Automobile high-voltage wire harness and high-voltage wire harness manufacturing method

Abstract

The invention relates to the field of automobile high-voltage wire harnesses, in particular to an automobile high-voltage wire harness and a manufacturing method of the automobile high-voltage wire harness, the automobile high-voltage wire harness comprises a matrix and a connector, and the matrix comprises a wire core layer, an insulating layer, a shielding layer, a sheath layer and an outer sheath which are sequentially arranged from inside to outside; the wire core layer is composed of the following components in percentage by weight: 60-75% of copper, 20-30% of aluminum, 0.5-2% of tin, 0.5-2% of nickel and 0.1-1% of silicon; the insulating layer is formed by combining the following components in percentage by weight: 50-70% of nano composite polymer, 20-40% of high-temperature cross-linked fluoroplastic and 10-20% of modified polyimide; the shielding layer comprises an aluminum foil layer, a conductive solvent curing layer and a silicon monoxide dielectric layer which are sequentially arranged outwards, and the insulating layer adopts the combination of a nano composite polymer, high-temperature cross-linked fluoroplastic and modified polyimide, so that excellent electrical insulating performance is provided; the aluminum foil layer, the conductive solvent curing layer and the silicon monoxide dielectric layer of the shielding layer provide good electromagnetic compatibility for the wire harness.

Description

Technical Field

[0001] The invention relates to the field of automobile high-voltage wire harnesses, and particularly to an automobile high-voltage wire harness and a method for manufacturing the high-voltage wire harness. Background Art

[0002] With the development of new energy vehicle technology, high-voltage wiring harness systems play an increasingly important role in electric vehicles. The high-voltage wiring harness system is responsible for transmitting high voltage and high current to drive various electrical equipment in the car. The high-voltage wiring harness system plays a vital role in new energy vehicles, but there are also some shortcomings and potential problems. The following are some of the main shortcomings of high-voltage wiring harnesses: high-voltage wiring harnesses carry high voltage and high current, and are prone to electromagnetic radiation and electromagnetic interference, which may have adverse effects on the electrical system of the entire vehicle, such as signal interference, equipment malfunction, etc. In order to reduce electromagnetic radiation and interference, high-voltage wiring harnesses need to take effective shielding measures and grounding designs, which increases the complexity of design and production; due to the high voltage, the high-voltage wiring harness has extremely high requirements for insulation performance, and the insulation layer needs to adopt a multi-layer composite structure to improve the insulation strength and voltage resistance level. However, even so, the insulation layer may still be damaged under long-term use or under specific conditions (such as high temperature and humid environment), resulting in safety hazards such as leakage or short circuit.

[0003] Therefore, in order to solve the deficiencies in the prior art, it is necessary to design a simple-structured automotive high-voltage wire harness and a method for manufacturing the high-voltage wire harness. Summary of the invention

[0004] The invention solves the problems of the prior art and provides an automobile high-voltage wire harness and a method for manufacturing the high-voltage wire harness.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] A high-voltage wiring harness for automobiles comprises a wiring harness mother body and a connector. The wiring harness mother body comprises a wire core layer, an insulating layer, a shielding layer, a sheath layer and an outer sheath arranged in sequence from the inside to the outside; the wire core layer is composed of the following weight percentages of 60-75% copper, 20-30% aluminum, 0.5-2% tin, 0.5-2% nickel and 0.1-1% silicon; the insulating layer is composed of the following weight percentages of 50-70% nano-composite polymer, 20-40% high-temperature cross-linked fluoroplastic and 10-20% modified polyimide; the shielding layer comprises an aluminum foil layer, a conductive solvent solidified layer and a silicon oxide dielectric layer arranged in sequence outwards.

[0007] A further improvement is that the nanocomposite polymer is composed of a basic polymer matrix and a nanoscale filler, wherein the nanoscale filler is at least one of nanoclay, carbon nanotubes or graphene, and the added amount of the nanoscale filler is 1 to 5% of the weight of the polymer matrix; the high-temperature cross-linked fluoroplastic is at least one of polytetrafluoroethylene or polyvinylidene fluoride and has been cross-linked.

[0008] As a further improvement, the sheath layer is composed of the following weight percentages: 40-60% thermoplastic elastomer, 20-40% cross-linked polyethylene and 10-30% chlorosulfonated polyethylene; the outer sheath is composed of the following weight percentages: 30-50% polyurethane, 20-40% polyvinyl chloride (PVC) and 10-30% polytetrafluoroethylene.

[0009] As a further improvement, the conductive solvent solidified layer has a mass ratio of 20% to 40%, the silicon dioxide dielectric layer has a mass ratio of 60% to 80%, and the conductive solvent solidified layer includes xylene, butanone and polyvinyl alcohol.

[0010] A method for preparing an automotive high-voltage wire harness comprises the following steps:

[0011] S1: Wire drawing: The raw materials copper, aluminum, tin, nickel and silicon are melted in a furnace and mixed evenly to form an alloy melt, and the alloy melt is drawn into a single wire of the required diameter through a wire drawing machine, and annealing is performed after wire drawing;

[0012] S2: Then the annealed monofilaments are twisted into one strand to form a core layer;

[0013] S3: Insulation treatment: Nanocomposite polymer, high temperature cross-linked fluoroplastic and modified polyimide insulation materials are mixed and placed in an extruder. The extruder evenly coats the insulation material on the surface of the wire core layer, and forms a solid insulation layer after cooling and solidification;

[0014] S4: Shielding layer manufacturing: fix an aluminum foil layer on the surface of the insulating layer, coat a layer of conductive solvent on the surface of the aluminum foil layer to form a conductive solvent solidified layer, spray a layer of conductive medium on the surface of the conductive solvent to form a silicon oxide dielectric layer, and bake in an oven after treatment to fully solidify the conductive solvent solidified layer and the silicon oxide dielectric layer;

[0015] S5: Sheath layer manufacturing: Thermoplastic elastomer, cross-linked polyethylene and chlorosulfonated polyethylene are mixed and placed in an extruder, and the extruder evenly coats the insulating material on the surface of the insulating layer to form a sheath layer;

[0016] S6: Outer sheath manufacturing: polyurethane, polyvinyl chloride (PVC) and polytetrafluoroethylene are mixed and placed into an extruder, and the extruder evenly coats the outer sheath on the surface of the sheath layer to make the outer sheath;

[0017] S7: Connector installation: The connectors at both ends of the high-voltage wire harness are manufactured using precision machining and injection molding technology.

[0018] As a further improvement, the melting temperature of the alloy melt in the step S1 is controlled at 1200° C. to 1400° C., the wire drawing speed is 10 m / s to 30 m / s, and the mixing time of the alloy melt in the step S1 is not less than 60 minutes.

[0019] As a further improvement, in the step S3, the temperature of the extruder is controlled at 180°C to 250°C, and the extrusion speed is 0.5m / s to 1.5m / s; in the step S4, the baking temperature is 120°C to 180°C, and the baking time is 30 minutes to 60 minutes.

[0020] As a further improvement, in the step S4, the thickness of the conductive solvent solidified layer is 0.01 mm to 0.05 mm, and the thickness of the silicon dioxide dielectric layer is 0.05 mm to 0.1 mm.

[0021] As a further improvement, in step S5, the ratio of the die diameter of the extruder to the diameter of the wire core layer is 1.2 to 1.5; in step S6, the surface of the outer sheath is coated with a wear-resistant coating or subjected to UV curing treatment; in step S7, the manufacture of the connector includes an electroplating process, wherein the electroplating layer is nickel or gold.

[0022] Compared with the prior art, the automotive high-voltage wire harness and the method for manufacturing the high-voltage wire harness of the present invention have the following beneficial effects:

[0023] The wire core layer is made of copper-aluminum alloy. The high conductivity of copper combined with the lightweight characteristics of aluminum provides excellent conductivity and lower density, reducing the overall weight of the wiring harness. At the same time, the addition of elements such as tin, nickel and silicon improves the mechanical properties of the alloy, making the wiring harness more durable when subjected to physical impact or long-term stress. The insulation layer adopts a combination of nano-composite polymers, high-temperature cross-linked fluoroplastics and modified polyimide, which provides excellent electrical insulation performance and effectively prevents leakage and short circuits. The multi-layer structure design of the shielding layer, including an aluminum foil layer, a conductive solvent-cured layer and a silicon oxide dielectric layer, provides good electromagnetic compatibility for the wiring harness and reduces the impact of electromagnetic interference on the vehicle's electrical system. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 The schematic diagram of the structure of the wiring harness mother body in the present invention is

[0025] Figure 2 A schematic diagram of the structure of the present invention

[0026] In the figure, 1-wire harness mother body, 11-wire core layer, 12-insulating layer, 13-shielding layer, 131-aluminum foil layer, 132-conductive solvent solidified layer, 133-silicon oxide dielectric layer, 14-sheath layer, 15-outer sheath, 2-connector. DETAILED DESCRIPTION

[0027] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limitations on the present invention.

[0028] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0029] Below is a combination of the embodiments and the attached Figures 1-2 , the technical solution of the present invention is further elaborated.

[0030] Example 1

[0031] A high-voltage wiring harness for automobiles comprises a wiring harness mother body 1 and a connector 2. The wiring harness mother body 1 comprises a wire core layer 11, an insulating layer 12, a shielding layer 13, a sheath layer 14 and an outer sheath 15 which are sequentially arranged from the inside to the outside; the wire core layer 11 is composed of the following weight percentages of 60-75% copper, 20-30% aluminum, 0.5-2% tin, 0.5-2% nickel and 0.1-1% silicon; the insulating layer 12 is composed of the following weight percentages of 50-70% nanocomposite polymer, 20-40% high-temperature cross-linked fluoroplastic and 10-20% modified polyimide; the shielding layer 13 comprises an aluminum foil layer 131, a conductive solvent solidified layer 132 and a silicon oxide dielectric layer 133 which are sequentially arranged outwards.

[0032] The wire core layer is made of copper-aluminum alloy. The high conductivity of copper combined with the lightweight characteristics of aluminum provides excellent conductivity and lower density, reducing the overall weight of the wiring harness. At the same time, the addition of elements such as tin, nickel and silicon improves the mechanical properties of the alloy, making the wiring harness more durable when subjected to physical impact or long-term stress. The insulation layer adopts a combination of nano-composite polymers, high-temperature cross-linked fluoroplastics and modified polyimide, which provides excellent electrical insulation performance and effectively prevents leakage and short circuits. The multi-layer structure design of the shielding layer, including an aluminum foil layer, a conductive solvent-cured layer and a silicon oxide dielectric layer, provides good electromagnetic compatibility for the wiring harness and reduces the impact of electromagnetic interference on the vehicle's electrical system.

[0033] A method for preparing an automotive high-voltage wire harness comprises the following steps:

[0034] S1: Wire drawing: The raw materials copper, aluminum, tin, nickel and silicon are melted in a furnace and mixed evenly to form an alloy melt, and the alloy melt is drawn into a single wire of the required diameter through a wire drawing machine, and annealing is performed after wire drawing;

[0035] S2: Then the annealed monofilaments are twisted into one strand to form a core layer 11;

[0036] S3: Insulation treatment: The nanocomposite polymer, high temperature cross-linked fluoroplastic and modified polyimide insulation material are mixed and placed in an extruder, and the extruder evenly coats the insulation material on the surface of the wire core layer, and forms a solid insulation layer 12 after cooling and solidification;

[0037] S4: manufacturing the shielding layer: fixing an aluminum foil layer 131 on the surface of the insulating layer 12, coating a layer of conductive solvent on the surface of the aluminum foil layer 131 to form a conductive solvent solidified layer 132, spraying a layer of conductive medium on the surface of the conductive solvent to form a silicon oxide dielectric layer 133, and placing the processed layers in an oven for baking to fully solidify the conductive solvent solidified layer 132 and the silicon oxide dielectric layer 133;

[0038] S5: manufacturing the sheath layer: the thermoplastic elastomer, the cross-linked polyethylene and the chlorosulfonated polyethylene are mixed and placed into an extruder, and the extruder evenly coats the insulating material on the surface of the insulating layer 12 to form the sheath layer 14;

[0039] S6: outer sheath manufacturing: polyurethane, polyvinyl chloride PVC and polytetrafluoroethylene are mixed and placed into an extruder, and the extruder evenly coats the outer sheath on the surface of the sheath layer 14 to form the outer sheath 15;

[0040] S7: Connector installation: The connectors 2 at both ends of the high-voltage wiring harness are manufactured through precision machining and injection molding technology.

[0041] The melting and mixing process is precisely controlled to ensure uniform alloy composition, thereby obtaining consistent physical and electrical properties; the optimization of wire drawing speed and annealing treatment ensures consistent wire diameter, improving the mechanical properties and flexibility of the wiring harness; through layer-by-layer coating and baking processes, the curing and adhesion of the shielding layer are ensured, and the anti-interference ability of the wiring harness is enhanced; the connectors use LV standard connectors, USCAR standard connectors or Japanese standard connectors. LV standard connectors have the largest circulation in the domestic market and relatively complete process standards. It is suitable for a variety of electrical connection needs, has good versatility, and is widely used in the connection of key components such as new energy vehicle battery packs and motor controllers. USCAR standard connectors are international standard connectors with high compatibility and reliability. Its design meets the strict requirements of the automotive industry, ensuring stable operation in harsh environments. It is mainly used in international brand new energy vehicles to meet global market needs; Japanese standard connectors are designed according to Japanese standards, focusing on refinement and high performance. This type of connector has a small size and excellent electrical performance.

[0042] As a further preferred embodiment, the nanocomposite polymer is composed of a basic polymer matrix and a nanoscale filler, wherein the nanoscale filler is at least one of nanoclay, carbon nanotubes or graphene, and the amount of the nanoscale filler added is 1 to 5% of the weight of the polymer matrix. This ratio range ensures the dispersibility of the filler and the processability of the composite material, while avoiding the processing difficulties and cost increases that may be caused by excessive filler content, improving the mechanical strength and heat resistance of the insulating layer, and enhancing the ability to resist chemical corrosion and environmental stress; the high-temperature cross-linked fluoroplastic is at least one of polytetrafluoroethylene or polyvinylidene fluoride and is cross-linked to improve its heat resistance and mechanical properties, so that it can maintain stable insulation properties in a high temperature environment.

[0043] As a further preferred embodiment, the jacket layer 14 is composed of the following weight percentages: 40-60% thermoplastic elastomer, 20-40% cross-linked polyethylene and 10-30% chlorosulfonated polyethylene, providing good mechanical properties, wear resistance and chemical resistance. Thermoplastic elastomer provides flexibility and elasticity, cross-linked polyethylene provides heat resistance and chemical stability, and chlorosulfonated polyethylene provides oil resistance and wear resistance; the outer jacket 15 is composed of the following weight percentages: 30-50% polyurethane, 20-40% polyvinyl chloride PVC and 10-30% polytetrafluoroethylene, polyurethane provides high strength and wear resistance, polyvinyl chloride provides good electrical insulation and cost-effectiveness, and polytetrafluoroethylene provides excellent chemical resistance and low friction coefficient, extending the service life of the wiring harness.

[0044] As a further preferred embodiment, the conductive solvent solidified layer 132 has a mass ratio of 20% to 40%, and the conductive solvent solidified layer 132 includes xylene, butanone and polyvinyl alcohol. The appropriate proportion of the conductive solvent helps to form a uniform conductive layer and provide a good shielding effect. The mixture of xylene, butanone and polyvinyl alcohol provides good adhesion and conductivity and is not easy to fall off or peel off; the silicon oxide dielectric layer 133 has a mass ratio of 60% to 80%, which provides additional dielectric properties and heat resistance, and helps to improve the overall performance of the shielding layer.

[0045] As a further preferred embodiment, the melting temperature of the alloy melt in the S1 step is controlled at 1200°C to 1400°C. This temperature range ensures that copper, aluminum and other added elements can be completely melted to form a uniform alloy. If the temperature is too low, aluminum and silicon may not be fully melted, while if the temperature is too high, copper may be oxidized or the furnace material may be damaged. The wire drawing speed is 10m / s to 30m / s. This temperature range ensures that copper, aluminum and other added elements can be completely melted to form a uniform alloy. If the temperature is too low, aluminum and silicon may not be fully melted, while if the temperature is too high, copper may be oxidized or the furnace material may be damaged. The mixing time of the alloy melt in the S1 step is not less than 60 minutes. A longer mixing time helps to ensure the uniform distribution of the metal elements in the alloy, thereby improving the electrical and mechanical properties of the final product.

[0046] As a further preferred embodiment, the temperature of the extruder in the step S3 is controlled at 180°C to 250°C. This temperature range ensures that the insulating material can be uniformly extruded without decomposition. Too low a temperature may cause uneven extrusion of the material, and too high a temperature may cause decomposition of the material. The extrusion speed is 0.5m / s to 1.5m / s. This speed range ensures the uniformity and surface smoothness of the insulating layer. Too slow a speed may cause the material to stay in the extruder for too long, affecting the material properties, and too fast a speed may cause uneven extrusion of the layer. The uniformity and surface quality of the insulating layer are improved, ensuring good insulation performance.

[0047] The baking temperature in step S4 is 120°C to 180°C, which ensures that the conductive solvent curing layer and the silicon oxide dielectric layer can be fully cured without overheating and damaging the insulating layer or other materials. The baking time is 30 minutes to 60 minutes, which ensures that the curing layer is fully cured and achieves the required electrical and mechanical properties. The shielding layer is fully cured, which improves the shielding effect and long-term stability.

[0048] As a further preferred embodiment, the thickness of the conductive solvent solidified layer 132 in the step S4 is 0.01 mm to 0.05 mm, which provides good conductivity and shielding effect while maintaining the flexibility of the wire harness; the thickness of the silicon oxide dielectric layer 133 is 0.05 mm to 0.1 mm, which ensures that the dielectric layer can effectively protect the wires without excessively increasing the outer diameter of the wire harness, thereby improving the protection performance and shielding effect of the shielding layer.

[0049] As a further preferred embodiment, the ratio of the die diameter of the extruder to the diameter of the wire core layer 11 in the step S5 is 1.2 to 1.5, and this ratio range ensures uniform thickness of the sheath layer and provides sufficient mechanical protection; the surface of the outer sheath 15 in the step S6 is coated with a wear-resistant coating or subjected to ultraviolet curing treatment, thereby extending the service life of the wiring harness; the manufacture of the connector 2 in the step S7 includes an electroplating process, wherein the electroplating layer is nickel or gold, and both nickel and gold are good conductive materials with good corrosion resistance. Nickel has a lower cost and is suitable for general environments; gold has better conductivity and corrosion resistance and is suitable for harsh environments.

[0050] The preferred specific embodiments of the present invention are described in detail above. It should be understood that a person skilled in the art can make many modifications and changes based on the concept of the present invention without creative work. Therefore, any technical solution that can be obtained by a person skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. An automotive high voltage wire harness, characterized in that: The invention comprises a wiring harness mother body and a connector. The wiring harness mother body comprises a wire core layer, an insulating layer, a shielding layer, a sheath layer and an outer sheath which are arranged in sequence from the inside to the outside. The wire core layer is composed of the following weight percentages: 60-75% copper, 20-30% aluminum, 0.5-2% tin, 0.5-2% nickel and 0.1-1% silicon. The insulating layer is composed of the following weight percentages: 50-70% nano composite polymer, 20-40% high temperature cross-linked fluoroplastic and 10-20% modified polyimide. The shielding layer comprises an aluminum foil layer, a conductive solvent solidified layer and a silicon oxide dielectric layer which are arranged in sequence outwards.

2. The automotive high voltage wire harness according to claim 1, characterized in that: The nanocomposite polymer is composed of a basic polymer matrix and a nanoscale filler, wherein the nanoscale filler is at least one of nanoclay, carbon nanotubes or graphene, and the added amount of the nanoscale filler is 1-5% of the weight of the polymer matrix; the high-temperature cross-linked fluoroplastic is at least one of polytetrafluoroethylene or polyvinylidene fluoride and is cross-linked.

3. The automotive high voltage wire harness according to claim 1, characterized in that: The sheath layer is composed of the following weight percentages: 40-60% thermoplastic elastomer, 20-40% cross-linked polyethylene and 10-30% chlorosulfonated polyethylene; the outer sheath is composed of the following weight percentages: 30-50% polyurethane, 20-40% polyvinyl chloride (PVC) and 10-30% polytetrafluoroethylene.

4. The automotive high voltage wire harness according to claim 1, characterized in that: The conductive solvent solidified layer has a mass ratio of 20% to 40%, the silicon dioxide dielectric layer has a mass ratio of 60% to 80%, and the conductive solvent solidified layer includes xylene, butanone and polyvinyl alcohol.

5. A method for preparing a high-voltage wiring harness for an automobile, characterized in that , including the following steps: S1: Wire drawing: The raw materials copper, aluminum, tin, nickel and silicon are melted in a furnace and mixed evenly to form an alloy melt, and the alloy melt is drawn into a single wire of the required diameter through a wire drawing machine, and annealing is performed after wire drawing; S2: Then the annealed monofilaments are twisted into one strand to form a core layer; S3: Insulation treatment: Nanocomposite polymer, high temperature cross-linked fluoroplastic and modified polyimide insulation materials are mixed and placed in an extruder. The extruder evenly coats the insulation material on the surface of the wire core layer, and forms a solid insulation layer after cooling and solidification; S4: Shielding layer manufacturing: fix an aluminum foil layer on the surface of the insulating layer, coat a layer of conductive solvent on the surface of the aluminum foil layer to form a conductive solvent solidified layer, spray a layer of conductive medium on the surface of the conductive solvent to form a silicon oxide dielectric layer, and bake in an oven after treatment to fully solidify the conductive solvent solidified layer and the silicon oxide dielectric layer; S5: Sheath layer manufacturing: Thermoplastic elastomer, cross-linked polyethylene and chlorosulfonated polyethylene are mixed and placed in an extruder, and the extruder evenly coats the insulating material on the surface of the insulating layer to form a sheath layer; S6: Outer sheath manufacturing: polyurethane, polyvinyl chloride (PVC) and polytetrafluoroethylene are mixed and placed into an extruder, and the extruder evenly coats the outer sheath on the surface of the sheath layer to make the outer sheath; S7: Connector installation: The connectors at both ends of the high-voltage wire harness are manufactured using precision machining and injection molding technology.

6. A method for preparing a high-voltage wiring harness for an automobile according to claim 5, characterized in that: In the step S1, the melting temperature of the alloy melt is controlled at 1200° C. to 1400° C., the wire drawing speed is 10 m / s to 30 m / s, and the mixing time of the alloy melt in the step S1 is not less than 60 minutes.

7. A method for preparing a high-voltage wiring harness for an automobile according to claim 5, characterized in that: In the step S3, the temperature of the extruder is controlled at 180° C. to 250° C., and the extrusion speed is 0.5 m / s to 1.5 m / s; in the step S4, the baking temperature is 120° C. to 180° C., and the baking time is 30 minutes to 60 minutes.

8. A method for preparing a high-voltage wiring harness for an automobile according to claim 5, characterized in that: In the step S4, the thickness of the conductive solvent solidified layer is 0.01 mm to 0.05 mm, and the thickness of the silicon dioxide dielectric layer is 0.05 mm to 0.1 mm.

9. A method for preparing a high-voltage wiring harness for an automobile according to claim 5, characterized in that: In step S5, the ratio of the die diameter of the extruder to the diameter of the wire core layer is 1.2 to 1.5; in step S6, the surface of the outer sheath is coated with a wear-resistant coating or subjected to ultraviolet curing treatment; in step S7, the manufacture of the connector includes an electroplating process, wherein the electroplating layer is nickel or gold.

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