main body of the wire harness, which can not save the cost of the wire harness. The cable is not protected, and after the cable is loaded and used, the cable insulation sheath is damaged due to vibration and friction on an installation part, and a short circuit is caused in severe cases to cause a combustion accident. In addition, the added injection molding part has single function and cannot meet other complicated requirements on the wire harness.

Therefore, in the technical field of wire harnesses, a wire harness and a forming method which are simple in production process, high in wire harness dimensional accuracy and long in service life are urgently needed, the cost of the wire harness can be reduced, the waterproof grade can be increased, the production efficiency can be improved, the product reject ratio can be reduced, and the service life of the wire harness can be prolonged.

Disclosure of Invention

Aiming at the technical problems, the invention aims to overcome the defects of the prior art, and provides a brand-new injection molding wire harness, which can greatly reduce the wire harness processing flow, reduce manual operation, improve the consistency of products, increase the waterproof grade and reduce the production cost of the products. The wire harness forming machine can realize one-time processing forming of the wire harness formed in a complex mode, improves production efficiency, and enables the application range of the wire harness to be wider. And can carry out one shot forming to the pencil that has sealed requirement, increase the leakproofness of pencil, reduce the use of materials such as daub, sealed glue to the life in waterproof zone is prolonged, improves the safety in utilization performance greatly.

The purpose of the invention is realized by the following technical scheme:

the invention relates to an injection-molded wire harness, which comprises a terminal and at least one conductor, wherein one end of the terminal is connected with an electric circuit of an electric device, the other end of the terminal is connected with the conductor, and the wire harness is provided with a protective layer which is formed by injection molding and covers the conductor, and at least one positioning device which is formed by injection molding and used for fixing the position of the wire harness or/and a sealing device which is used for water proofing. It should be noted that, unlike the conventional wire harness, the wire harness of the present invention may use a cable with an insulating layer, or may be directly injection-molded using a conductor. The conductor may be processed in various forms, such as rolled conductor cutting, copper foil cutting, conductor printing, 3D printing, and the like. The wire harness can be selected and optimized according to different wire harness use environments, raw materials are saved to a greater extent, the processing time is reduced, and the product quality is improved.

According to the injection molding wire harness, all parts are connected together through heating melting and then cooling molding, so that the injection molding wire harness is of an integral structure, mutual abrasion among the parts does not exist, the relative positioning size is accurate, the service life is greatly prolonged compared with that of a traditional wire harness, and the safety can be guaranteed.

Preferably, the conductor is further provided with an insulating layer outside, and the protective layer is injected outside the insulating layer.

Preferably, the positioning device comprises a first fixing device connected with the wiring harness and a mounting device connected with the mounting end of the wiring harness in a matching way, and the mounting device is connected to the first fixing device.

It should be noted that, when the general wiring harness is installed, the wiring harness is connected with the installation end by using the positioning device when exceeding a certain length, so as to ensure that the wiring harness can be fixed on the installation end, such as an engine, a sheet metal frame or other pipelines. If no positioning device is arranged, the wiring harnesses can move on the mounting end mutually, so that the abrasion of the wiring harnesses is increased, and in addition, abnormal sound can be generated due to the movement of the wiring harnesses, so that the use feeling of automobiles, airplanes, ships or various household appliances is influenced.

Preferably, the first fixing device is a cylindrical structure, and the inner wall of the cylindrical structure is matched with the outer surface of the protective layer and wraps the outer surface of the protective layer.

The cylindrical structure is used for enhancing the strength of the fixing device and preventing the positioning device from falling off from the wire harness under the stress.

Preferably, the assembling device is a columnar structure, and the periphery of the columnar structure is provided with an inverted tooth structure.

The inverted tooth structure is used for preventing the columnar structure from falling off from the mounting hole when the columnar structure is matched with the mounting hole of the mounting end.

Preferably, the mounting means has a clip-like structure.

Preferably, the clip-like structure is provided with a groove, and barbs are arranged on two side walls in the groove. Set up the barb in the recess, be for when the clip column structure matches with the panel beating edge of installation end, can block the panel beating edge, prevent the clip column structure is followed drop on the panel beating edge.

Preferably, the fitting means has a circular ring structure or a C-ring structure. The annular structure or the C-shaped ring structure is used for preventing the assembling device from falling off from the pipeline when the assembling device is matched with other pipelines at the installation end.

Preferably, the positioning device is a plastic part processed by using an injection molding mode. Because positioner all is with installation end rigid connection, if use the rubber spare, the deflection is big, then the condition that the connection is insecure can appear, consequently can use the working of plastics that hardness and elasticity are all better.

Preferably, the sealing means includes a second fixing means connected to the wire harness and a waterproof means having one end connected to the second fixing means.

Preferably, the second fixing device is a cylindrical structure, and the inner wall of the cylindrical structure is matched with the outer surface of the protective layer and wraps the outer surface of the protective layer. The cylindrical structure is used for enhancing the strength of the fixing device and preventing the sealing device from falling off from the wiring harness under the stress.

Preferably, the sealing device is a rubber piece processed by using an injection molding mode. Because the sealing device needs to seal the sealing end of the wire harness, the sealing end of the wire harness is subjected to injection molding and sealing by adopting elastic materials such as rubber pieces and the like, so that water in the external environment is prevented from entering the wire harness, the corrosion of a wire harness conductor is prevented, the service life of the wire harness is seriously shortened, and safety accidents are seriously caused.

The sealed end of the wire harness refers to that the wire harness passes through some through holes on the partition plate of the dry area and the wet area when being installed, and in order to prevent water in the wet area from entering the dry area, a waterproof device on the wire harness is required to be matched and sealed with the through holes on the partition plate. Furthermore, when the wire harness is in a wet area, the conductors are exposed between the protective layer of the wire harness and the terminals, and the exposed conductors and the terminals are required to be sealed and wrapped by a sealing device, so that the conductors and the terminals are prevented from being corroded by water in the external environment. In addition, when the sheath is used in a wet area, a sealing device is required to seal the hole of the sheath in order to prevent the terminal and the conductor from being corroded due to water entering the sheath.

Preferably, the wire harness is further provided with at least one sheath inserted into the electric device, and the terminal is fitted in a corresponding hole of the sheath.

Preferably, the sheath is integrally injection moulded onto at least the terminal.

The conductor is connected with the sheath through the connected terminal, and in order to ensure the firm connection between the conductor and the sheath, the conductor and the sheath can be fixed together by the protective layer when the protective layer is injected, so that the service life of the wire harness is prolonged.

Preferably, the conductor is a solid conductor, a flat conductor, a conductor of a multi-strand wire. According to the different service environment of pencil, the conductor can select different structures for use.

Preferably, the terminal is connected to the conductor of a solid conductor, a flat conductor, a stranded wire by crimping or welding.

Generally, when the conductor and the terminal are made of the same material or similar materials, a crimping manner is adopted. And when the conductor and the terminal are made of materials with larger difference, a welding mode is adopted.

Preferably, the cross section of the conductive part of the conductor is in a circular, elliptical, polygonal, wavy or irregular structure.

Depending on the structure of the conductor in the wire harness, conductive portions of different cross-sectional areas may be selected to form a conductive loop.

Preferably, when the number of the conductors is more than two and belongs to the same loop, the non-terminal side conductor is connected to be a conductor connection point according to the requirement of the loop by adopting a crimping or welding mode.

Preferably, the conductor connection points are sealed by integral injection molding.

The conductor connecting point can greatly save the use of conductor materials, so that current is shunted by different conductors at a proper position. Due to the fact that the crimping or welding mode is adopted, stress of the conductors on two sides of the conductor connecting point is concentrated, stress can be applied to the conductor connecting point to break in the follow-up use process, and the wire harness is out of function, and therefore the mode of integral injection molding is needed to be used for wrapping and protecting the conductor connecting point. The conductor connecting points in the wet area are integrally injected and molded, and the sealing and waterproof effects can be achieved.

Compared with the prior art, the invention has the beneficial effects that:

1. the traditional design concept of the wire harness is that various raw materials such as a cable, a terminal, a sheath, a fixing device, a waterproof device, an adhesive tape and a supporting wire casing are purchased and processed respectively and then assembled into a finished wire harness product. However, the production process is particularly complicated, the processing procedures are multiple, the reject ratio in the production process is high, and the size and the performance of the finished wire harness are difficult to guarantee. The inventor of the application finds that other parts except the conductor and the terminal are basically plastic parts and rubber parts on the wire harness, and most of the conventional production process methods of the plastic parts and the rubber parts are injection molding, so that the wire harness protective layer, the positioning device and the waterproof device are processed by using the injection molding method, the cost of the wire harness can be reduced, the production efficiency can be improved, the reject ratio of products can be reduced, and the service life of the wire harness can be prolonged.

2. The wire harness is directly injection-molded by using the conductor, the processing form of the conductor can be diversified, and the selection and optimization can be carried out according to different wire harness use environments, so that the wire harness raw materials are saved to a greater extent, the processing time is reduced, and the wire harness product quality is improved. And more diversified design choices are provided for a wire harness designer, the cost of the wire harness is optimized, and the stability of the wire harness product is improved. The injection molding protective layer replaces the manual operation of the sleeve and the rubber coating cloth in the traditional wiring harness, and can realize automatic production, and the more branches of the wiring harness, the more working hours are saved. In addition, the protective layer manufactured by the injection molding process avoids the defects of inaccurate size and insufficient protection of the joint in manual rubber coating operation, can better ensure the product quality of the wire harness, and prolongs the service life of the wire harness.

3. According to the wire harness, an integral injection molding processing mode is adopted, the protective layer, the positioning device, the sealing device and other parts of the wire harness can be tightly combined, the waterproof effect of the wire harness can reach the IP67 grade, after the wire harness is subjected to a salt spray experiment, a high-low temperature experiment, a vibration experiment and an aging experiment, the mechanical property and the electrical property between a wire harness conductor and a terminal are slightly influenced, the product quality of the wire harness can be better ensured, and the service life of the wire harness is prolonged. The material of moulding plastics is more various simultaneously, can select different materials of moulding plastics according to the service environment difference, makes the pencil softer, and the anti-vibration effect is better, can use in the environment that the vibration environment is abominable, and the life of the extension pencil that is showing improves the security of pencil.

4. The wire harness can also adopt a wire with an insulating layer, and when the wire harness loop is less, or the wire is longer in length and the requirement on sealing performance is not high, the wire with the insulating layer is adopted, so that the cost of an injection mold can be reduced.

5. The positioning device is processed by using the injection molding mode, the adhesive tape fixing and the ribbon fixing positioning device are replaced, the position size of the positioning device is ensured by the mold, the size is accurate, the consistency is good, and the quality of a wire harness product can be better ensured. Meanwhile, the positioning device is integrally molded on the wire harness, so that the wire harness positioning device is more firm in combination, is not easy to fall off, has a better positioning effect, rarely has size deviation and even breaks away from the wire harness in a severe environment of a vibration environment, so that the wire harness positioning function fails, and the service life of the wire harness can be obviously prolonged. The assembling device adopts an injection molding processing mode, can be set to different styles according to different shapes of the wire harness mounting end, is more convenient for wire harness mounting, and obviously improves the wire harness mounting efficiency. The positioning device adopts a plastic part, the injection molding processing is more convenient, the elasticity of the plastic part can be better installed and matched when the positioning device is assembled with the wiring harness installation end, the installation efficiency of the positioning device is obviously improved, and meanwhile, the corrosion resistance of the plastic part is high, so that the service life of the wiring harness is greatly prolonged.

6. By using the sealing device processed by the injection molding mode, the wet area and the dry area are sealed by using the sealing device in the using environment of the wire harness, so that water in the wet area is prevented from entering the dry area or entering an electric loop to damage an electric circuit in the dry area, the function failure of an electric appliance is caused, and a safety accident can be caused in the serious case. The injection molding process of the invention is used for integrally injection molding the sealing device, the sealing device does not need to be pre-expanded and then the wire harness is inserted like the common wire harness processing, the position and the size of the sealing device can be ensured to be accurate, the sealing device and the protective layer can be combined more tightly, cement and sealant are not needed, and the material cost and the installation time are saved. Because once stereotypes, sealing device is not fragile, and is inseparabler with the combination of pencil protective layer to in the relatively abominable environment of vibration environment, sealing device can not appear size deviation and break away from the pencil even and lead to the sealed function failure of pencil, the life of extension pencil that can show. Meanwhile, the sealing device can be arranged between the terminal and the conductor and between the sheath and the protective layer, so that the conductor can be better sealed, the conductor is prevented from being corroded by water in the external environment, and the service life of the wire harness is prolonged remarkably. The sealing device adopts the rubber piece, and is better with other part laminating nature, and the elasticity of rubber piece makes the leakproofness of pencil better simultaneously, the life of the improvement pencil that is showing.

7. According to the wire harness, the independent sheath or the integrally injection-molded sheath is used, so that the wire harness can be more quickly installed in a matching manner with an electric device, the installation efficiency is improved, the damaged wire harness can be quickly replaced, the maintenance efficiency of the wire harness is improved, and the labor cost is reduced. The sheath of an organic whole injection moulding, processing is more swift, and is inseparabler with terminal, protective layer or insulating layer laminating, is showing the sealed grade that improves the pencil.

8. The conductor is solid conductor, flat conductor, stranded conductor to and the cross section of various conductor conducting parts, can adopt corresponding conductor structure according to the actual service environment of pencil, save the pencil cost, improve pencil installation effectiveness. Meanwhile, the cross sections of different conductor structures and conductor conductive parts can adapt to terminals of different connection modes, so that a wire harness designer can conveniently select the terminals and conductors used by the wire harness, the cost of the wire harness is optimized, and the product stability of the wire harness is improved.

9. In the wire harness of the present invention, when the number of the conductors is more than two and belongs to the same circuit, the non-terminal-side conductors are connected to form the conductor connection points by crimping or welding according to the circuit requirements, so that the amount of the conductors used can be reduced and the cost of the wire harness can be significantly reduced when the wire harness is designed. Simultaneously the conductor tie point is sealed by whole parcel of moulding plastics, can guarantee that the conductor tie point can not be destroyed in pencil installation and use, in abominable vibration environment, is moulded plastics wholly that the sealed conductor tie point of parcel can not be by the vibration fracture to whole parcel of moulding plastics is sealed can prevent the corruption of external environment's water to the conductor tie point, is showing the life of extension pencil.

10. The invention also provides a method for preparing the integrated injection molding wire harness, which adopts different process flows according to different wire harness structures, can obviously improve the production efficiency of the wire harness and reduce the cost of the wire harness.

The foregoing description is only an overview of the technical solutions of the present invention, and in order to make the technical means of the present invention more clearly understood, the present invention may be implemented in accordance with the content of the description, and in order to make the above and other objects, features, and advantages of the present invention more clearly understood, the following preferred embodiments are described in detail with reference to the accompanying drawings.

Drawings

FIG. 1 is a schematic diagram of a single conductor, unsheathed, wiring harness with a positioning device and a sealing device according to the present invention.

FIG. 2 is a schematic diagram of a wiring harness with a sheath, a protective layer, a positioning device, and a sealing device for a plurality of conductors according to the present invention.

Fig. 3-1 is a schematic cross-sectional view of a bundle of individual conductors with a protective layer according to the present invention.

Fig. 3-2 is a schematic cross-sectional view of a wiring harness of the present invention having a plurality of conductors with protective layers arranged side by side.

Fig. 3-3 are cross-sectional views of a wiring harness with a plurality of conductors having a protective layer according to the present invention arranged in a loop.

Fig. 3-4 are schematic cross-sectional views of a wiring harness with multiple conductors having insulation and protective layers according to the present invention.

Fig. 4 is a schematic diagram of a multi-conductor, wire harness with conductor connection points in accordance with the present invention.

FIG. 5 is a schematic structural diagram of the positioning device of the present invention.

Fig. 6 is a schematic view of an assembly device for the inverted tooth structure.

Fig. 7 is a schematic view of an assembly device of the clip-like structure.

Fig. 8 is a schematic view of an assembly apparatus of a C-ring structure.

Fig. 9 is a schematic view showing the construction of the wire harness of the present invention with a sealing means fitted to a through hole of a partition plate.

Fig. 10 is a schematic view of the structure of the sealing device of the conductor, the terminal and the protective layer according to the present invention.

Fig. 11 is a schematic view of the structure of the sealing means of the sheath of the present invention.

FIG. 12 is a schematic structural view of an integrally molded sheath according to the present invention.

Wherein the reference symbols are: 1. terminal, 2, conductor, 3, insulating layer, 4, sealing device, 5, positioner, 6, sheath, 7, protective layer, 8, pencil protection device, 9, watertight fittings, 10, second fixing device, 11, assembly quality, 12, first fixing device, 13, waterproof cover, 14, draw-in groove.

Detailed Description

To further illustrate the technical means and effects of the present invention adopted to achieve the predetermined objects, the following detailed description of the embodiments, structures, features and effects according to the present invention with reference to the accompanying drawings and preferred embodiments is as follows:

example 1

As shown in fig. 1 and 3-1, the wire harness is composed of a single conductor, and two ends of the conductor 2 are respectively connected with the terminals 1. The terminal 1 is a copper terminal made of a copper alloy with a copper content of 60%, which can ensure good conductivity and workability. The surface of the terminal 1 is plated with nickel, or plated with one of cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver or gold, and the plating layer can slow down the corrosion of the terminal and prolong the service life of the terminal. One end of the terminal 1 is connected to the conductor 2, and the other end of the terminal 1 is used to connect an electric circuit of an electric device in use. In this embodiment, the conductor 2 is composed of a multi-core wire, and the cross section of the multi-core wire is circular. In other embodiments, the conductor 2 may also be a solid conductor and a flat conductor. The cross-section of the conductive part of the conductor 2 may also be oval, polygonal, wavy or profiled. The wire harness is provided with a protective layer 7 which is formed by injection molding and covers the outer part of the conductor 2, the protective layer 7 is made of plastic or rubber, and in the embodiment, the protective layer 7 is made of PVC; and at least one injection-molded positioning device 5 for fixing the position of the wiring harness or/and a sealing device 4 for waterproofing.

Wherein the conductor 2 can be an external wire with an insulating layer 3, and a protective layer 7 is injected outside the insulating layer 3; it is also possible to directly inject the protective layer 7 outside the conductor 2. As shown in fig. 3-1, the single conductor 2 is arranged in the middle, and a protective layer 7 is injected on the periphery.

After the conductor 2 is cut to a fixed length, two ends of the conductor are respectively connected with the terminal 1 in a crimping or welding mode. Then placing the semi-finished product into an injection mold, and performing injection molding on the protective layer 7, the positioning device 5 and the sealing device 4 according to the determined size, wherein the specific injection molding method comprises the following steps:

(1) preparing a semi-finished wire harness;

(2) putting the required raw materials into injection molding equipment, drying, and putting the wire harness semi-finished product prepared in the step (1) into an injection mold; or putting the wire harness semi-finished product prepared in the step (1) into an injection mold, putting the required raw materials into injection molding equipment, and drying.

(3) Starting the injection molding equipment to heat and melt the raw materials, and injecting the raw materials into an injection mold for molding.

The material of the positioning device 5 is PA66, and in other embodiments, the positioning device 5 is a plastic piece processed by injection molding. The positioning device 5 comprises a first fixing device 12 connected with a wire harness and an assembling device 11 matched and connected with the wire harness mounting end, and the assembling device 11 is connected to the first fixing device 12; the first fixing device 12 is a cylindrical structure, and the inner wall of the cylindrical structure is matched with the outer surface of the protective layer 7 and wrapped on the outer surface of the protective layer 7. The specific structure of the assembling device 11 can be an inverted tooth structure inserted into the mounting hole, namely: the assembling device is of a columnar structure, and the periphery of the columnar structure is provided with an inverted tooth structure which is inserted and clamped with the hole to be installed; in other embodiments, the assembling device may also be a clip-shaped structure which is connected with the plate in a matching manner, specifically, the assembling device is provided with a groove, and two side walls in the groove are provided with barbs which are clamped with the plate; but may also be of annular or C-ring configuration with an assembly of tubular or cylindrical structures.

The material of the sealing device 4 is EPDM, and in another embodiment, the sealing device 4 is a rubber material processed by injection molding. In order to prevent water in the wet area from entering the dry area, as shown in fig. 9, the sealing device 4 in this embodiment includes a second fixing device 10 connected to the wiring harness and a waterproof device 9 connected to the second fixing device 10, wherein the wiring harness passes through some through holes in the partition board between the dry area and the wet area when installed; the structure of the second fixing device 10 is a tubular structure, the inner wall of the tubular structure is matched with the outer surface of the protective layer 7, the outer surface of the protective layer 7 is wrapped, and the structure of the waterproof device 9 comprises a waterproof sleeve 13, one end of the waterproof sleeve 13 is connected with the second fixing device 10, the other end of the waterproof sleeve 13 is connected with the other end of the waterproof sleeve, and a clamping groove 14 assembled with a waterproof hole is formed.

When the wire harness is in a wet area, a sealing device is arranged among the protective layer 7, the conductor 2 and the terminal 1 of the wire harness, the protective layer 7, the conductor 2 and the terminal 1 are packaged in a sealing mode, as shown in fig. 10, the sealing device 4 is injected and molded outside the connection part of the conductor 2, the terminal 1 and the conductor 2 and the protective layer, the part corresponding to the conductor 2 and the terminal 1 is the waterproof device 9, and the part corresponding to the protective layer 7 is the second fixing device 10.

Example 2

As shown in fig. 2, 3-2, and 3-3, the wire harness is composed of more than one conductor 2, each conductor 2 is connected with a terminal 1 at two ends, and the surface of the terminal 1 is plated with zinc, or plated with one of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, copper, silver, or gold. The conductor 2 and the terminal 1 are the same as those in embodiment 1, and are not described in detail. The difference from example 1 is: the wire harness is further provided with at least one sheath 6 which is inserted into an electric device, after the conductor 2 is connected with the terminal 1, the terminal 1 is assembled in the sheath 6, different terminals 1 correspond to different hole positions of the sheath 6 according to design requirements, so that the functions of different loops are achieved, and meanwhile, the terminal 1 can be protected from being damaged. The sheath 6 is integrally injection molded onto at least the terminal 1.

After the conductors 2 are cut to a fixed length, both ends of the conductors are connected with the terminal 1 in a crimping or welding mode. And then placing the semi-finished product into an injection mold, performing injection molding on the protective layer 7, the positioning device 5 and the sealing device 4 according to the determined size, and performing injection molding on the wiring harness protective layer 7, the wiring harness protective device 8 and the positioning device 5 or the sealing device 4.

In this embodiment, when the wire harness is in a wet area, the sealing device 4 is disposed between the protective layer 7, the conductor 2 and the terminal 1 of the wire harness, and the protective layer 7, the conductor 2 and the terminal 1 are hermetically wrapped, as shown in fig. 10, the sealing device 4 is injection-molded outside the connection part of the conductor 2 and the terminal 1 and the protective layer 7, the part corresponding to the conductor 2 and the terminal 1 is the waterproof device 9, and the part corresponding to the protective layer 7 is the second fixing device 10.

The specific injection molding method comprises the following steps:

(1) preparing a semi-finished wire harness;

Wherein: the parameters of injection molding comprise heating temperature, cooling temperature, injection molding pressure, injection molding time and the like, and the injection molding is carried out according to the conventional injection molding equipment and is a conventional operation method. The method comprises the following steps: the finished product after injection molding cannot have the defects of impurities, pits, flash, air holes and the like.

As shown in fig. 3-2 and 3-3, the plurality of conductors 2 are arranged in the middle, and the protective layer 7 is injected on the periphery, so that the plurality of conductors 2 are bound together to prevent the conductors 2 from scattering during the installation of the wire harness, and the plurality of conductors 2 are insulated and isolated to protect the plurality of conductors 2 from being damaged by short circuit and external forces such as scraping and grinding after the installation of the wire harness. In this embodiment, the conductor 2 is a solid conductor or a flat conductor, and the cross section of the conductive portion of the conductor 2 is a special-shaped structure, and may also be an ellipse or a wave. The protective layer 7 is made of PVC. The positioning device 5 and the sealing device 4 are the same as those in embodiment 1, and are not described in detail.

Example 3

As shown in fig. 4, the wire harness is composed of more than one conductor 2, the terminal of one part of the conductor 2 is connected with the terminal 1, and the terminal of the other part of the conductor 2 is connected as a conductor connection point by adopting a crimping or welding mode according to the circuit requirement. The surface of the terminal 1 is plated with silver, and may be plated with one of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, or gold. After the conductor 2 is connected with the terminal 1, the terminal 1 is assembled in a sheath 6 which is inserted into an electric device, and different hole positions of the sheath 6 correspond to different terminals 1 according to design requirements. During preparation, the conductor connecting point is integrally sealed into a wiring harness protection device 8; the wire harness protection device 8 is a rubber or plastic part processed in an injection molding mode. As shown in fig. 3-4, an insulating layer 3 is disposed outside the conductor 2, a protective layer 7 is injected outside the insulating layer 3, and the terminal 1 and the sheath 6 are the same as those in embodiment 1 and are not described in detail.

After the plurality of conductors 2 are cut to a fixed length, part of the conductors 2 are connected with the terminal 1 by crimping or welding according to design requirements. When the other part of the conductors 2 are more than two and belong to the same loop, the non-terminal side conductors are connected into conductor connection points by adopting a crimping or welding mode according to the loop requirement. And then placing the semi-finished product into an injection mold, according to the determined size, performing injection molding on the protective layer 7 according to the injection molding step described in embodiment 2, then performing injection molding on the wiring harness protection device 8, and finally performing injection molding on the positioning device 5 and/or the sealing device 4. In the present embodiment, the conductor 2 is made of a multi-strand wire, and the cross section of the conductive part of the conductor 2 is a polygonal structure. The wire harness protection device 8 is made of plastic, and in other applications, the wire harness protection device 8 can also be made of rubber. The protective layer 7, the positioning device 5 and the sealing device 4 are the same as those in embodiment 2, and are not described in detail.

In the injection molding wire harness preparation method, when the semi-finished wire harness is provided with the sheath 6, the terminal 1 of the connecting conductor 2 is inserted into the corresponding hole position of the sheath 6, and then injection molding is carried out; or firstly, the semi-finished wire harness is subjected to injection molding, and then the terminal 1 of the connecting conductor 2 is inserted into the corresponding hole position of the sheath 6.

As shown in fig. 11, when the sheath 6 is in a wet area, in order to prevent water from entering into the sheath 6, a sealing device 4 is provided to seal the hole position of the sheath 6, a waterproof device 9 is injected into the connecting gap between the sheath 6 and the conductor 2 to seal the sheath 6 for waterproofing, and a second fixing device 10 is connected to the end of the waterproof device 9 and the sheath 6. The waterproof device 9 is formed by injection molding, and the second fixing device 10 is of a sleeve structure matched with the outer protective layer 7 of the conductor 2.

As shown in fig. 12, the sheath 6 of this embodiment may be formed by integral injection molding, the semi-finished product of the wire harness is put into an injection mold, the sheath 6 is formed by integral injection molding on at least the terminal 1, in other embodiments, the sheath 6 may be formed by integral injection molding on the terminal 1 and the conductor 2, or the sheath 6 may be formed by integral injection molding on the terminal 1, the conductor 2 and the protective layer 7.

In order to demonstrate the influence of the wire harness processed by the conventional method and the integrally injection-molded wire harnesses according to embodiments 1 to 3 of the present invention on the mechanical and electrical properties of the terminals and conductors of the wire harness, the inventors of the present application performed a series of experiments on the mechanical properties, electrical properties and lifetime of the wire harnesses processed by the above two different methods.

The specific experimental process is as follows: the actual using environment of the wire harness is simulated, but the testing condition is increased to a degree which is much severer than the ordinary environment, and the testing effect which can be achieved for a long time under the actual using environment can be obtained in a short time. The series of experiments included: 1) testing the drawing force and voltage drop of the terminal 1 and the conductor 2 of the two wire harnesses to obtain the initial mechanical and electrical properties of the wire harnesses; 2) the salt spray test is carried out for 1000 hours, and salt water is sprayed on the two wiring harnesses by using a salt spray test box, so that the ten-year salt spray resistance test in the ordinary coastal environment can be replaced; 3) the high-low temperature test of 200 hours, make two kinds of wire harnesses in the highest and lowest temperature of service environment each hour respectively, the temperature switching time is less than 5 seconds, carry on 100 cycles, can substitute the high-low temperature resistant test of 10 years of external cold and hot alternate environment; 4) the vibration test for 120 hours is carried out, two wire harnesses are fixed on a vibration test table, the vibration amplitude is selected according to the use environment, the vibration of the two wire harnesses is carried out in three directions, and the vibration test for 10 years in the common use vibration environment can be replaced; 5) and 6000-hour aging test, namely putting the two wiring harnesses into an aging test box, simulating an environment exceeding a rated use condition, and replacing the aging test in a 20-year common use environment. After each experiment, the voltage drop values and the pull force values of the terminal 1 and the conductor 2 of the two kinds of wire harnesses were tested. The results of the experiments are shown in tables 1-1, tables 1-2 and tables 1-3.

Tables 1 to 1: influence of conventional wire harness and integral injection molding wire harness on drawing force and voltage drop of terminal and conductor (before experiment and after 1000 hours salt spray experiment)

Tables 1 to 2: influence of conventional wire harness and integral injection molding wire harness on terminal and conductor pull-out force and voltage drop (200-hour high and low temperature experiment and 120-hour vibration experiment)

Tables 1 to 3: influence of conventional wire harness and integral injection molded wire harness on drawing force and voltage drop of terminal and conductor (6000 hours aging test)

As can be seen from the results of the above tables 1-1, tables 1-2 and tables 1-3: the initial drawing force value and the voltage drop value of the wire harness processed by the traditional method and the wire harness integrally molded by injection molding are relatively close to those of the terminal 1 and the conductor 2.

After a 1000-hour salt spray test, a 200-hour high and low temperature test, a 120-hour vibration test and a 6000-hour aging test are respectively carried out on the wire harness, the pulling force values of the terminal 1 and the conductor 2 after the tests are far higher than those of the terminal 1 and the conductor 2 after the wire harness tests processed by the traditional method, and the pulling force values are closer to the initial pulling force value.

In the wire harness processed by the traditional method, the drawing force values of the terminal 1 and the conductor 2 after the experiment are obviously lower, the mechanical property is unstable, and the terminal 1 of the wire harness is possibly separated from the conductor 2, so that the wire harness is short-circuited, the function is failed if the wire harness is light, and the combustion accident is caused if the wire harness is heavy.

In the wire harness formed by integral injection molding, the voltage drop of the terminal 1 and the conductor 2 after the experiment is basically approximate to the initial voltage drop of the terminal 1 and the conductor 2 of the wire harness processed by the traditional method.

In the wire harness processed by the traditional method, after an experiment, the voltage drop value of the terminal 1 and the conductor 2 is also obviously reduced, the electrical performance is unstable, the contact resistance of the terminal 1 and the conductor 2 of the wire harness is increased, the terminal 1 and the conductor 2 of the wire harness can be heated and reddened during conduction, and serious accidents can be caused by burning due to overhigh temperature in serious cases.

Therefore, the mechanical property and the electrical property of the integrally injection-molded wire harness of the terminal 1 and the conductor 2 after the experiment are far superior to those of the wire harness processed by the traditional method, the product reject ratio can be reduced, and the service life of the wire harness can be prolonged.

In order to demonstrate the positioning effect of the fixing device in the vibration environment of the wire harness processed by the conventional method and the wire harness integrally injection-molded in the embodiments 1 to 3 of the present invention, 100 pieces of the two wire harnesses were selected, and the performance of the fixing device of the wire harness was subjected to a vibration test. The results are shown in the following table:

table 2: influence of conventional wire harness and integral injection molded wire harness on performance of fixing device in vibration test (120-hour vibration test)

As can be seen from the above table, in the conventional wire harness fixing and positioning device using a cable tie, the amount of size deviation of the positioning device 5 accounts for 52% of the total amount of the wire harness, the amount of wire harness detachment accounts for 11% of the total amount of the wire harness, and the defective rate is very high; the traditional wire harness uses the adhesive tape to fix the positioning device 5, the amount of the size deviation of the positioning device 5 accounts for 69% of the total amount of the wire harness, the amount of the wire harness separation accounts for 24% of the total amount of the wire harness, the reject ratio is very high, the installation and the function realization of the wire harness are seriously influenced, and the function failure of the wire harness can be caused in serious cases.

And three kinds of positioner 5 of integrative injection moulding pencil, the quantity that the size squinted accounts for pencil total number only 0%, 1% and 1%, and the quantity that the pencil breaks away from accounts for pencil total number and all is 0%. Consequently, integrative injection moulding pencil, positioner 5 and pencil combine more firmly, and positioner 5 is difficult for droing, and the location effect is better to in the environment that vibration environment is abominable, positioner 5 appears the size deviation very few and breaks away from the pencil even and leads to the pencil locate function to become invalid, the life of extension pencil that can show.

In order to demonstrate the protection grades of the wire harness processed by the conventional method and the wire harness integrally injection-molded in the embodiments 1 to 3 of the present invention, 100 pieces of the two wire harnesses were selected for testing the performance of the sealing device 4 of the wire harness under the erosion of the external dust and water. The results are shown in the following table:

table 3: traditional wire harness and integrated injection molding wire harness, and protection grade passing rate of sealing device

As can be seen from the above table, in the protection level test of IP54, the protection level passing rates of the three sealing devices 4 of the conventional wire harness are only 89%, 92% and 88%; in the protection grade test of IP67, the protection grade passing rate is only 68%, 75% and 71%, the protection grade passing rate is very low, the sealing performance of the wire harness cannot be ensured, and the corrosion of dust and water in the external environment to the conductor 2 cannot be prevented, so that the function failure of the wire harness is caused.

In the protection grade test of IP54, the protection grade passing rate of three sealing devices 4 of the integrated injection molding wire harness is 100%; in the protection grade test of IP67, the protection grade pass rate is 99%, 100% and 100%, can satisfy the sealing performance of pencil completely, makes the leakproofness of pencil better, prevents the corruption of external environment's dust and water to the conductor, the life of the improvement pencil that is showing.

In order to demonstrate that the connection points of the conductors of the wire harness processed by the conventional method and the wire harness integrally injection-molded in the embodiments 1 to 3 of the present invention are wrapped in different protection modes, and the risk of breakage of the connection points of the conductors, 100 pieces of each of the two wire harnesses are selected, and after a 120-hour vibration test is performed on the wire harnesses, the breakage rate of the connection points of the conductors is measured. The results are shown in the following table:

table 4: fracture ratio of conventional wire harness and integral injection molded wire harness, conductor connection point

As can be seen from the above table, in the two conductor connection point wrapping manners of the conventional wire harness, after the wire harness is subjected to a vibration test for 120 hours, the conductor connection points are wrapped by adhesive tapes, the breakage rate of the conductor connection points is 26%, the conductor connection points are wrapped by heat shrink tubes, and the breakage rate of the conductor connection points is 18%. The breakage rate of the conductor connection point is very high, and the conduction performance of the wire harness in a severe vibration environment cannot be guaranteed, so that the risk of great wire harness function failure exists.

The utility model has the advantages of the parcel conductor tie point of moulding plastics of integrative injection moulding pencil, the fracture ratio of conductor tie point is 0%, can satisfy the turn-on performance of pencil in abominable vibration environment completely, the life of the improvement pencil that is showing.

The above embodiments are only preferred embodiments of the present invention, and the protection scope of the present invention is not limited thereby, and any insubstantial changes and substitutions made by those skilled in the art based on the present invention are within the protection scope of the present invention.

Claims

1. An injection molded wire harness, characterized in that: the pencil includes terminal and an at least conductor, the electric return circuit of power consumption device is connected to terminal one end, the terminal other end with the conductor is connected, be provided with injection moulding on the pencil, the cladding in the outside protective layer of conductor to and injection moulding's at least one positioner or be used for waterproof sealing device of fixed pencil position.

2. The injection molded wire harness according to claim 1, characterized in that: the conductor is also provided with an insulating layer outside, and the protective layer is moulded plastics outside the insulating layer.

3. The injection molded wire harness according to claim 1, characterized in that: the positioning device comprises a first fixing device connected with the wiring harness and an assembling device connected with the mounting end of the wiring harness in a matched mode, and the assembling device is connected to the first fixing device.

4. The injection molded wire harness according to claim 3, characterized in that: the first fixing device is of a cylindrical structure, and the inner wall of the cylindrical structure is matched with the outer surface of the protective layer and wrapped on the outer surface of the protective layer.

5. The injection molded wire harness according to claim 3, characterized in that: the device is of a columnar structure, and the periphery of the columnar structure is provided with an inverted tooth structure.

6. The injection molded wire harness according to claim 3, characterized in that: the mounting device has a clip-like structure.

7. The injection molded wire harness as claimed in claim 6, wherein the clip-like structure has a groove, and barbs are provided on both sidewalls of the groove.

8. The injection molded wire harness according to claim 3, characterized in that: the fitting device has a ring-shaped structure or a C-shaped ring structure.

9. The injection molded wire harness according to claim 3, characterized in that: the positioning device is a plastic piece processed in an injection molding mode.

10. The injection molded wire harness according to claim 1, characterized in that: the sealing device comprises a second fixing device and a waterproof device, wherein the second fixing device is connected with the wiring harness, and one end of the waterproof device is connected to the second fixing device.

11. The injection molded wire harness of claim 10, wherein: the second fixing device is of a cylindrical structure, and the inner wall of the cylindrical structure is matched with the outer surface of the protective layer and wrapped on the outer surface of the protective layer.

12. The injection molded wire harness of claim 10, wherein: the sealing device is a rubber piece processed in an injection molding mode.

13. The injection molded wire harness according to claim 1, characterized in that: the wire harness is further provided with at least one sheath which is inserted into the electric device, and the terminal is assembled in the corresponding hole of the sheath.

14. The injection molded wire harness of claim 13, wherein: the sheath is integrally injection molded onto at least the terminal.

15. The injection molded wire harness according to claim 1, characterized in that: the conductor is a solid conductor, a flat conductor or a conductor of a multi-strand wire.

16. The injection molded wire harness according to claim 1, characterized in that: the terminal is connected to the conductor of a solid conductor, a flat conductor, a multi-strand wire by means of crimping or welding.

17. The injection molded wire harness according to claim 1, characterized in that: the cross section of the conductive part of the conductor is circular or elliptical, polygonal, wavy or irregular.

18. The injection molded wire harness according to claim 1, characterized in that: when the conductors are more than two and belong to the same loop, the non-terminal side conductors are connected into conductor connection points by adopting a crimping or welding mode according to the loop requirement.

19. The injection molded wire harness of claim 18, wherein: the conductor connecting points are integrally encapsulated and encapsulated by injection molding.