Wiring harness module and combined wiring harness

Abstract

The present invention provides a wiring harness module and a combined wiring harness, which includes a conductor portion and an insulating portion that encloses the conductor portion. The conductor portion includes at least one conductor, each conductor connected to at least one input conductive connector and at least one output conductive connector. By connecting the input conductive connectors and output conductive connectors of different wiring harness modules, the electrical connection of the conductors of different wiring harness modules is achieved. The combined wiring harness is formed by splicing multiple wiring harness modules in a preset splicing method, and the conductors of the multiple wiring harness modules are electrically connected through the input conductive connectors and the output conductive connectors. In the present invention, each wiring harness module can be connected to at least two other wiring harness modules, and each conductor can be electrically connected to at least two other conductors, thereby being able to be combined into a complex conductive loop.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical connection, in particular to a wiring harness module and a combined wiring harness. Background Art

[0002] As the electrical functions of vehicles like cars, trains, and ships become increasingly complex, the number of corresponding electrical circuits increases. Consequently, the number of wiring harness loops connecting various electrical devices and power sources also increases, leading to a gradual increase in the size and complexity of wiring harnesses. For example, the main wiring harness for a C-class car has approximately 800-1000 loops, assembled into a single large harness and distributed throughout the vehicle body. If a wiring harness is partially damaged, the entire harness must be replaced. Furthermore, due to factors such as personalized customization, wiring harness loops and branches are becoming increasingly flexible, requiring the simultaneous production of different harness models. This makes mass production unsuitable, requiring the addition of specialized equipment and tooling, placing high demands on production personnel's skills and harness testing capabilities. Consequently, complex wiring harnesses are extremely difficult to produce and repair. Summary of the Invention

[0003] The object of the present invention is to provide a wiring harness module and a combined wiring harness to solve the problem that complex wiring harnesses are difficult to produce and repair.

[0004] To achieve the above-mentioned objectives, the present invention proposes a wiring harness module, comprising a conductor part and an insulating part that encloses the conductor part, wherein the conductor part includes at least one conductor, each of which is connected to at least one input conductive connector and at least one output conductive connector. By connecting the input conductive connectors and output conductive connectors of different wiring harness modules, the electrical connection of the conductors of different wiring harness modules is achieved.

[0005] The wiring harness module as described above, wherein the conductor portion includes a plurality of conductors insulated from each other.

[0006] The wiring harness module as described above, wherein the conductor portion includes a connecting section, and at least two conductors are electrically connected through the connecting section.

[0007] In the wiring harness module as described above, each of the conductors has one or more input contacts, each of which is connected to an input conductive connector; and each of the conductors has one or more output contacts, each of which is connected to an output conductive connector.

[0008] The wiring harness module as described above, wherein at least one of the input conductive connector and the output conductive connector protrudes from the insulating portion.

[0009] In the wiring harness module as described above, the input conductive connector and the output conductive connector are both docking connectors protruding from the insulating portion. By overlapping and fixing the docking connectors of different wiring harness modules, electrical connection of the conductors of different wiring harness modules is achieved.

[0010] As described above, in the wiring harness module, one of the input conductive connector and the output conductive connector is a male end pin protruding from the insulating portion, and the other is a female end slot recessed in the insulating portion. By plugging the male end pin and the female end slot of different wiring harness modules together, the electrical connection of the conductors of different wiring harness modules is achieved.

[0011] The wiring harness module as described above, wherein the male end pin and / or the female end slot are at least partially plated.

[0012] In the wiring harness module as described above, the plating 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.

[0013] The wiring harness module as described above, wherein the plating layer includes a bottom layer and a surface layer.

[0014] The wiring harness module as described above, wherein the bottom layer material is one or more of gold, silver, nickel, tin, tin-lead alloy, and zinc; the surface layer material is one or more of gold, silver, nickel, tin, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy.

[0015] The wiring harness module as described above, wherein the bottom layer has a thickness of 0.01 μm-15 μm.

[0016] The wiring harness module as described above, wherein the bottom layer has a thickness of 0.1 μm-9 μm.

[0017] The wiring harness module as described above, wherein the surface layer has a thickness of 0.5 μm-55 μm.

[0018] The wiring harness module as described above, wherein the surface layer has a thickness of 1 μm-35 μm.

[0019] In the wiring harness module as described above, the conductor and the input conductive connector are electrically connected by crimping, welding or integral molding, and the conductor and the output conductive connector are electrically connected by crimping, welding or integral molding.

[0020] In the wiring harness module as described above, the insulating portion has a surface to be spliced, and the insulating portions of different wiring harness modules are connected by splicing the surfaces to be spliced ​​of different wiring harness modules.

[0021] In the wiring harness module as described above, the insulating portion has two end surfaces that are opposite to each other in the length direction of the wiring harness module, and the surfaces to be spliced ​​include at least one of the end surfaces.

[0022] In the wiring harness module as described above, the insulating portion has a side circumferential surface arranged along the circumference of the wiring harness module, and the surface to be spliced ​​includes at least a portion of the side circumferential surface.

[0023] In the wiring harness module as described above, the side peripheral surface comprises a plane, and the surface to be spliced ​​comprises at least a portion of the plane; and / or the side peripheral surface comprises a curved surface, and the surface to be spliced ​​comprises at least a portion of the curved surface.

[0024] In the wiring harness module as described above, splicing fixtures are provided on the surface to be spliced ​​or on the adjacent surface of the surface to be spliced, and the surfaces to be spliced ​​of different wiring harness modules are relatively fixed by connection between the splicing fixtures.

[0025] In the wiring harness module as described above, the splicing and fixing parts are adhesive layers, magnetic parts, plug-in parts, clip-on parts, bolt structures, rivet structures, welding parts, binding parts or locking parts.

[0026] The wiring harness module as described above, wherein the separation force applied when the spliced ​​surfaces are separated after splicing is at least 0.5N.

[0027] In the wiring harness module as described above, the input conductive connector and the output conductive connector are provided on the surface to be spliced.

[0028] The wiring harness module as described above, wherein the wiring harness module has a length direction, the insulating part has two end faces arranged opposite to each other in the length direction of the wiring harness module and a side surface arranged along the circumference of the wiring harness module; at least one of the input conductive connectors is arranged at one of the end faces or the side surface, and at least one of the output conductive connectors is arranged at one of the end faces or the side surface.

[0029] In the wiring harness module as described above, the insulating portion is made of a flexible material.

[0030] In the wiring harness module as described above, the conductor is a solid wire, a multi-core twisted wire, a conductive foil or a flat cable.

[0031] In the wiring harness module as described above, a wiring harness fixing piece for fixedly connecting to a base supporting the wiring harness is provided on the outer wall of the insulating portion.

[0032] The wiring harness module as described above, wherein the cross-sectional shape of the wiring harness module is circular, elliptical, rectangular, polygonal, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, semi-arc-shaped, arc-shaped, or wavy structure.

[0033] In the wiring harness module as described above, the material of the conductor is a combination of one or more of metal, conductive ceramic, carbon-containing conductor, solid electrolyte, mixed conductor, and conductive polymer material.

[0034] In the wiring harness module as described above, the conductor is made of copper or copper alloy or aluminum or aluminum alloy.

[0035] The wiring harness module as described above, wherein a shielding layer is provided on the periphery or inside of the insulating part.

[0036] The present invention also provides a combined wiring harness, which is formed by splicing a plurality of the wiring harness modules described above in a preset splicing manner, and the conductors of the plurality of wiring harness modules are electrically connected through the input conductive connector and the output conductive connector.

[0037] As described above, the combined wiring harness, wherein the preset splicing method includes at least one of a transverse splicing method and a longitudinal splicing method, the longitudinal splicing method is splicing along a longitudinal direction parallel to the length direction of the wiring harness module, and the transverse splicing method is splicing along a transverse direction perpendicular to the length direction of the wiring harness module.

[0038] As described above, the combined wiring harness, wherein the preset splicing method includes the transverse splicing method and the longitudinal splicing method, the main wiring harness segment of the combined wiring harness is formed by the transverse splicing method, and the branch wiring harness segment of the combined wiring harness is formed by the longitudinal splicing method.

[0039] The characteristics and advantages of the wiring harness module and the combined wiring harness of the present invention are:

[0040] 1. The wiring harness modules of the present invention are used to form a wiring harness. Since each conductor of each wiring harness module is connected to at least one input conductive connector and at least one output conductive connector, each wiring harness module can be connected to at least two other wiring harness modules, and each conductor can be electrically connected to at least two other conductors, thereby forming a complex conductive loop.

[0041] 2. The wiring harness module of the present invention can realize the connection of parallel circuits by providing multiple input conductive connectors and / or multiple output conductive connectors. When a complex wiring harness is assembled, the number of wiring harness modules can be reduced, thereby reducing the volume of the wiring harness and lowering the cost.

[0042] 3. The wiring harness module of the present invention is provided with a male end plug and a female end slot as an input conductive connector and an output conductive connector. By plugging the male end plug and the female end slot together, the conductors of different wiring harness modules can be electrically connected. The structure is simple and the connection operation is very convenient.

[0043] 4. The insulating portion of the wiring harness module of the present invention is provided with a surface to be spliced. By connecting the insulating portions of different wiring harness modules, the combined connection of the wiring harness modules is made more secure, and the wiring harness modules are not easily disconnected or loosened, thereby improving the safety and reliability of the electrical connection;

[0044] 5. The combined wiring harness of the present invention can be produced in a modular, batch, and automated manner, and can be assembled in a personalized manner, thereby improving production efficiency, increasing the pass rate, and facilitating maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The following drawings are intended only to illustrate and explain the present invention, and are not intended to limit the scope of the present invention.

[0046] Figure 1 1 is a schematic structural diagram of an embodiment of a wiring harness module of the present invention;

[0047] Figure 2 yes Figure 1 Schematic diagram of the side-by-side splicing of the center harness modules;

[0048] Figure 3 yes Figure 1 Schematic diagram of side-by-side and end-to-end splicing of center harness modules;

[0049] Figure 4 is a structural schematic diagram of another embodiment of the wiring harness module of the present invention;

[0050] Figure 5 yes Figure 4 Schematic diagram of the center wiring harness module end-to-end splicing;

[0051] Figure 6 yes Figure 4 Schematic diagram of the side-by-side splicing of the center harness modules;

[0052] Figure 7 is a schematic diagram of a connection method of different wiring harness modules in the present invention;

[0053] Figure 8 yes Figure 7 A schematic diagram of an embodiment of the connection between the male end pin and the female end socket;

[0054] Figure 9 yes Figure 7 A schematic diagram of another embodiment of the connection between the male end pin and the female end socket;

[0055] Figure 10 yes Figure 7 A schematic diagram of the structure of the male end pin and the female end slot;

[0056] Figure 11 yes Figure 7 Another schematic diagram of the structure of the male end pin and the female end slot;

[0057] Figure 12 It is a schematic diagram of the side splicing of different wiring harness modules in the present invention;

[0058] Figure 13 yes Figure 12 A top view of

[0059] Figure 14 is a schematic diagram of another connection method of different wiring harness modules in the present invention;

[0060] Figure 15 is a schematic diagram of a first embodiment of a conductor of a wiring harness module in the present invention;

[0061] Figure 16 is a schematic diagram of a second embodiment of a conductor of a wiring harness module of the present invention;

[0062] Figure 17 is a schematic diagram of a third embodiment of a conductor of a wiring harness module in the present invention;

[0063] Figure 18 This is a schematic diagram of the structure of the wiring harness fixing member provided on the wiring harness module of the present invention;

[0064] Figure 19 This is a structural diagram of an embodiment of the present invention in which a splicing fixture is provided on a wiring harness module;

[0065] Figure 20 yes Figure 19 Side view of;

[0066] Figure 21 yes Figure 19 Schematic diagram of the connection status of the two wiring harness modules;

[0067] Figure 22 This is a structural schematic diagram of another embodiment of providing a splicing fixture on a wiring harness module in the present invention;

[0068] Figure 23 yes Figure 22 Schematic diagram of the connection status of the two wiring harness modules;

[0069] Figure 24 This is a schematic diagram of the wiring harness module in the present invention being connected to the connector of the electrical device via the plug-in sheath module.

[0070] Description of main component numbers:

[0071] 100, wiring harness module; 101, male end pin; 102, female end slot; 103, docking connector; 104, end face;

[0072] 105, lateral surface; 106, flat surface; 107, curved surface; 110, conductor portion; 111, conductor;

[0073] 112, connecting section; 120, insulating portion; 121, surface to be spliced; 130, input conductive connector;

[0074] 140, output conductive connector; 150, splicing fixture; 160, harness fixture; 170, strapping tape;

[0075] 200, plug-in sheath module; 201, male sheath; 202, female sheath; 300, connector; 301, male terminal. DETAILED DESCRIPTION

[0076] In order to have a clearer understanding of the technical features, purposes and effects of the present invention, the specific embodiments of the present invention are now described with reference to the accompanying drawings. Among them, the terms "first", "second", etc. are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, the meaning of "multiple" is two or more. In the description of the present invention, unless otherwise specified, the term "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 intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in this patent can be understood according to the specific circumstances.

[0077] Implementation Method 1

[0078] like Figure 1 、 Figure 3 As shown, the present invention provides a wiring harness module 100, which includes a conductor part 110 and an insulating part 120 that encloses the conductor part 110. The conductor part 110 includes at least one conductor 111, and 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 the output conductive connectors 140 of different wiring harness modules 100, the electrical connection of the conductors 111 of different wiring harness modules 100 is achieved.

[0079] The wiring harness module of the present invention is used to combine into a wiring harness. Since each conductor 111 of each wiring harness module 100 is connected to at least one input conductive connector 130 and at least one output conductive connector 140, each wiring harness module can be connected to at least two other wiring harness modules, and each conductor can be electrically connected to at least two other conductors, thereby being able to be combined into a complex conductive loop.

[0080] like Figure 2 、 Figure 3 、 Figure 5 As shown, when the wiring harness is assembled, the conductors of multiple wiring harness modules are connected through the input conductive connector 130 and the output conductive connector 140 according to the required wiring harness conductive circuit (see Figure 3 ), the combination mode is flexible, and the assembly and disassembly are convenient. During maintenance, only the damaged wiring harness module needs to be disassembled, and there is no need to replace the entire wire harness or the entire group of wire harnesses, which reduces production and maintenance costs.

[0081] Taking the combination of three wiring harness modules 100 as an example, the three wiring harness modules 100 are respectively the first wiring harness module, the second wiring harness module and the third wiring harness module. When combined, the output conductive connector 140 of the first wiring harness module can be connected to the input conductive connector 130 of the second wiring harness module, and the output conductive connector 140 of the second wiring harness module can be connected to the input conductive connector 130 of the third wiring harness module, so as to realize the electrical connection of the three wiring harness modules 100 in sequence.

[0082] The wiring harness module of the present invention can be mass-produced, automatically produced, and individually assembled, thereby improving production efficiency and the pass rate.

[0083] Furthermore, the cross-sectional area of ​​the conductor 111 is 0.1 mm 2 -260mm 2 In the wiring harness, the cross-sectional area of ​​the conductor 111 determines the current that the conductor 111 can conduct. Generally, the conductor 111 that realizes signal conduction has a smaller current and a smaller cross-sectional area. For example, the minimum cross-sectional area of ​​the signal line conductor 111 of the automotive wiring harness can reach 0.1mm. 2 , and the conductor 111 that realizes power conduction has a large current and a large cross-sectional area of ​​the conductor 111. For example, in a car battery harness, the maximum cross-sectional area of ​​the conductor 111 reaches 260mm 2 For conductors 111 with a smaller cross-sectional area, the conductors 111 may be arranged by using a wire feeding mechanism for laying. For conductors 111 with a larger cross-sectional area, 3D printing of the conductors 111 or direct laying of the formed conductors 111 may be used.

[0084] Furthermore, the insulating portion 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.

[0085] Furthermore, the breakdown strength of the insulating part 120 is 0.3KV / mm-35KV / mm. The breakdown strength is also called the dielectric breakdown strength. It indicates the highest electric field strength that the material can withstand to avoid being destroyed (broken down) under the action of the electric field. When the breakdown strength of the insulating part 120 is lower than 0.3KV / mm, some thinner insulating parts 120 may be broken down under normal voltage, resulting in invalid insulation. When the breakdown strength of the insulating part 120 is higher than 35KV / mm, since high voltages higher than 35KV will not appear in general vehicle environments, the use of materials with too high breakdown strength will increase the cost of the integrated wiring harness module, resulting in design waste.

[0086] Furthermore, the thickness of the insulating part 120 is 0.03mm-5mm. If the thickness of the insulating part 120 is less than 0.03mm, not only can the breakdown voltage of the insulating part 120 not be guaranteed to be higher than the operating voltage, but the wear resistance of the insulating part 120 cannot be guaranteed. After repeated scraping, the insulating part 120 will be damaged, exposing the conductor 111, resulting in leakage or short circuit, causing line damage and functional failure. If the thickness of the insulating part 120 is equal to 5mm, the breakdown voltage, insulation resistance and wear resistance of the insulating part 120 can all meet the requirements. However, when the thickness is greater than 5mm, the thickness of the insulating part 120 is relatively large, and problems such as pores and collapse may occur during the processing, which reduces the performance of the insulating part 120. In addition, 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.

[0087] like Figures 1 to 3 As shown, in one embodiment, the conductor portion 110 includes a plurality of mutually insulated conductors 111, wherein each conductor 111 is connected to at least one input conductive connector 130 and at least one output conductive connector 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 instruction information is transmitted to the electrical device, which is convenient for combination into a complex wiring harness. When combining into a complex wiring harness, the number of wiring harness modules 100 spliced ​​side by side is reduced, the volume of the complex wiring harness is reduced, the structure of the complex wiring harness is simplified, and the wiring harness cost is further reduced.

[0088] In one embodiment, each conductor 111 of the conductor portion 110 may be an integral structure or a split structure formed by connecting multiple conductor segments, and the multiple conductor segments may be connected by terminals (eg, Figure 15 As shown), it can also be connected by welding (as Figure 16 As shown), it is also possible to connect by drilling holes into the insulating portion 120 and pouring conductive material into the holes (as shown Figure 17 shown).

[0089] In one embodiment, the conductor portion 110 includes a connecting section 112, and at least two conductors 111 are electrically connected via the connecting section 112. When two or more conductors need to conduct current or signals in the same loop, these conductors 111 need to be electrically connected together, such as Figure 13 , Figure 17 As shown, by providing the connecting section 112, different conductors 111 can be electrically connected, thereby reducing the loops in the electrical appliance, optimizing the electrical layout, and reducing the volume of the wiring harness.

[0090] Furthermore, the connecting section 112 can be connected to both ends or the middle portion of the conductor 111 by crimping or welding.

[0091] In one embodiment, each conductor 111 has one or more input contacts, each of which is connected to an input conductive connector 130 ; each conductor 111 has one or more output contacts, each of which is connected to an output conductive connector 140 .

[0092] See Figure 13 In a first feasible technical solution, each conductor 111 has multiple input contacts and one output contact, and the multiple input contacts are respectively connected to an input conductive connector 130, that is, each conductor 111 is connected to multiple input conductive connectors 130 and one output conductive connector 140. When the multiple input conductive connectors 130 are respectively electrically connected to multiple other conductors, a parallel circuit connection is realized.

[0093] See Figure 13 In a second feasible technical solution, each conductor 111 has an input contact and multiple output contacts, and the multiple output contacts are respectively connected to an output conductive connector 140. That is, each conductor 111 is connected to an input conductive connector 130 and multiple output conductive connectors 140. When the multiple output conductive connectors 140 are respectively electrically connected to multiple other conductors, a parallel circuit connection is achieved.

[0094] See Figure 13 In a third feasible technical solution, each conductor 111 has multiple input contacts and multiple output contacts. The multiple input contacts are respectively connected to an input conductive connector 130, and the multiple output contacts are respectively connected to an output conductive connector 140. That is, each conductor 111 is connected to multiple input conductive connectors 130 and multiple output conductive connectors 140. When the multiple input conductive connectors 130 are respectively electrically connected to multiple other conductors, and the multiple output conductive connectors 140 are respectively electrically connected to multiple other conductors, a parallel circuit connection is achieved.

[0095] like Figure 14As shown, in another specific embodiment, the input conductive connector 130 and the output conductive connector 140 are both docking connectors 103 protruding from the insulating portion 120. By overlapping and fixing the docking connectors 103 of different wiring harness modules 100, the electrical connection of the conductors 111 of different wiring harness modules 100 is achieved. For example, the docking connectors 103 of different wiring harness modules 100 are detachably connected by bolts.

[0096] like Figure 7 、 Figure 14 As shown, in one embodiment, at least one of the input conductive connector 130 and the output conductive connector 140 protrudes from the insulating portion 120 to facilitate connection between the input conductive connector 130 and the output conductive connector 140 of different wiring harness modules 100 .

[0097] like Figures 7 to 13 As shown, in a specific embodiment, one of the input conductive connector 130 and the output conductive connector 140 is a male end plug 101 protruding from the insulating portion 120, and the other is a female end socket 102 recessed in the insulating portion 120. By plugging the male end plug 101 and the female end socket 102 of different wiring harness modules (such as Figure 8 As shown), the electrical connection of the conductors 111 of different wiring harness modules 100 is realized, the structure is simple, and the connection operation is very convenient.

[0098] In order to facilitate the connection between the male end plug 101 and the female end slot 102, an outward-expanding guide slope (such as Figure 9 shown).

[0099] The male end plug 101 and the female end slot 102 are matched in shape, and the cross-sectional shape of the two can be square (such as Figure 10 as shown) or round (as Figure 11 shown).

[0100] In one embodiment, the male end pin 101 and / or the female end socket 102 are at least partially coated in order to improve corrosion resistance, improve conductivity, increase the number of plugging and unplugging times, and better extend the service life of the male end pin 101 and the female end socket 102.

[0101] The plating layer can be provided on the male end plug 101 and the female end socket 102 by electroplating, chemical plating, magnetron sputtering or vacuum plating.

[0102] Electroplating is a process that uses the principle of electrolysis to plate a thin layer of other metals or alloys on certain metal surfaces.

[0103] The chemical plating method is a metal deposition process that produces metal through a controllable redox reaction under the catalytic action of the metal.

[0104] Magnetron sputtering utilizes the interaction of magnetic and electric fields to cause electrons to spiral near the target surface, thereby increasing the probability of electrons striking argon gas to generate ions. These ions, under the influence of the electric field, collide with the target surface, sputtering the target material.

[0105] The vacuum plating method is to deposit various metal and non-metallic films on the surface of plastic parts through distillation or sputtering under vacuum conditions.

[0106] The plating 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. Copper, as an active metal, will undergo oxidation reactions with oxygen and water during use. Therefore, one or more inactive metals are required as plating to extend the service life of the male end plug 101 and the female end socket 102. In addition, for the male end plug 101 and the female end socket 102 that need to be frequently plugged in and out, a good wear-resistant metal is also required as the plating, which can greatly increase the service life of the male end plug 101 and the female end socket 102. In addition, the male end plug 101 and the female end socket 102 require good electrical conductivity. The conductivity and stability of the above metals are better than those of copper or copper alloys, which can enable the male end plug 101 and the female end socket 102 to obtain better electrical performance and longer service life.

[0107] To demonstrate the impact of different plating materials on the overall performance of male pin 101 and female socket 102, the inventors used male pin 101 and female socket 102 samples of the same specifications and material, but with different plating materials, to conduct a series of plugging and unplugging cycles and corrosion resistance tests. To demonstrate the advantages and disadvantages of the selected materials and other commonly used electroplating materials, the inventors also used tin, nickel, and zinc as plating materials in the experiments. The experimental results are shown in Table 1 below.

[0108] The plugging and unplugging times listed in Table 1 below were simulated by fixing the male pin 101 and the female socket 102 on a test bench. A mechanical device was used to simulate plugging and unplugging the male pin 101 and the female socket 102. After every 100 plugging and unplugging cycles, the test was stopped to observe damage to the surface coating of the male pin 101 and the female socket 102. If the surface coating was scratched, exposing the material of the male pin 101 and the female socket 102, the test was stopped and the plugging and unplugging times at that time were recorded. A plugging and unplugging time of less than 8,000 cycles was considered unqualified.

[0109] The corrosion resistance time test in Table 1 below involved placing male pin 101 and female socket 102 in a salt spray test chamber. Salt spray was applied to various locations on male pin 101 and female socket 102. The test was then removed every 20 hours for cleaning and observation of surface corrosion. This constituted a cycle. Testing was stopped until the surface corrosion area of ​​male pin 101 and female socket 102 exceeded 10% of the total area. The cycle count was then recorded. In this example, a cycle count of less than 80 was considered unsatisfactory.

[0110] Table 1: Effects of different plating materials on the number of insertions and extractions and corrosion resistance of male pins and female sockets

[0111]

[0112] As can be seen from the table above, when the coating materials are gold, silver, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy, the experimental results significantly exceed the standard values, and the performance is relatively stable. When the coating materials are nickel, tin, tin-lead alloy, and zinc, the experimental results also meet the requirements. Therefore, the inventors selected the coating materials as one or more combinations of gold, silver, nickel, tin, tin-lead alloy, zinc, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy.

[0113] In one embodiment, the plating layer includes a base layer and a surface layer, and the plating layer is formed by a multi-layer plating method. After the male pin 101 and the female socket 102 are processed, there are still many gaps and holes under the surface microscopic interface. These gaps and holes are the biggest cause of wear and corrosion of the male pin 101 and the female socket 102 during use. Therefore, it is necessary to first plate a base layer on the surface of the male pin 101 and the female socket 102 to fill the surface gaps and holes, so that the surface of the male pin 101 and the female socket 102 is smooth and free of holes, and then plate the surface layer. The bonding will be stronger and smoother, and the plating surface will be free of gaps and holes, so that the wear resistance, corrosion resistance, and electrical performance of the male pin 101 and the female socket 102 are better, and the service life of the male pin 101 and the female socket 102 is greatly extended.

[0114] In one embodiment, the bottom layer material is one or more of gold, silver, nickel, tin, tin-lead alloy, and zinc; the surface layer material is one or more of gold, silver, nickel, tin, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy.

[0115] In another embodiment, the thickness of the bottom layer is 0.01 μm-15 μm. Preferably, the thickness of the bottom layer is 0.1 μm-9 μm.

[0116] In another embodiment, the thickness of the surface layer is 0.5 μm-55 μm. Preferably, the thickness of the surface layer is 1 μm-35 μm.

[0117] To demonstrate the impact of variations in base plating thickness on the overall performance of the male pin 101 and female socket 102, the inventors conducted a series of temperature rise and corrosion resistance time tests on male pins 101 and female sockets 102 samples of the same specifications and material, but with different nickel base plating thicknesses and the same silver surface plating thickness. The experimental results are shown in Table 2 below.

[0118] The temperature rise test in Table 2 below involves passing the same current through male plug 101 and female socket 102 after mating. The temperature at the same location on male plug 101 and female socket 102 is measured in a closed environment before power is applied and after the temperature stabilizes. The absolute difference is then taken. In this embodiment, a temperature rise greater than 50K is considered unqualified.

[0119] The corrosion resistance time test in Table 2 below involved placing male pin 101 and female socket 102 in a salt spray test chamber. Salt spray was applied to various locations on male pin 101 and female socket 102. The test was performed every 20 hours, followed by cleaning and observation for surface corrosion. This constituted a test cycle. The test was terminated when the surface corrosion area of ​​male pin 101 and female socket 102 exceeded 10% of the total surface area. The test cycle was then recorded. In this example, a test cycle of less than 80 cycles was considered unsatisfactory.

[0120] Table 2: Effects of different base coating thicknesses on temperature rise and corrosion resistance of male pins and female sockets

[0121]

[0122] As shown in Table 2, when the underlying nickel plating thickness is less than 0.01 μm, the temperature rise of the male pin 101 and the female socket 102 meets the requirements. However, due to the thin coating, the corrosion resistance cycles of the male pin 101 and the female socket 102 are less than 80, which does not meet the performance requirements of the male pin 101 and the female socket 102. This has a significant impact on the overall performance and lifespan of the male pin 101 and the female socket 102, and in severe cases, can lead to a drastic reduction in product lifespan or even failure and combustion. When the underlying nickel plating thickness is greater than 15 μm, the thicker the underlying plating, the heat generated by the male pin 101 and the female socket 102 cannot be dissipated, resulting in unqualified temperature rise. Moreover, the thicker the coating, the more likely it is to fall off the surface of the male pin 101 and the female socket 102, resulting in a decrease in the corrosion resistance cycles. Therefore, the inventors selected an underlying plating thickness of 0.01 μm to 15 μm. Preferably, the inventors found that when the thickness of the underlying plating layer is 0.1 μm-9 μm, the combined effect of temperature rise and corrosion resistance of the male end pin 101 and the female end slot 102 is better. Therefore, in order to further improve the safety, reliability and practicality of the product itself, the thickness of the underlying plating layer is preferably 0.1 μm-9 μm.

[0123] To demonstrate the impact of changes in surface plating thickness on the overall performance of the male pin 101 and female socket 102, the inventors conducted a series of temperature rise and corrosion resistance time tests on male pins 101 and female sockets 102 samples with the same specifications and materials, the same nickel-plated base thickness, and different silver-plated surface thicknesses. The experimental results are shown in Table 3 below.

[0124] The experimental method is the same as the above experimental method.

[0125] Table 3: Effect of different surface coating thicknesses on temperature rise and corrosion resistance

[0126]

[0127] As shown in Table 3, when the surface silver plating thickness is less than 0.5 μm, the temperature rise of the male pin 101 and the female socket 102 meets the requirements. However, due to the thin coating, the corrosion resistance cycle count of the male pin 101 and the female socket 102 is less than 80, which does not meet the performance requirements for the male pin 101 and the female socket 102. This has a significant impact on the overall performance and lifespan of the male pin 101 and the female socket 102, and in severe cases, can lead to a drastic reduction in product lifespan or even failure and combustion. When the surface silver plating thickness exceeds 55 μm, the thicker surface coating prevents heat from being dissipated, resulting in unqualified temperature rise. Furthermore, the thicker coating is more likely to peel off the surface of the male pin 101 and the female socket 102, resulting in a decrease in the corrosion resistance cycle count. Furthermore, since the surface plating metal is relatively expensive, using a thicker plating layer does not improve performance and has no practical value. Therefore, the inventors selected a surface silver plating layer thickness of 0.1 μm-55 μm.

[0128] Preferably, the inventors found that when the thickness of the surface coating is 1 μm-35 μm, the combined effect of temperature rise and corrosion resistance of the male end pin 101 and the female end slot 102 is better. Therefore, in order to further improve the safety, reliability and practicality of the product itself, the surface coating thickness is preferably 1 μm-35 μm.

[0129] In one embodiment, the conductor 111 and the input conductive connector 130 are electrically connected by crimping, welding, or integral molding, and the conductor 111 and the output conductive connector 140 are electrically connected by crimping, welding, or integral molding.

[0130] The crimping process involves assembling the input conductive connector 130 or the output conductive connector 140 with the conductor 111 and then using a crimping machine to press the two together. The advantage of crimping is its mass production capability. By using interlocking terminals and automatic crimping machines, it is possible to quickly and efficiently produce large quantities of products with consistent quality.

[0131] The welding method includes one or more of friction welding, ultrasonic welding, arc welding, laser welding and resistance welding.

[0132] Friction welding refers to a method of welding that uses the heat generated by friction between the contact surfaces of the workpieces as a heat source to cause the workpieces to undergo plastic deformation under pressure.

[0133] Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the two surfaces of the objects rub against each other to form a fusion between the molecular layers.

[0134] Arc welding refers to the use of electric arc as a heat source and the physical phenomenon of air discharge to convert electrical energy into the thermal energy and mechanical energy required for welding, thereby achieving the purpose of connecting metals. The main methods include arc welding, submerged arc welding, gas shielded welding, etc.

[0135] Laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source.

[0136] Resistance welding refers to a method of welding that uses a strong current to pass through the contact point between the electrode and the workpiece, generating heat due to the contact resistance.

[0137] The one-piece molding method refers to directly forming the input conductive connector 130 or the output conductive connector 140 on the conductor 111, eliminating the need for further connection processing between the input conductive connector 130 or the output conductive connector 140 and the conductor 111, thereby reducing processing steps and improving production efficiency.

[0138] like Figure 7 As shown, in one embodiment, the insulating portion 120 has a surface 121 to be spliced. By splicing the surfaces 121 to be spliced ​​of different wiring harness modules 100 , the insulating portions 120 of different wiring harness modules 100 are connected.

[0139] This embodiment not only connects the conductors 111 of different wiring harness modules 100 through the input conductive connector 130 and the output conductive connector 140, but also connects the insulating parts 120 of different wiring harness modules 100, thereby making the combined connection of the wiring harness modules more secure, making it difficult for the wiring harness modules to be disconnected, and improving the safety and reliability of the electrical connection.

[0140] like Figure 7 As shown, in the first specific embodiment, the insulating portion 120 has two end faces 104 arranged opposite to each other in the length direction of the wiring harness module 100, and the surface to be spliced ​​121 includes at least one end face 104, that is, the end face of the wiring harness module 100 is spliced ​​with the insulating portion of other wiring harness modules, such as the end faces of two wiring harness modules 100 are spliced, so that the wiring harness module 100 is spliced ​​end to end, so that the wiring harness can be extended to form a branch wiring harness of the combined wiring harness.

[0141] like Figure 12 As shown, in the second specific embodiment, the insulating portion 120 has a side circumferential surface 105 arranged along the circumference of the wiring harness module 100, and the surface to be spliced ​​121 includes at least a portion of the side circumferential surface 105, that is, the side of the wiring harness module 100 is spliced ​​with the insulating portion of other wiring harness modules, such as the side splicing of two wiring harness modules 100, to achieve side-by-side splicing of the wiring harness modules 100, thereby widening the wiring harness to form the main wiring harness of the combined wiring harness.

[0142] For example, Figure 1 、 Figure 2 、 Figure 3 As shown, the insulating portion 120 is in the shape of a quadrangular prism, the insulating portion 120 has four sides, and the surface to be joined 121 includes at least a portion of at least one of the sides, for example, including two, three or four sides. For another example, the insulating portion 120 is in the shape of a triangular prism, the insulating portion 120 has three sides, and the surface to be joined 121 includes at least a portion of at least one of the sides, for example, including two or three sides.

[0143] In this embodiment, the side surface 105 of the insulating portion 120 further includes a plane 106 (eg Figure 3 As shown), the surface to be joined 121 includes at least a portion of the plane 106, and / or the side surface 105 includes a curved surface 107 (as shown Figure 4 As shown in FIG, the surface to be joined 121 includes at least a portion of the curved surface 107 .

[0144] For example, when the insulating portion 120 is in the shape of a triangular prism or a quadrangular prism, its side surface 105 is a plane 106 (e.g. Figure 3 As shown), when the insulating portion 120 is cylindrical, its side surface 105 is a curved surface 107 (as shown Figure 4 shown).

[0145] The first specific embodiment and the second specific embodiment mentioned above can be implemented separately or in combination.

[0146] like Figures 19 to 23 As shown, in one embodiment, a splicing fixture 150 is provided at the surface to be spliced ​​121 of the insulating portion 120 or at the adjacent surface of the surface to be spliced ​​121, and the surfaces to be spliced ​​121 of different wiring harness modules 100 are relatively fixed by the connection between each other's splicing fixtures 150, that is, the insulating portions 120 of different wiring harness modules 100 are fixedly connected by the splicing fixtures 150 to prevent loosening during use.

[0147] In one embodiment, the splicing and fixing member 150 is an adhesive layer, a magnetic member, a plug-in member, a clamping member, a bolt structure, a rivet structure, a welding member, a binding member or a locking member.

[0148] In a first feasible technical solution, the splicing fixture 150 is an adhesive layer, which is provided on the surface to be spliced ​​121 , and the surfaces to be spliced ​​121 of different wiring harness modules 100 are fixedly connected by bonding.

[0149] In the second feasible technical solution, the splicing fixing part 150 is a magnetic part, which is arranged on the surface 121 to be spliced. The surfaces 121 to be spliced ​​of different wiring harness modules 100 are magnetically connected through the magnetic part. The connection is convenient and fast, and is mainly used in environments where the bonding force requirements for the wiring harness modules are not high.

[0150] In the third feasible technical solution, the splicing fixture 150 is a plug-in connector, such as Figures 22 to 23 As shown, a pin is provided on one surface 121 to be spliced, and a slot is provided on the other surface 121 to be spliced. The pin is inserted into the slot and fixed, thereby fixing the surfaces 121 to be spliced ​​of different wiring harness modules 100 to be spliced.

[0151] In a fourth feasible technical solution, the splicing fixture 150 is a clamping member, with a claw provided on one surface 121 to be spliced ​​and a slot provided on the other surface 121 to be spliced. The claw and the slot are assembled and fixed, thereby fixing the surfaces 121 to be spliced ​​of different wiring harness modules 100 to be spliced.

[0152] In a fifth feasible technical solution, the splicing fixture 150 is a bolt structure comprising a bolt and a nut. The bolt is fixed to one surface 121 to be spliced, and the nut is rotatably disposed on the other surface 121 to be spliced. Alternatively, the nut is fixed to one surface 121 to be spliced, and the bolt is rotatably disposed on the other surface 121 to be spliced. After the bolt and nut are threadedly engaged and tightened, the surfaces 121 to be spliced ​​of different wiring harness modules 100 are fixedly connected. The minimum bolt and nut size of the bolt structure is M3, and the minimum torque when tightening the bolt structure is 0.2 Nm.

[0153] In the sixth feasible technical solution, the splicing fixing part 150 is a rivet structure, including a rivet and a fixing hole. The fixing hole is set on the two surfaces to be spliced ​​121. The rivet passes through the fixing hole, and the rivet is deformed through one end to tighten the fixing hole, so that the surfaces to be spliced ​​121 of different wiring harness modules 100 are fixedly connected.

[0154] In a seventh feasible technical solution, the splicing fixture 150 is a welding fixture, which is disposed on the two surfaces to be spliced ​​121. A welding machine is used to melt and connect the welding fixture together, thereby fixing the surfaces to be spliced ​​121 of different wiring harness modules 100. The welding machine includes a hot melt welding machine and an ultrasonic welding machine.

[0155] In the eighth feasible technical solution, the splicing fixture 150 is a binding member, and a groove is provided on the surface to be spliced ​​121. The binding member is used to bind the surface to be spliced ​​121 together at the groove position, so that the surface to be spliced ​​121 of different wiring harness modules 100 are fixedly connected. The binding member includes a cable tie, a pipe clamp, a hook lock, etc. Figure 6As shown, this solution is suitable for use when the wiring harness modules 100 are spliced ​​side by side.

[0156] In a ninth feasible technical solution, the splicing fixing member 150 is a locking member, which is provided at the adjacent surface of the surface to be spliced ​​121 (such as Figures 19 to 21 As shown), or provided on the surface to be spliced ​​121 (as shown Figures 22 to 23 As shown), the surfaces 121 to be spliced ​​of different wiring harness modules 100 are fastened together by means of locking fasteners.

[0157] In one embodiment, the separation force applied to separate the surfaces to be spliced ​​121 after splicing is at least 0.5N. In different usage environments and for different wiring harness modules 100, the requirements for the bonding force between the wiring harness modules 100 are different. In order to ensure that different wiring harness modules 100 will not be separated unnecessarily due to misoperation or vibration, the inventor sets the separation force applied to separate the surfaces to be spliced ​​121 after splicing to be at least 0.5N.

[0158] like Figure 7 、 Figure 12 As shown, in one embodiment, the input conductive connector 130 and the output conductive connector 140 are arranged at the surface to be spliced ​​121, that is, the conductor connection points and the insulation part connection points of different wiring harness modules 100 are located in the same area, which further improves the reliability of the electrical connection and makes the splicing operation of the wiring harness module faster.

[0159] For example, when the input conductive connector 130 and the output conductive connector 140 are respectively the male end pin 101 and the female end slot 102, the male end pin 101 and the female end slot 102 are both arranged on the surface to be spliced ​​121. When splicing two wiring harness modules 100, when the male end pin 101 and the female end slot 102 of the two wiring harness modules 100 are plugged in, the surfaces to be spliced ​​121 of the two wiring harness modules 100 are also contacted and fixed, which makes the operation very simple and convenient, thereby improving the assembly efficiency.

[0160] In one embodiment, the wiring harness module has a length direction, and the insulating portion 120 has two end surfaces 104 (eg, Figure 5 ) and the side circumferential surface 105 (as shown) provided along the circumference of the wiring harness module 100 Figure 12 at least one input conductive connector 130 is provided at an end surface 104 or a side surface 105, and at least one output conductive connector 140 is provided at an end surface 104 or a side surface 105.

[0161] For example, an input conductive connector 130 and an output conductive connector 140 are provided on the side surface 105 of the insulating part 120, or an input conductive connector 130 is provided on the side surface 105 of the insulating part 120 and an output conductive connector 140 is provided on one end surface of the insulating part 120, or an input conductive connector 130 and an output conductive connector 140 are provided on both end surfaces of the insulating part 120, so as to realize a variety of different wiring harness module splicing methods.

[0162] In one embodiment, the insulating portion 120 is made of a flexible material to provide the wiring harness with flexibility. For example, the insulating portion 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.

[0163] In one embodiment, the insulating portion 120 is formed by one or more processes selected from the group consisting of extrusion, injection molding, spraying, dipping, slush molding, electrophoresis, braiding, and winding, and wraps around the conductor portion 110 .

[0164] In one embodiment, the conductor 111 is a solid wire, a multi-core twisted wire, a conductive foil, or a flat cable. When the wiring harness module 100 is simple in shape and conducts a large current, the conductor 111 can use a solid wire, which is not easy to deform, but has a large conduction area and can conduct a larger current. When the wiring harness module 100 is complex in shape, or often needs to be bent, the conductor 111 can use a multi-core twisted wire, which is soft and can be wound and not easy to break. When the installation space of the wiring harness module 100 is small, or when it is installed in a narrow environment, the conductor 111 can use a conductive foil or a flat cable, which can reduce the height of the wiring harness module 100 as much as possible, facilitate installation, and also facilitate heat dissipation of the conductor 111.

[0165] In one embodiment, the material of the conductor 111 is one or more of metal, conductive ceramic, carbon-containing conductor, solid electrolyte, mixed conductor, and conductive polymer material.

[0166] In one embodiment, the conductor 111 is made of one or more of 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 its alloys, titanium or its alloys, zinc or its alloys, copper or its alloys, silver or its alloys, and gold or its alloys. Preferably, the conductor 111 is made of copper or its alloys, or aluminum or its alloys. Copper conductors have excellent electrical conductivity and ductility, making them a preferred material for cable conductors. However, with rising copper prices, the cost of using copper as conductor material is increasing. Therefore, researchers are seeking alternatives to copper to reduce costs. Aluminum accounts for approximately 7.73% of the Earth's crust. With optimized extraction technology, its price is relatively low. Furthermore, aluminum is lighter than copper and has a conductivity second only to copper. Therefore, aluminum can partially replace copper in electrical connections. Therefore, replacing copper with aluminum is a growing trend in automotive electrical connections.

[0167] In other embodiments, other non-metallic materials may also be used as the conductor 111 , such as graphene among carbon-containing conductors, which is also an excellent conductor material.

[0168] like Figure 18 As shown, in one embodiment, a harness fixing member 160 is provided on the outer wall of the insulating portion 120 for fixing to a base supporting the harness. For example, the harness module 100 is fixed to an installation location such as a sheet metal part of an automobile via the harness fixing member 160. For example, the harness fixing member 160 is fixed to the installation location by a snap connection, a screw connection, or a plug-in connection.

[0169] In one embodiment, the cross-sectional shape of the wiring harness module 100 is circular, elliptical, rectangular, polygonal, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, semi-arc-shaped, arc-shaped, or wavy. In the longitudinal direction of the wiring harness module 100, it can extend in a straight line or along a curved line. The cross-sectional shape of the wiring harness module 100 is designed in various shapes to facilitate designers to select different cross-sectional shapes of the wiring harness module 100 according to the actual layout environment, thereby reducing the volume of the wiring harness module 100, optimizing the environment in which the wiring harness module 100 is assembled, and improving the safety of the wiring harness module 100.

[0170] In one embodiment, a shielding layer, such as a braided silk layer or a foil-wrapped layer, is provided around or inside the insulating portion 120 of the wiring harness module 100. The shielding layer can reduce electromagnetic interference from the wiring harness module itself or from the outside, ensuring signal stability and improving the stability of the wiring harness module 100.

[0171] Implementation Method 2

[0172] like Figure 2 、 Figure 3 、 Figure 5、 Figure 12 As shown, the present invention also provides a combined wiring harness, which is composed of multiple wiring harness modules 100 of Embodiment 1 spliced ​​together according to a predetermined splicing method. The conductors 111 of the multiple wiring harness modules 100 are electrically connected via input conductive connectors 130 and output conductive connectors 140. The structures of the multiple wiring harness modules 100 can be the same or different. The other structures and beneficial effects of this embodiment are the same as those of Embodiment 1 and are not further described here.

[0173] The combined wiring harness of the present invention is formed by splicing wiring harness modules 100, and is easy to assemble and disassemble. During maintenance, only the damaged wiring harness module needs to be disassembled, and there is no need to replace the entire wiring harness or the entire group of wiring harnesses, thereby reducing production and maintenance costs.

[0174] The combined wiring harness of the present invention is modularly produced and individually assembled, thereby improving production efficiency and the qualification rate.

[0175] In one embodiment, the preset splicing method includes at least one of a transverse splicing method and a longitudinal splicing method. The longitudinal splicing method is splicing along a longitudinal direction parallel to the length direction of the wiring harness module 100, and the transverse splicing method is splicing along a transverse direction perpendicular to the length direction of the wiring harness module 100.

[0176] In one embodiment, the preset splicing method includes a transverse splicing method and a longitudinal splicing method. The transverse splicing method is used to form a trunk harness segment of the combined wiring harness, and the longitudinal splicing method is used to form a branch harness segment of the combined wiring harness.

[0177] like Figure 24 As shown, in one embodiment, the wiring harness module located at the outermost end of the combined wiring harness is connected to the plug-in sheath module 200 so as to be plugged into the connector 300 of the electrical device through the plug-in sheath module 200. Specifically, the plug-in sheath module includes a male sheath 201 and a female sheath 202. For example, the male sheath 201 is sleeved on the outside of the wiring harness module 100, and the female sheath 202 is sleeved on the outside of the connector 300 of the electrical device. When the female end slot 102 of the wiring harness module 100 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 into, thereby realizing the electrical connection between the combined wiring harness and the electrical device.

[0178] Compared with the prior art, the combined wiring harness of the present invention has at least the following advantages:

[0179] 1. The combined wiring harness is made up of wiring harness modules. The wiring harness modules can be produced in batches and automatically, with high production efficiency and high pass rate;

[0180] 2. When installing a wiring harness, many functional parts usually need to be installed in advance, which hinders the installation of the subsequent wiring harness, wastes labor costs, and complicates the assembly process. However, when assembling the combined wiring harness of the present invention, the wiring harness modules can be installed step by step, bypassing the pre-installed functional parts, making the installation and assembly of the wiring harness and functional parts simple and convenient, saving workshop assembly man-hours and improving production efficiency.

[0181] 3. When the wiring harness assembly is damaged, the damaged wiring harness module can be directly replaced without replacing the entire wiring harness, which saves maintenance time and reduces maintenance costs;

[0182] 4. When there are many wiring harness loops, wiring harness modules can be added in the radial direction of the wiring harness to increase the wiring harness loops, and they can be combined in a variety of ways to save costs and installation time;

[0183] 5. The wiring harness module can be designed and produced according to the shape of the installation position and assembly position. During the final assembly, it can be directly installed in conjunction with the installation position and assembly position, saving installation time and reducing the number of fixings used during installation;

[0184] 6. The wiring harness module can use flexible conductors and insulators. When there is displacement deformation at the wiring harness installation position, the flexible wiring harness module can be used to greatly reduce the damage to the wiring harness caused by displacement deformation at the installation position and improve the safety of the wiring harness;

[0185] 7. By using the assembled wiring harness module, the wiring harness modules in different physical areas can be replaced according to the wiring harness configuration, while the wiring harness modules in other physical installation areas do not need to be replaced because the circuits are the same. This solves the current situation where the same wiring harness assembly with different functional configurations needs to be remanufactured as a whole, saves a lot of production resources, and lays the foundation for the hardwareization of the wiring harness.

[0186] The above description is only an illustrative embodiment of the present invention and is not intended to limit the scope of the present invention. Any equivalent changes and modifications made by any person skilled in the art without departing from the concept and principle of the present invention should fall within the scope of protection of the present invention. It should also be noted that the various components of the present invention are not limited to the above-mentioned overall application. The various technical features described in the specification of the present invention can be selected for use alone or in combination according to actual needs. Therefore, the present invention naturally covers other combinations and specific applications related to the invention point of this case.

Claims

1. A wiring harness module (100), characterized in that: The wiring harness module comprises a conductor portion (110) and an insulating portion (120) enclosing the conductor portion (110); the conductor portion (110) comprises a plurality of mutually insulated conductors (111); each conductor (111) is connected to at least one input conductive connector (130) and at least one output conductive connector (140); and by connecting the input conductive connectors (130) and the output conductive connectors (140) of different wiring harness modules (100), the conductors (111) of different wiring harness modules (100) are electrically connected; Each of the conductors (111) has a plurality of input contacts, and the plurality of input contacts are respectively arranged on different branches of the conductor (111), and the plurality of input contacts are respectively connected to an input conductive connector (130), and the plurality of input conductive connectors (130) connected to each of the conductors (111) are respectively electrically connected to a plurality of other conductors to achieve connection of a parallel circuit; or / and each of the conductors (111) has a plurality of output contacts, and the plurality of output contacts are respectively arranged on different branches of the conductor (111), and the plurality of output contacts are respectively connected to an output conductive connector (140), and the plurality of output conductive connectors (140) connected to each of the conductors (111) are respectively electrically connected to a plurality of other conductors to achieve connection of a parallel circuit.

2. The wiring harness module according to claim 1, wherein: The conductor portion (110) comprises a connecting section (112), and at least two conductors (111) are electrically connected via the connecting section (112).

3. The wiring harness module according to claim 1, wherein: At least one of the input conductive connector (130) and the output conductive connector (140) protrudes from the insulating portion (120).

4. The wiring harness module according to claim 3, wherein: The input conductive connector (130) and the output conductive connector (140) are both docking connectors (103) protruding from the insulating portion (120), and the electrical connection of the conductors (111) of different wiring harness modules (100) is achieved by overlapping and fixing the docking connectors (103) of different wiring harness modules (100).

5. The wiring harness module according to claim 1, wherein: One of the input conductive connector (130) and the output conductive connector (140) is a male end plug (101) protruding from the insulating portion (120), and the other is a female end slot (102) recessed in the insulating portion (120). By plugging the male end plug (101) and the female end slot (102) of different wiring harness modules, the electrical connection of the conductors (111) of different wiring harness modules (100) is achieved.

6. The wiring harness module according to claim 5, wherein: The male end plug (101) and / or the female end slot (102) are at least partially plated.

7. The wiring harness module according to claim 6, wherein: The plating 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.

8. The wiring harness module according to claim 6, wherein: The plating layer includes a bottom layer and a surface layer.

9. The wiring harness module according to claim 8, wherein: The bottom layer material is one or more of gold, silver, nickel, tin, tin-lead alloy, and zinc; The surface layer material is one or more of gold, silver, nickel, tin, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver, and silver-gold-zirconium alloy.

10. The wiring harness module according to claim 8, wherein The thickness of the bottom layer is 0.01 μm-15 μm.

11. The wiring harness module according to claim 8, wherein The thickness of the bottom layer is 0.1 μm-9 μm.

12. The wiring harness module according to claim 8, wherein The thickness of the surface layer is 0.5 μm-55 μm.

13. The wiring harness module according to claim 8, wherein The surface layer has a thickness of 1 μm to 35 μm.

14. The wiring harness module according to any one of claims 1 to 5, characterized in that: The conductor (111) and the input conductive connector (130) are electrically connected by means of crimping, welding or integral molding, and the conductor (111) and the output conductive connector (140) are electrically connected by means of crimping, welding or integral molding.

15. The wiring harness module according to claim 1, wherein: The insulating portion (120) has a surface (121) to be spliced, and the insulating portions (120) of different wiring harness modules (100) are connected by splicing the surfaces (121) to be spliced ​​of different wiring harness modules (100).

16. The wiring harness module according to claim 15, wherein: The insulating portion (120) has two end surfaces (104) arranged opposite to each other in the length direction of the wiring harness module (100), and the surface to be spliced ​​(121) includes at least one of the end surfaces (104).

17. The wiring harness module according to claim 15, wherein: The insulating portion (120) has a side circumferential surface (105) arranged along the circumference of the wiring harness module (100), and the surface to be spliced ​​(121) includes at least a partial area of ​​the side circumferential surface (105).

18. The wiring harness module according to claim 17, wherein: The side surface (105) includes a plane (106), and the surface to be joined (121) includes at least a partial area of ​​the plane (106), and / or the side surface (105) includes a curved surface (107), and the surface to be joined (121) includes at least a partial area of ​​the curved surface (107).

19. The wiring harness module according to claim 15, wherein: A splicing fixture (150) is provided at the surface to be spliced ​​(121) or at a surface adjacent to the surface to be spliced ​​(121), and the surfaces to be spliced ​​(121) of different wiring harness modules (100) are relatively fixed by connection between the splicing fixtures (150).

20. The wiring harness module according to claim 19, wherein: The splicing fixing part (150) is an adhesive layer, a magnetic part, a plug-in part, a clamping part, a bolt structure, a rivet structure, a welding part, a binding part or a locking part.

21. The wiring harness module according to claim 15, wherein: The separation force applied when the spliced ​​surfaces (121) are separated is at least 0.5N.

22. The wiring harness module according to any one of claims 15 to 21, characterized in that: The input conductive joint (130) and the output conductive joint (140) are provided at the surface to be spliced ​​(121).

23. The wiring harness module according to any one of claims 1 to 5, characterized in that: The wiring harness module has a length direction, and the insulating portion (120) has two end surfaces (104) arranged opposite to each other in the length direction of the wiring harness module (100) and a side circumferential surface (105) arranged along the circumference of the wiring harness module (100); At least one of the input conductive connectors (130) is provided at one of the end surfaces (104) or the side circumferential surface (105), and at least one of the output conductive connectors (140) is provided at one of the end surfaces (104) or the side circumferential surface (105).

24. The wiring harness module according to any one of claims 1 to 5, characterized in that: The insulating part (120) is made of a flexible material.

25. The wiring harness module according to any one of claims 1 to 5, characterized in that: The conductor (111) is a solid wire, a multi-core twisted wire, a conductive foil or a flat cable.

26. The wiring harness module according to any one of claims 1 to 5, characterized in that: A wire harness fixing piece (160) for fixedly connecting to a base supporting the wire harness is provided on the outer wall of the insulating portion (120).

27. The wiring harness module according to any one of claims 1 to 5, characterized in that: The cross-sectional shape of the wiring harness module (100) is circular, elliptical, rectangular, polygonal, E-shaped, F-shaped, H-shaped, K-shaped, L-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, semi-arc-shaped, arc-shaped, or wavy.

28. The wiring harness module according to any one of claims 1 to 5, characterized in that: The material of the conductor (111) is a combination of one or more of metal, conductive ceramic, carbon-containing conductor, solid electrolyte, mixed conductor, and conductive polymer material.

29. The wiring harness module according to claim 28, wherein: The conductor (111) is made of copper or copper alloy or aluminum or aluminum alloy.

30. The wiring harness module according to any one of claims 1 to 5, characterized in that: A shielding layer is provided on the periphery or inside of the insulating part (120).

31. A combined wiring harness, characterized in that: The combined wiring harness is formed by splicing a plurality of wiring harness modules (100) according to any one of claims 1 to 19 in a preset splicing manner, and the conductors (111) of the plurality of wiring harness modules (100) are electrically connected via the input conductive connector (130) and the output conductive connector (140).

32. The combined wiring harness according to claim 31, wherein: The preset splicing method includes at least one of a transverse splicing method and a longitudinal splicing method, wherein the longitudinal splicing method is splicing along a longitudinal direction parallel to the length direction of the wiring harness module (100), and the transverse splicing method is splicing along a transverse direction perpendicular to the length direction of the wiring harness module (100).

33. The combined wiring harness according to claim 32, wherein: The preset splicing method includes the transverse splicing method and the longitudinal splicing method. The transverse splicing method is used to form the main wiring harness segment of the combined wiring harness, and the longitudinal splicing method is used to form the branch wiring harness segment of the combined wiring harness.

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