WO2023005930A1 - 线束模块及组合式线束 - Google Patents
线束模块及组合式线束 Download PDFInfo
- Publication number
- WO2023005930A1 WO2023005930A1 PCT/CN2022/107934 CN2022107934W WO2023005930A1 WO 2023005930 A1 WO2023005930 A1 WO 2023005930A1 CN 2022107934 W CN2022107934 W CN 2022107934W WO 2023005930 A1 WO2023005930 A1 WO 2023005930A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- wire harness
- harness module
- module according
- conductor
- modules
- Prior art date
Links
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G15/00—Cable fittings
- H02G15/08—Cable junctions
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/04—Protective tubing or conduits, e.g. cable ladders or cable troughs
- H02G3/0462—Tubings, i.e. having a closed section
- H02G3/0487—Tubings, i.e. having a closed section with a non-circular cross-section
Definitions
- the application relates to the technical field of electrical connection, in particular to a wiring harness module and a combined wiring harness.
- the present application provides a wire harness module and a combined wire harness to solve the problem that complex wire harnesses are difficult to produce and maintain.
- the embodiment of the first aspect of the present application provides a wire harness module, including a conductor part and an insulating part enclosing the conductor part, the conductor part includes at least one conductor, and each conductor is connected to at least one input conductive connector and at least one The output conductive connector is to realize the electrical connection of the conductors of different wire harness modules by connecting the input conductive connectors and output conductive connectors of different wire harness modules.
- the embodiment of the second aspect of the present application provides a combined wire harness, which is spliced by multiple wire harness modules according to the preset splicing method of the embodiment of the first aspect, and the conductors of the multiple wire harness modules conduct electricity through the input
- the connector is electrically connected to the output conductive connector.
- each wiring harness module of the present application are used to combine into a wiring harness. Since each conductor of each wiring harness module is connected to at least one input conductive joint and at least one output conductive joint, each wiring harness module can be connected to at least two other wiring harness modules. A conductor can be electrically connected to at least two other conductors so that complex conductive loops can be combined;
- the wire harness module of the present application can realize the connection of parallel circuits by setting multiple input conductive connectors and/or multiple output conductive connectors, and can reduce the number of wire harness modules when combined into complex wire harnesses, thereby reducing the number of wire harnesses The volume, reduce the cost;
- the wiring harness module of this application can realize the electrical connection of the conductors of different wiring harness modules by setting the male-end plug and the female-end slot as the input conductive connector and the output conductive connector, and plugging the male-end plug and the female-end slot. Simple structure, very convenient connection operation;
- the insulating part of the wiring harness module of the present application is provided with a surface to be spliced.
- the combined wiring harness of the present application can be produced in a modular, mass-produced, automated manner, and assembled individually, which can improve production efficiency, increase the pass rate, and facilitate maintenance.
- Fig. 1 is a schematic structural view of an embodiment of a wiring harness module of the present application
- Fig. 2 is a schematic diagram of side-by-side splicing of the wiring harness modules in Fig. 1;
- Fig. 3 is a schematic diagram of side-by-side splicing and end-to-end splicing of the wiring harness modules in Fig. 1;
- Fig. 4 is a schematic structural view of another embodiment of the wiring harness module of the present application.
- Fig. 5 is a schematic diagram of end-to-end splicing of the wiring harness module in Fig. 4;
- Fig. 6 is a schematic diagram of side-by-side splicing of the wiring harness modules in Fig. 4;
- Fig. 7 is a schematic diagram of a connection mode of different wiring harness modules in the present application.
- Fig. 8 is a schematic diagram of an embodiment of plugging the male end plug and the female end slot in Fig. 7;
- Fig. 9 is a schematic diagram of another embodiment of plugging the male end plug and the female end slot in Fig. 7;
- Fig. 10 is a schematic structural view of the male pin and the female slot in Fig. 7;
- Fig. 11 is another schematic diagram of the structure of the male pin and the female slot in Fig. 7;
- Figure 12 is a schematic diagram of side splicing of different wiring harness modules in this application.
- Fig. 13 is a top view of the wiring harness module in Fig. 12;
- Fig. 14 is a schematic diagram of another connection mode of different wiring harness modules in the present application.
- Fig. 15 is a schematic diagram of a first embodiment of a conductor of the wiring harness module in the present application.
- 16 is a schematic diagram of a second embodiment of a conductor of the wiring harness module in the present application.
- 17 is a schematic diagram of a third embodiment of a conductor of the harness module in the present application.
- Fig. 18 is a structural schematic diagram of the wiring harness fixing member provided on the wiring harness module in the present application.
- Fig. 19 is a schematic structural view of an embodiment of a splicing fixture provided on a wire harness module in the present application.
- Figure 20 is a side view of the wiring harness module in Figure 19;
- Fig. 21 is a schematic diagram of the connection state of two wiring harness modules in Fig. 19;
- Fig. 22 is a schematic structural view of another embodiment in which splicing fixtures are arranged on the wiring harness module in the present application;
- Fig. 23 is a schematic diagram of the connection state of the two wiring harness modules in Fig. 22;
- Fig. 24 is a schematic diagram of the connection between the wire harness module and the connector of the electric device through the plug-in sheath module in the present application.
- connection should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, a direct connection, or an indirect connection through an intermediary.
- the embodiment of the first aspect of the present application provides a wire harness module 100
- the wire harness module 100 includes a conductor part 110 and an insulating part 120 enclosing the conductor part 110
- the conductor part 110 includes at least one conductor 111
- Each conductor 111 is connected to at least one input conductive connector 130 and at least one output conductive connector 140, by connecting the input conductive connectors 130 and output conductive connectors 140 of different wire harness modules 100, the electrical connection of the conductors 111 of different wire harness modules 100 is realized.
- the wiring harness module of the present application is used to be combined into a wiring harness. Since each conductor 111 of each wiring harness module 100 is connected to at least one input conductive joint 130 and at least one output conductive joint 140, each wiring harness module can be connected to at least two other wiring harness modules. , each conductor can be electrically connected to at least two other conductors so that complex conductive loops can be combined.
- the three wire harness modules 100 are respectively the first wire harness module, the second wire harness module and the third wire harness module.
- the output conductive connector 140 of the first wire harness module can be connected to the second wire harness
- the input conductive connector 130 of the module is connected, and the output conductive connector 140 of the second wire harness module is connected with the input conductive connector 130 of the third wire harness module, so as to realize the electrical connection of the three wire harness modules 100 in sequence.
- the wiring harness module of the present application can be mass-produced and automated and assembled individually, which can improve production efficiency and pass rate.
- the cross-sectional area of the conductor 111 is 0.1 mm 2 -260 mm 2 .
- the cross-sectional area of the conductor 111 determines the current that the conductor 111 can conduct.
- the conductor 111 that realizes signal conduction has a small current and a small cross-sectional area, such as the signal line conductor of the automobile wiring harness.
- the minimum cross-sectional area of 111 can reach 0.1mm 2
- the conductor 111 that realizes the power conduction has a large current
- the cross-sectional area of the conductor 111 is also large.
- the maximum cross-sectional area of the conductor 111 reaches 260mm 2 in the wiring harness of a car battery.
- the wire feeding mechanism can be used to lay the conductor 111.
- the 3D printed conductor 111 can be used or the formed conductor 111 can be laid directly. Methods.
- the insulating part 120 is made of one or more of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene.
- the breakdown strength of the insulating part 120 is 0.3KV/mm-35KV/mm. Breakdown strength is also called dielectric breakdown strength. Indicates the highest electric field strength that a material can withstand under the action of an electric field to avoid being destroyed (breakdown).
- Breakdown strength of the insulating portion 120 is lower than 0.3KV/mm, some thinner insulating portions 120 may be broken down under normal voltage, resulting in ineffective insulation.
- the breakdown strength of the insulating part 120 is higher than 35KV/mm, since the high voltage higher than 35KV will not appear in the general vehicle environment, choosing a material with too high breakdown strength will increase the cost of the integrated wiring harness module, resulting in design waste.
- the thickness of the insulating part 120 is 0.03mm-5mm. If the thickness of the insulating part 120 is less than 0.03 mm, not only the breakdown voltage of the insulating part 120 cannot be guaranteed to be higher than the operating voltage, but also the wear resistance of the insulating part 120 cannot be guaranteed. If it is damaged, the conductor 111 is exposed, resulting in leakage or short circuit, causing damage to the circuit and failure of the function.
- the thickness of the insulating part 120 is equal to 5 mm, the breakdown voltage, insulation resistance and wear resistance of the insulating part 120 can meet the requirements, but when the thickness is greater than 5 mm, the thickness of the insulating part 120 is relatively large, and pores or collapse may occur during processing etc., the performance of the insulating part 120 is reduced, and the material of the insulating part 120 is wasted, and the processing steps and time are increased. Therefore, the thickness of the insulating part 120 is selected to be 0.03mm-5mm.
- the conductor part 110 includes a plurality of mutually insulated conductors 111, wherein each conductor 111 is connected to at least one input conductive contact 130 and at least one output conductive contact 140, that is,
- Each wiring harness module 100 has a plurality of mutually insulated conductors 111, and each conductor 111 transmits different currents and signals, so that the command information is transmitted to the electrical device, which is convenient for combining into complex wiring harnesses.
- the number of side-by-side splicing of the wiring harness modules 100 is reduced, the volume of the complex wiring harness is reduced, the structure of the complex wiring harness is simplified, and the cost of the wiring harness is further reduced.
- each conductor 111 of the conductor part 110 can be an integral structure, or a split structure formed by connecting multiple conductors, and the multiple conductors can be connected by terminals (as shown in FIG. 15 ), It can also be connected by welding (as shown in FIG. 16 ), and can also be connected by punching holes into the insulating part 120 and pouring conductive material into the holes (as shown in FIG. 17 ).
- the conductor portion 110 includes a connection section 112 through which at least two conductors 111 are electrically connected.
- connection section 112 through which at least two conductors 111 are electrically connected.
- connection section 112 may be connected to both ends or the middle part of the conductor 111 by means of crimping or welding.
- each conductor 111 has one or more input contacts, and each input contact is connected to an input conductive contact 130; each conductor 111 has one or more output contacts, and each output contact is connected to an output conductive contact 140.
- each conductor 111 has multiple input contacts and one output contact, and the multiple input contacts are respectively connected to an input conductive joint 130, that is, each conductor 111 is connected to multiple
- the input conductive connector 130 and one output conductive connector 140 are respectively electrically connected to a plurality of other conductors, the parallel circuit connection is realized.
- each conductor 111 has an input contact and multiple output contacts, and the multiple output contacts are respectively connected to an output conductive joint 140, that is, each conductor 111 is connected to an input
- the conductive connector 130 and the plurality of output conductive connectors 140 realize the connection of a parallel circuit when the plurality of output conductive connectors 140 are respectively electrically connected to a plurality of other conductors.
- each conductor 111 has multiple input contacts and multiple output contacts, the multiple input contacts are respectively connected to an input conductive joint 130, and the multiple output contacts are respectively connected to an output Conductive joints 140, that is, each conductor 111 is connected to multiple input conductive joints 130 and multiple output conductive joints 140.
- multiple input conductive joints 130 are electrically connected to multiple other conductors
- multiple output conductive joints 140 are respectively connected to multiple When two other conductors are electrically connected, the connection of a parallel circuit is realized.
- both the input conductive connector 130 and the output conductive connector 140 are butt joints 103 protruding from the insulating part 120 , and the butt joints 103 of different wiring harness modules 100 are overlapped and fixed.
- the electrical connection of the conductors 111 of different wire harness modules 100 is realized.
- the butt joints 103 of different wire harness modules 100 are detachably connected by bolts.
- At least one of the input conductive connector 130 and the output conductive connector 140 protrudes from the insulating part 120, so as to facilitate the input conductive connector 130 and the output conductive connector of different wiring harness modules 100 Connector 140 is connected.
- one of the input conductive connector 130 and the output conductive connector 140 is the male pin 101 protruding from the insulating part 120 , and the other is recessed in the
- the female end slot 102 in the insulating part 120 realizes the electrical connection of the conductors 111 of different wire harness modules 100 by plugging the male end pins 101 of different wire harness modules and the female end slots 102 (as shown in FIG. 8 ). Simple, the connection operation is very convenient.
- an outwardly expanding guide slope can be provided at the end of the male plug 101 (as shown in FIG. 9 ).
- the shape of the male pin 101 and the female socket 102 match, and the cross-sectional shape of the two can be square (as shown in FIG. 10 ) or circular (as shown in FIG. 11 ).
- At least part of the male pin 101 and/or the female socket 102 has a plating layer, which is to improve corrosion resistance, improve electrical conductivity, increase the number of times of insertion, and better extend the male pin 101 and Service life of the receptacle socket 102 .
- the coating can be provided on the male pin 101 and the female socket 102 by means of electroplating, electroless plating, magnetron sputtering or vacuum plating.
- the electroplating method is the process of plating a thin layer of other metals or alloys on some metal surfaces by using the principle of electrolysis.
- the electroless plating method is a process of metal deposition through a controllable oxidation-reduction reaction under the catalysis of metals.
- the magnetron sputtering method uses the interaction between the magnetic field and the electric field to make electrons run in a spiral shape near the target surface, thereby increasing the probability of electrons colliding with argon to generate ions.
- the generated ions hit the target surface under the action of the electric field to sputter out the target material.
- the vacuum plating method is to deposit various metal and non-metal films on the surface of plastic parts by distillation or sputtering under vacuum conditions.
- the coating material is one or more of gold, silver, nickel, tin, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy.
- an active metal copper will undergo oxidation reaction with oxygen and water during use, so one or more inert metals are required as the coating to prolong the service life of the male pin 101 and the female socket 102 .
- a better wear-resistant metal is also required as the coating, which can greatly increase the service life of the male pin 101 and the female socket 102 .
- the male end pin 101 and the female end slot 102 need good electrical conductivity. The conductivity and stability of the above metals are better than copper or copper alloys, so that the male end plug 101 and the female end slot 102 can obtain Better electrical performance and longer service life.
- the number of plugging and unplugging in Table 1 below is to fix the male pin 101 and the female end slot 102 on the test bench respectively, and use a mechanical device to simulate plugging and unplugging of the male pin 101 and the female end slot 102, and every 100 times If the surface coating of the male end pin 101 and the female end slot 102 is damaged, the surface coating is scratched and the material of the male end pin 101 and the female end slot 102 is exposed, then the experiment is stopped. Record the number of plugging and unplugging at that time. Insertion times less than 8000 times are unqualified.
- the corrosion resistance time test in Table 1 below is to put the male end pin 101 and the female end slot 102 into the salt spray test box, and spray the various positions of the male end pin 101 and the female end slot 102 Salt spray, take out and clean every 20 hours to observe the surface corrosion, that is, a cycle, until the surface corrosion area of the male end pin 101 and the female end slot 102 is greater than 10% of the total area, stop the test, and record the cycle at that time number. In this embodiment, the number of cycles less than 80 is considered unqualified.
- Table 1 Effects of different coating materials on the plug-in and pull-out times and corrosion resistance of male pins and receptacle slots
- the coating material is gold, silver, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, silver-gold-zirconium alloy
- the experimental results are more than the standard value, and the performance is relatively stable .
- the coating material is gold, silver, nickel, tin, tin-lead alloy, zinc
- the coating material is gold, silver, nickel, tin, tin-lead alloy, zinc, silver-antimony alloy, One or more combinations of palladium, palladium-nickel alloy, graphite silver, graphene silver, silver-gold-zirconium alloy.
- the plating layer includes a bottom layer and a surface layer, and the plating layer adopts a multi-layer plating method.
- the plating layer adopts a multi-layer plating method.
- the underlying material is one or more of gold, silver, nickel, tin, tin-lead alloy, and zinc; the surface material is gold, silver, nickel, tin, tin-lead alloy, silver-antimony alloy, palladium , palladium nickel alloy, graphite silver, graphene silver, silver gold zirconium alloy in one or more.
- the thickness of the bottom layer is 0.01 ⁇ m-15 ⁇ m.
- the thickness of the bottom layer is 0.1 ⁇ m-9 ⁇ m.
- the thickness of the surface layer is 0.5 ⁇ m-55 ⁇ m.
- the thickness of the surface layer is 1 ⁇ m-35 ⁇ m.
- the temperature rise test in Table 2 below is to pass the same current through the plugged male plug 101 and the female slot 102, and test the male plug 101 and the female plug 101 and the female plug before power-on and after temperature stabilization in a closed environment. The temperature at the same position of the tank 102 is compared and the absolute value is taken. In this embodiment, a temperature rise greater than 50K is considered unqualified.
- the corrosion resistance time test in Table 2 below is to put the male end pin 101 and the female end slot 102 into the salt spray test box, and spray the various positions of the male end pin 101 and the female end slot 102 Salt spray, take out and clean every 20 hours to observe the surface corrosion, that is, a cycle, until the surface corrosion area of the male end pin 101 and the female end slot 102 is greater than 10% of the total area, stop the test, and record the cycle at that time number. In this embodiment, the number of cycles less than 80 is considered unqualified.
- the thickness of the bottom layer of nickel plating is greater than 15 ⁇ m, due to the thicker bottom layer, the heat generated by the male end pin 101 and the female end slot 102 cannot be dissipated, so that the temperature rise of the male end pin 101 and the female end slot 102 is unqualified. Moreover, the thicker coating is easy to fall off from the surfaces of the male pin 101 and the female socket 102 , resulting in a decrease in the number of cycles of corrosion resistance. Therefore, the inventors choose the thickness of the bottom plating layer to be 0.01 ⁇ m-15 ⁇ m.
- the inventors found that when the thickness of the underlying coating is 0.1 ⁇ m-9 ⁇ m, the comprehensive effect of the temperature rise and corrosion resistance of the male pin 101 and the female socket 102 is better. Therefore, in order to further improve the safety and reliability of the product itself In terms of performance and practicability, the thickness of the underlying coating is preferably 0.1 ⁇ m-9 ⁇ m.
- the inventor used the male pin 101 and female socket 101 with the same specification and material, the same thickness of the nickel-plated bottom layer, and different thicknesses of the silver-plated surface layer. End socket 102 samples were tested for a series of temperature rise and corrosion resistance time, and the experimental results are shown in Table 3 below.
- the experimental method is the same as the above-mentioned experimental method.
- the thickness of the surface silver plating layer is greater than 55 ⁇ m, due to the thicker surface coating, the heat generated by the male pin 101 and the female end slot 102 cannot be dissipated, so that the temperature rise of the male end pin 101 and the female end slot 102 is unqualified. Moreover, the thicker coating is easy to fall off from the surfaces of the male pin 101 and the female socket 102 , resulting in a decrease in the number of cycles of corrosion resistance. Moreover, since the surface coating metal is more expensive, the use of a thicker coating does not improve performance, and there is no use value. Therefore, the inventor chooses the thickness of the surface silver plating layer to be 0.1 ⁇ m-55 ⁇ m.
- the inventors found that when the thickness of the surface coating is 1 ⁇ m-35 ⁇ m, the comprehensive effect of the temperature rise and corrosion resistance of the male pin 101 and the female socket 102 is better. Therefore, in order to further improve the safety and reliability of the product itself And practicability, preferably the thickness of the surface coating is 1 ⁇ m-35 ⁇ m.
- the conductor 111 is electrically connected to the input conductive connector 130 by crimping, welding or integral molding, and the conductor 111 is electrically connected to the output conductive connector 140 by crimping, welding or integral molding.
- the crimping is a production process of assembling the input conductive connector 130 or the output conductive connector 140 with the conductor 111, and using a crimping machine to press the two into one.
- the advantage of crimping is mass production. By using interlock terminals and automatic crimping machines, it is possible to quickly manufacture large quantities of stable quality products.
- the welding method includes one or more of friction welding, ultrasonic welding, arc welding, laser welding and resistance welding.
- the friction welding method refers to the method of welding by using the heat generated by the friction of the contact surface of the workpiece as the heat source to cause the workpiece to undergo plastic deformation under pressure.
- the ultrasonic welding method is to use high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects are rubbed against each other to form fusion between molecular layers.
- the arc welding method refers to using the arc as a heat source and using the physical phenomenon of air discharge to convert electrical energy into thermal energy and mechanical energy required for welding, so as to achieve the purpose of connecting metals.
- the main methods are electrode arc welding, submerged arc welding, and gas protection. welding etc.
- Laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source.
- the resistance welding method refers to a method that uses a strong current to pass through the contact point between the electrode and the workpiece, and generates heat from the contact resistance to achieve welding.
- integral molding means that the input conductive joint 130 or the output conductive joint 140 is directly formed on the conductor 111, and there is no need to perform connection processing between the input conductive joint 130 or the output conductive joint 140 and the conductor 111, which reduces the processing steps and improves production efficiency. .
- the insulating part 120 has a surface to be spliced 121 , and the connection of the insulating parts 120 of different wire harness modules 100 is realized by splicing the surfaces 121 to be spliced of different wire harness modules 100 .
- the insulating part 120 has two end faces 104 oppositely arranged in the length direction of the wire harness module 100, and the surface 121 to be spliced includes at least one end face 104, that is, the wire harness module 100
- the end faces of the wire harness modules are spliced with the insulating parts of other wire harness modules, for example, the end faces of two wire harness modules 100 are spliced to realize end-to-end splicing of the wire harness modules 100, so that the wire harness can be extended to form a branch wire harness of the combined wire harness.
- the insulating part 120 has a side peripheral surface 105 arranged along the circumference of the wire harness module 100, and the surface 121 to be spliced includes at least a part of the side peripheral surface 105, that is, the wire harness
- the side of the module 100 is spliced with the insulating parts of other wire harness modules, such as the side splicing of two wire harness modules 100, so that the side by side splicing of the wire harness modules 100 is realized, so that the wire harness can be widened to form the main wire harness of the combined wire harness.
- the shape of the insulating part 120 is a quadrangular prism, and the insulating part 120 has four sides, and the surface 121 to be spliced includes at least a partial area of at least one of the sides, for example including two , three or four sides, another example, the shape of the insulating part 120 is a triangular prism, the insulating part 120 has three sides, and the surface 121 to be spliced includes at least a partial area of at least one of the sides, for example including two or three side.
- the side peripheral surface 105 of the insulating portion 120 includes a plane 106 (as shown in FIG. As shown in FIG. 4 ), the surface 121 to be spliced includes at least a partial area of the curved surface 107 .
- the side peripheral surface 105 is a plane 106 (as shown in FIG. 3 ), and when the shape of the insulating portion 120 is cylindrical, its side peripheral surface 105 is a curved surface. 107 (as shown in Figure 4).
- the first specific embodiment and the second specific embodiment above can be implemented individually or in combination.
- a splicing fixture 150 is provided at the surface 121 to be spliced of the insulating part 120 or at an adjacent surface of the surface 121 to be spliced, and the surfaces 121 to be spliced of different wire harness modules 100 They are relatively fixed through the connection between the splicing fixtures 150 , that is, the insulating parts 120 of different wire harness modules 100 are fixedly connected by the splicing fixtures 150 to prevent loosening during use.
- the splicing fixing part 150 is an adhesive layer, a magnetic attraction part, a plug-in part, a clamping part, a bolt structure, a rivet structure, a welding part, a binding part or a locking part.
- the splicing fixture 150 is an adhesive layer, and the adhesive layer is disposed on the surface 121 to be spliced, and the surfaces 121 to be spliced of different wire harness modules 100 are fixedly connected by bonding.
- the splicing fixture 150 is a magnetic attraction, and the magnetic attraction is arranged on the surface 121 to be spliced, and the surfaces 121 to be spliced of different wiring harness modules 100 are magnetically connected through the magnetic attraction, and the connection is convenient and quick , mainly used in the environment where the binding force of the wiring harness module is not high.
- the splicing fixture 150 is a plug-in piece. As shown in FIGS. The slots are fixed behind, so that the surfaces 121 to be spliced of different wire harness modules 100 are fixedly connected.
- the splicing fixing member 150 is a clamping member, and a claw is provided on a surface 121 to be spliced. Another surface 121 to be spliced is provided with a card slot, and the claws are fixed with the card slot after being assembled, so that the surfaces 121 to be spliced of different wire harness modules 100 are fixedly connected.
- the splicing fixture 150 is a bolt structure, the bolt structure includes a bolt and a nut, the bolt is fixed on one surface 121 to be spliced, and the nut is arranged on the other surface 121 to be spliced and can rotate; or , the nut is fixed on one surface 121 to be spliced, and the bolt is arranged on the other surface 121 to be spliced and can rotate; after the bolt and the nut are screwed and tightened, the surfaces 121 to be spliced of different wire harness modules 100 are fixedly connected.
- the minimum bolt structure is M3 bolts and nuts, and the minimum torque when the bolt structure is tightened is 0.2Nm.
- the splicing fixture 150 is a rivet structure, including a rivet and a fixing hole, the fixing hole is arranged on the two surfaces 121 to be spliced, the rivet passes through the fixing hole, and deforms the rivet through one end, The fixing holes are tightened, so that the surfaces 121 to be spliced of different wire harness modules 100 are fixedly connected.
- the splicing fixing part 150 is a welding part, and the welding part is arranged on the two surfaces 121 to be spliced, and a welding machine is used to melt and connect the welding parts together, so that the different wiring harness modules 100
- the surfaces 121 to be spliced are fixedly connected.
- Welding machines include hot melt welding machines and ultrasonic welding machines.
- the splicing fixture 150 is a binding piece, and a groove is provided on the surface 121 to be spliced, and the binding piece is used to bind the surface 121 to be spliced together at the position of the groove, so that different wire harness modules 100
- the surfaces 121 to be spliced are fixedly connected.
- Binding parts include cable ties, pipe hoops, hook locks, etc. As shown in FIG. 6 , this solution is suitable for use when wiring harness modules 100 are spliced side by side.
- the splicing fixture 150 is a locking member, and the locking member is arranged on the adjacent surface of the surface to be spliced 121 (as shown in FIGS. 19 to 21 ), or on the surface to be spliced. 121 (as shown in FIG. 22 to FIG. 23 ), the surfaces 121 to be spliced of different wire harness modules 100 are clamped and fixed by locking members.
- the separation force applied to the surfaces 121 to be spliced after splicing is at least 0.5N.
- the requirements for the bonding force between the wire harness modules 100 not the same, in order to ensure that the different wire harness modules 100 will not be separated unnecessarily due to misoperation or vibration, the inventors set the separation force applied by the surfaces 121 to be spliced to be at least 0.5N after splicing.
- the input conductive connector 130 and the output conductive connector 140 are arranged at the surface 121 to be spliced, that is, the conductor connection and the insulation part connection of different wire harness modules 100 are located in the same area, The reliability of the electrical connection is further improved, and the splicing operation of the wiring harness module is also made faster.
- the male end plug 101 and the female end slot 102 are both arranged on the surface 121 to be spliced, and two wire harness modules 100 are spliced together.
- the surface 121 to be spliced of the two wire harness modules 100 is also contacted and fixed, the operation is very simple and convenient, and the assembly efficiency is improved.
- the wire harness module has a lengthwise direction
- the insulating part 120 has two end faces 104 (as shown in FIG. Surface 105 (as shown in FIG. 12 ); at least one input conductive connector 130 is provided at one end surface 104 or the side peripheral surface 105 , and at least one output conductive connector 140 is provided at one end surface 104 or the side peripheral surface 105 .
- an input conductive joint 130 and an output conductive joint 140 are provided at the side peripheral surface 105 of the insulating part 120, or an input conductive joint 130 is provided at the side peripheral surface 105 of the insulating part 120 and an output conductive joint is provided at one end surface of the insulating part 120.
- the conductive joint 140, or the two end surfaces of the insulating part 120 are respectively provided with an input conductive joint 130 and an output conductive joint 140, so as to realize various splicing modes of the wiring harness modules.
- the material of the insulation part 120 is a flexible material, so that the wire harness has flexibility.
- the insulating part 120 is made of one or more combinations of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene.
- the insulating part 120 is formed by one or more processes of extrusion process, injection molding process, spraying process, dipping process, slush molding process, electrophoresis process, weaving process and winding process, and wraps the conductor Section 110.
- the conductor 111 is a solid wire, a multi-core twisted wire, a conductive foil or a flat cable.
- the conductor 111 can use a solid wire, which is not easily deformed, but has a large conduction area and can conduct a larger current.
- the conductor 111 can use a multi-core twisted wire, which is soft and can be wound, and is not easy to break.
- the conductor 111 can use conductive foil or flat cable, which can reduce the height of the wire harness module 100 as much as possible, which is convenient for installation and heat dissipation of the conductor 111 .
- the material of the conductor 111 is one or a combination of metals, conductive ceramics, carbon-containing conductors, solid electrolytes, mixed conductors, and conductive polymer materials.
- the material of the conductor 111 is nickel or its alloys, cadmium or its alloys, zirconium or its alloys, chromium or its alloys, cobalt or its alloys, manganese or its alloys, aluminum or its alloys, tin or One or more of its alloys, titanium or its alloys, zinc or its alloys, copper or its alloys, silver or its alloys, gold or its alloys.
- the material of the conductor 111 is copper or copper alloy or aluminum or aluminum alloy.
- the conductor material made of copper has good electrical conductivity and good ductility, and is the first choice as a cable conductor material. However, as the price of copper increases day by day, the material cost of using copper as a wire will become higher and higher.
- non-metallic materials can also be used as the conductor 111 , such as graphene among carbon-containing conductors, which is also an excellent conductor material.
- the outer wall of the insulating part 120 is provided with a wire harness fixing member 160 for fixed connection with the substrate supporting the wire harness, for example, the wire harness module 100 is fixed to the sheet metal of the automobile through the wire harness fixing member 160 parts, etc., at the installation location.
- the wire harness fixing member 160 is fixed to the installation position by clamping, screwing or plugging.
- the cross-sectional shape of the wire harness module 100 is circular, oval, rectangular, polygonal, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, U-shaped, V-shaped, or W-shaped. Or X-shaped, Y-shaped, Z-shaped, semi-arc, arc or wavy structure; in the length direction of the harness module 100, it can extend along a straight line, or bend along a curve.
- the cross-sectional shape of the wire harness module 100 is designed into various shapes, which is convenient for designers to select cross-sections of the wire harness module 100 of different shapes according to the actual layout environment, reduce the volume of the wire harness module 100, optimize the assembly environment of the wire harness module 100, and improve the wiring harness module. 100% security.
- a shielding layer is further provided on the periphery or inside of the insulating part 120 of the wire harness module 100 , for example, the shielding layer is a wire braided layer or a foil wound layer.
- the shielding layer can reduce the electromagnetic interference of itself or the outside world, ensure the stability of the signal, and improve the stability of the wiring harness module 100 .
- the embodiment of the second aspect of the present application provides a combined wire harness, which is spliced by multiple wire harness modules 100 according to the preset splicing method of the embodiment of the first aspect.
- the conductors 111 of the multiple wire harness modules 100 are electrically connected through the input conductive joints 130 and the output conductive joints 140, wherein the structures of the multiple wire harness modules 100 may be the same or different.
- the combined wire harness of the present application is spliced by the wire harness modules 100, which is easy to assemble and disassemble. During maintenance, only the damaged wire harness module needs to be disassembled, and there is no need to replace the whole wire harness or a whole group of wire harnesses, thereby reducing production and maintenance costs.
- the combined wiring harness of the present application is produced in a modular manner and assembled individually, thereby improving production efficiency and qualification rate.
- the preset splicing method includes at least one of a horizontal splicing method and a longitudinal splicing method, the longitudinal splicing method is splicing along a longitudinal direction parallel to the length direction of the wire harness module 100, and the The transverse direction of the length direction of the module 100 is spliced.
- the preset splicing method includes a horizontal splicing method and a vertical splicing method.
- the main wire harness section of the combined wire harness is formed by the horizontal splicing method, and the branch wire harness sections of the combined wire harness are formed by the vertical splicing method.
- the wire harness module located at the outermost end of the combined wire harness is connected to the mating sheath module 200, so as to be mated with the connector 300 of the electrical device through the mating sheath module 200, specifically,
- the plug-in sheath module includes a male sheath 201 and a female sheath 202.
- the male sheath 201 is set outside the wiring harness module 100
- the female sheath 202 is set outside the connector 300 of the electrical device.
- the female end of the wiring harness module 100 When the slot 102 is plugged into the male terminal 301 of the connector 300 of the electrical device, the male sheath 201 and the female sheath 202 are also plugged in, so as to realize the electrical connection between the combined wire harness and the electrical device.
- the combined wire harness of the present application has at least the following advantages:
- the combined wiring harness is spliced by wiring harness modules.
- the wiring harness modules can be produced in batches and automatically, with high production efficiency and high pass rate;
- the wiring harness modules can be installed step by step. It can bypass the pre-installed functional parts, making wiring harness installation and assembling functional parts simple and convenient, saving workshop assembly man-hours and improving production efficiency;
- the damaged wiring harness module can be replaced directly without replacing the entire wiring harness, which not only saves maintenance man-hours, but also reduces maintenance costs;
- wire harness modules can be added in the radial direction of the wire harness to increase the wire harness loops, and can be combined in a variety of ways to save cost and installation time;
- the wiring harness module can be designed and produced according to the shape of the installation location and assembly location profiling, and can be directly matched with the installation location and assembly location during final assembly, saving installation man-hours and reducing the number of fixing parts used during installation;
- the wiring harness module can use flexible conductors and insulators. When there is displacement and deformation in the installation position of the wiring harness, the flexible wiring harness module can be used to greatly reduce the damage to the wiring harness caused by the displacement and deformation of the installation position, and improve the safety of the wiring harness;
- the wire harness modules in different physical areas can be replaced according to the wire harness configuration, and the wire harness modules in other physical installation areas do not need to be replaced due to the same circuit, which solves the problem of the same wire harness with different functional configurations.
- the current situation that requires overall remanufacturing saves a lot of production resources and lays the foundation for the hardware of the wiring harness.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Multi-Conductor Connections (AREA)
- Insulated Conductors (AREA)
- Coupling Device And Connection With Printed Circuit (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
Description
Claims (35)
- 一种线束模块(100),其中,所述线束模块包括导体部分(110)和封闭所述导体部分(110)的绝缘部分(120),所述导体部分(110)包括至少一个导体(111),每个所述导体(111)连接至少一个输入导电接头(130)和至少一个输出导电接头(140),通过将不同线束模块(100)的输入导电接头(130)和输出导电接头(140)连接,实现不同线束模块(100)的导体(111)的电连接。
- 如权利要求1所述的线束模块,其中,所述导体部分(110)包括多个相互绝缘的导体(111)。
- 如权利要求1所述的线束模块,其中,所述导体部分(110)包括连接段(112),至少两个导体(111)通过所述连接段(112)电连接。
- 如权利要求1所述的线束模块,其中,每个所述导体(111)具有一个或多个输入接点,每个所述输入接点连接一所述输入导电接头(130);每个所述导体(111)具有一个或多个输出接点,每个所述输出接点连接一所述输出导电接头(140)。
- 如权利要求1所述的线束模块,其中,所述输入导电接头(130)和所述输出导电接头(140)中的至少一者凸出于所述绝缘部分(120)。
- 如权利要求5所述的线束模块,其中,所述输入导电接头(130)和所述输出导电接头(140)均为凸出于所述绝缘部分(120)的对接头(103),通过将不同线束模块(100)的对接头(103)搭接固定,实现不同线束模块(100)的导体(111)的电连接。
- 如权利要求1所述的线束模块,其中,所述输入导电接头(130)和所述输出导电接头(140)中的一者为凸出于所述绝缘部分(120)的公端插销(101),且另一者为凹设于所述绝缘部分(120)内的母端插槽(102),通过将不同线束模块的所述公端插销(101)和所述母端插槽(102)插接,实现不同线束模块(100)的所述导体(111)的电连接。
- 如权利要求7所述的线束模块,其中,所述公端插销(101)和/或所述母端插槽(102)至少部分上具有镀层。
- 如权利要求8所述的线束模块,其中,所述镀层材质为金、银、镍、锡、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银、银金锆合金中的一种或多种。
- 如权利要求8所述的线束模块,其中,所述镀层包括底层和表层。
- 如权利要求10所述的线束模块,其中,所述底层材质为金、银、镍、锡、锡铅合金、锌中的一种或多种;所述表层材质为金、银、镍、锡、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨 烯银、银金锆合金中的一种或多种。
- 如权利要求10所述的线束模块,其中,所述底层的厚度为0.01μm-15μm。
- 如权利要求10所述的线束模块,其中,所述底层的厚度为0.1μm-9μm。
- 如权利要求10所述的线束模块,其中,所述表层的厚度为0.5μm-55μm。
- 如权利要求10所述的线束模块,其中,所述表层的厚度为1μm-35μm。
- 如权利要求1至7任一项所述的线束模块,其中,所述导体(111)和所述输入导电接头(130)通过压接、焊接或一体成型的方式电连接,所述导体(111)和所述输出导电接头(140)通过压接、焊接或一体成型的方式电连接。
- 如权利要求1所述的线束模块,其中,所述绝缘部分(120)具有待拼接表面(121),通过将不同线束模块(100)的待拼接表面(121)拼接,实现不同线束模块(100)的绝缘部分(120)的连接。
- 如权利要求17所述的线束模块,其中,所述绝缘部分(120)具有在所述线束模块(100)的长度方向上相对设置的两个端面(104),所述待拼接表面(121)包括至少一个所述端面(104)。
- 如权利要求17所述的线束模块,其中,所述绝缘部分(120)具有沿所述线束模块(100)的周向设置的侧周面(105),所述待拼接表面(121)包括所述侧周面(105)的至少部分区域。
- 如权利要求19所述的线束模块,其中,所述侧周面(105)包括平面(106),所述待拼接表面(121)包括所述平面(106)的至少部分区域,且/或,所述侧周面(105)包括曲面(107),所述待拼接表面(121)包括所述曲面(107)的至少部分区域。
- 如权利要求17所述的线束模块,其中,所述待拼接表面(121)处或所述待拼接表面(121)的相邻表面处设有拼接固定件(150),不同线束模块(100)的待拼接表面(121)之间通过彼此的拼接固定件(150)之间的连接而相对固定。
- 如权利要求21所述的线束模块,其中,所述拼接固定件(150)为粘贴层、磁吸件、插接件、卡接件、螺栓结构、铆钉结构、焊接件、捆扎件或锁扣件。
- 如权利要求17所述的线束模块,其中,拼接后的所述拼接表面(121)分开所施加的分离力至少为0.5N。
- 如权利要求17至23任一项所述的线束模块,其中,所述输入导电接头(130)和所述输出导电接头(140)设于所述待拼接表面(121)处。
- 如权利要求1至7任一项所述的线束模块,其中,所述线束模块具有长度方向,所述绝缘部分(120)具有在所述线束模块(100)的长度方向上相对设置的两个端面(104)和 沿所述线束模块(100)的周向设置的侧周面(105);至少一个所述输入导电接头(130)设于一所述端面(104)处或所述侧周面(105)处,至少一个所述输出导电接头(140)设于一所述端面(104)处或所述侧周面(105)处。
- 如权利要求1至7任一项所述的线束模块,其中,所述绝缘部分(120)的材质为柔性材质。
- 如权利要求1至7任一项所述的线束模块,其中,所述导体(111)为实心导线、多芯绞合线、导电箔片或扁形排线。
- 如权利要求1至7任一项所述的线束模块,其中,所述绝缘部分(120)的外壁上设有用于与支撑线束的基体固定连接的线束固定件(160)。
- 如权利要求1至7任一项所述的线束模块,其中,所述线束模块(100)的横截面形状呈圆形或椭圆形或矩形或多边形或E形或F形或H形或K形或L形或T形或U形或V形或W形或X形或Y形或Z形或半弧形或弧形或波浪形结构。
- 如权利要求1至7任一项所述的线束模块,其中,所述导体(111)的材质为金属、导电陶瓷、含碳导体、固体电解质、混合导体、导电高分子材料中的一种或多种的组合。
- 如权利要求30所述的线束模块,其中,所述导体(111)的材质为铜或铜合金或铝或铝合金。
- 如权利要求1至7任一项所述的线束模块,其中,所述绝缘部分(120)的***或内部设有屏蔽层。
- 一种组合式线束,其中,所述组合式线束由多个权利要求1至21任一项所述的线束模块(100)按照预设拼接方式拼接而成,多个所述线束模块(100)的导体(111)之间通过所述输入导电接头(130)和所述输出导电接头(140)电连接。
- 如权利要求33所述的组合式线束,其中,所述预设拼接方式包括横向拼接方式和纵向拼接方式中的至少一种,所述纵向拼接方式为沿平行于所述线束模块(100)的长度方向的纵向方向拼接,所述横向拼接方式为沿垂直于所述线束模块(100)的长度方向的横向方向拼接。
- 如权利要求34所述的组合式线束,其中,所述预设拼接方式包括所述横向拼接方式和所述纵向拼接方式,通过所述横向拼接方式形成所述组合式线束的主干线束段,通过所述纵向拼接方式形成所述组合式线束的分支线束段。
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CA3225267A CA3225267A1 (en) | 2021-07-30 | 2022-07-26 | Wiring harness module and combined wiring harness |
MX2024001434A MX2024001434A (es) | 2021-07-30 | 2022-07-26 | Modulo de arnes de cableado y arnes de cableado combinado. |
EP22848535.5A EP4379971A1 (en) | 2021-07-30 | 2022-07-26 | Wiring harness module and combined wiring harness |
KR1020247002991A KR20240026209A (ko) | 2021-07-30 | 2022-07-26 | 와이어링 하니스 모듈 및 조합식 와이어링 하니스 |
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CN202121766135.0U CN215771835U (zh) | 2021-07-30 | 2021-07-30 | 一种线束模块及组合式线束 |
CN202121766135.0 | 2021-07-30 | ||
CN202110876044.0A CN113471781A (zh) | 2021-07-30 | 2021-07-30 | 一种线束模块及组合式线束 |
CN202110876044.0 | 2021-07-30 |
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-
2022
- 2022-07-26 CA CA3225267A patent/CA3225267A1/en active Pending
- 2022-07-26 MX MX2024001434A patent/MX2024001434A/es unknown
- 2022-07-26 KR KR1020247002991A patent/KR20240026209A/ko unknown
- 2022-07-26 WO PCT/CN2022/107934 patent/WO2023005930A1/zh active Application Filing
- 2022-07-26 EP EP22848535.5A patent/EP4379971A1/en active Pending
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CA3225267A1 (en) | 2023-02-02 |
MX2024001434A (es) | 2024-02-29 |
EP4379971A1 (en) | 2024-06-05 |
KR20240026209A (ko) | 2024-02-27 |
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