A wiring harness and a manufacturing method thereof

Abstract

This invention discloses a wire harness and its manufacturing method. The wire harness includes a wire harness, a connector, a fixing part, a housing, and a waterproof part. The wire harness has multiple wires, one end of which is connected to the connector. Each wire has a conductor and an insulating coating covering the outer periphery of the conductor. The fixing part has a first through hole and is fitted onto one end of the wire harness near the connector through the first through hole. The housing has multiple grooves of different shapes and a second through hole. Part of the wire harness and part of the fixing part are disposed within the grooves of the housing, and the connector is disposed within the second through hole. The waterproof part has multiple protrusions of different shapes, which are used to seal the gaps between the connector, part of the wire harness, and part of the fixing part and the housing. By providing protrusions of different shapes on the waterproof part, the protrusions can seal the gaps between the connector, part of the wire harness, and part of the fixing part and the housing, thereby improving the waterproof effect of the wire harness.

Description

Technical Field

[0001] This invention relates to the field of wire harness technology, and more particularly to a wire harness and its manufacturing method. Background Technology

[0002] With the development of electrification, wire harnesses are very common electronic components in both industrial and civilian fields. Numerous wire harnesses are needed for connections between and within devices, serving as power and signal connections. Wire harnesses have connectors at one or both ends. When wire harnesses operate in high-humidity environments, the waterproof performance of these connectors becomes particularly important. Poor waterproofing at the connectors can easily lead to short circuits due to moisture ingress, causing serious safety hazards.

[0003] Existing wire harness structures are relatively simple, mostly using rubber sleeves for sealing and waterproofing. This not only provides poor waterproofing but also leads to water ingress at the connections due to wear and tear on the rubber sleeves over long-term use. Therefore, there is an urgent market need to develop a wire harness with better waterproofing performance to help solve these problems. Summary of the Invention

[0004] The purpose of this invention is to provide a wire harness in which the protrusions on the waterproof part can seal the gaps between the connector, part of the wire harness and part of the fixing part and the outer shell, thereby improving the waterproof effect of the wire harness.

[0005] The purpose of this invention is to provide a method for manufacturing a wire harness, in which a waterproof part is disposed on the outer shell by injection molding, and the waterproof part is more tightly bonded to the outer shell, which not only makes the wire harness more robust and durable, but also improves the sealing effect of the wire harness, thereby improving the waterproof effect of the wire harness.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] A wire harness, comprising:

[0008] A wire harness having multiple wires, each wire having a conductor and an insulating covering layer around the conductor;

[0009] A connector, wherein one end of the wire is connected to the connector;

[0010] A fixing part having a first through hole, the fixing part being sleeved on one end of the wire harness near the connector part through the first through hole;

[0011] The housing has multiple grooves of different shapes and a second through hole. Part of the wire harness and part of the fixing part are disposed in the grooves of the housing, and the connector part is disposed in the second through hole.

[0012] The waterproof part has multiple protrusions of different shapes, which are used to seal the gaps between the connector, part of the wire harness and part of the fixing part and the housing.

[0013] Preferably, the outer shell is provided with one or more recesses, and the waterproof part is provided with one or more protrusions, the protrusions being inserted into the recesses.

[0014] Preferably, the outer shell is provided with a slot, and the fixing part is provided with a corresponding step, with part of the step engaging in the slot.

[0015] Preferably, the fixing part is further provided with a positioning post, and the waterproof part is provided with a corresponding third through hole, and the positioning post is sleeved in the third through hole.

[0016] Preferably, a snap-fit ​​structure is provided on each side of the outer shell. The snap-fit ​​structure has a snap-fit ​​surface, a first protrusion and a second protrusion, and the first protrusion and the second protrusion are disposed on the snap-fit ​​surface.

[0017] Preferably, the snap-fit ​​structure is an elastic component.

[0018] Preferably, each of the wires has one or more of the conductors;

[0019] The number of the connectors is one or more.

[0020] Preferably, the wire harness further includes a protective shell for covering the wires.

[0021] A method for manufacturing a wire harness, comprising:

[0022] Step S1: The connector and the fixing part are installed on the wire harness to form a semi-finished product;

[0023] Step S2: Install the semi-finished product processed in step S1 onto the outer shell and form a gap;

[0024] Step S3: Fill the gaps treated in step S2 by injection molding to form a waterproof part.

[0025] Preferably, the fixing part is further provided with a positioning post, the outer shell is provided with a slot, and the fixing part is provided with a corresponding step. In step S3, during the injection molding process, the mold abuts against the positioning post on the fixing part to restrict the movement of the fixing part, and part of the step is engaged in the slot to restrict the movement of the fixing part.

[0026] Compared with the prior art, the beneficial effects of the present invention include at least the following:

[0027] The wire harness of the present invention improves the waterproof effect by providing protrusions of different shapes on the waterproof part. The protrusions can seal the gaps between the connector part, part of the wire harness and part of the fixing part and the outer shell.

[0028] The manufacturing method of the wire harness of the present invention uses injection molding to set the waterproof part onto the outer shell, so that the waterproof part is more tightly bonded to the outer shell, resulting in a better sealing effect of the wire harness and thus improving the waterproof effect of the wire harness. The injection molding method also makes the waterproof part more robust and durable. When the wire harness is subjected to external pressure or impact, it can prevent the wire harness from leaking water and causing a short circuit, thereby avoiding serious safety hazards. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the wire harness structure according to an embodiment of the present invention.

[0030] Figure 2 This is an exploded view of the wire harness according to an embodiment of the present invention.

[0031] Figure 3 This is a schematic diagram of the wire harness, connector, and fixing part of the wire harness according to an embodiment of the present invention.

[0032] Figure 4 This is a schematic diagram of the outer shell of the wire harness according to an embodiment of the present invention.

[0033] Figure 5 This is a schematic diagram of the waterproof part of the wire harness according to an embodiment of the present invention.

[0034] Figure 6 This is a flowchart of a wire harness manufacturing method according to an embodiment of the present invention.

[0035] In the diagram: 10. Wire harness; 11. Wire; 111. Conductor; 112. Insulation layer; 12. Protective shell; 20. Connector; 30. Fixing part; 31. First through hole; 32. Step; 33. Positioning post; 40. Outer shell; 41. Groove; 42. Second through hole; 43. Recess; 44. Slot; 45. Snap-on structure; 451. Snap-on surface; 452. First protrusion; 453. Second protrusion; 50. Waterproof part; 51. Protrusion; 52. Protruding post; 53. Third through hole; 54. Fourth through hole. Detailed Implementation

[0036] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein; rather, they are provided to make the invention more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art. The same reference numerals in the drawings denote the same or similar structures, and therefore repeated descriptions of them will be omitted.

[0037] The terms used to express position and direction in this invention are illustrated with reference to the accompanying drawings, but changes can be made as needed, and all such changes are included within the scope of protection of this invention.

[0038] Reference Figures 1 to 5 The wire harness of the present invention includes: a wire harness 10, a connector 20, a fixing part 30, a housing 40, and a waterproof part 50. The connector 20 and the fixing part 30 are disposed on the wire harness 10. The connector 20, a portion of the wire harness 10, and a portion of the fixing part 30 are disposed inside the housing 40. The waterproof part 50 is disposed on the housing 40 to seal the gap between the connector 20, a portion of the wire harness 10, and a portion of the fixing part 30 and the housing 40.

[0039] Specifically, the wire harness 10 has multiple wires 11, each wire 11 having a conductor 111 and an insulating covering layer 112 enclosing the conductor 111. The conductors 111 at both ends of the wire 11 can be partially exposed outside the insulating covering layer 112 to facilitate electrical connection between the wire 11 and other components. Each wire 11 includes one or more conductors 111. In this embodiment, each wire 11 has one conductor 111, which can be a metal such as copper, aluminum, tin, silver, or gold. The insulating covering layer 112 can be made of plastic, rubber, paper, or other insulating materials. The wire harness 10 also includes a protective shell 12, which can bind the multiple wires 10 together to prevent the multiple wires 11 from scattering. The protective shell 12 can be made of insulating material or metal. In this embodiment, the protective shell 12 is made of wear-resistant plastic and is used to cover the wires 11.

[0040] One end of the wire 11 is connected to the connector 20, and there can be one or more connectors 20. Electrical connection between the wire 11 and the connector 20 can be achieved by welding, pressing, snapping, or other methods. The connector 20 is preferably made of metal, such as copper, aluminum, tin, silver, or gold. The connector 20 can be various types of terminals, and no special limitation is made here. In this embodiment, the connector 20 is a hollow cylindrical terminal with a through hole, through which the wire 11 is snapped onto the connector 20.

[0041] The fixing part 30 has a first through hole 31. The fixing part 30 is sleeved on one end of the wire harness 10 near the connector part 20 through the first through hole 31. The first through hole 31 and the wire harness 10 are preferably tightly fitted, which can reduce the gap between the fixing part 30 and the wire harness 10. On the one hand, it can prevent relative shaking between the fixing part 30 and the wire harness 10, and on the other hand, it can provide better sealing between the fixing part 30 and the wire harness 10. The fixing part 30 can be made of metal, plastic or other materials. In this embodiment, the fixing part 30 is made of metal. The fixing part 30 made of metal is stronger and prevents the fixing part 30 from deforming under external force.

[0042] The outer casing 40 has multiple grooves 41 of different shapes and a second through hole 42. A portion of the wire harness 10 and a portion of the fixing part 30 are disposed within the grooves 41 of the outer casing 40, and a connector 20 is disposed within the second through hole 42. The space of the grooves 41 of the outer casing 40 is larger than the volume of the portion of the wire harness 10 and the portion of the fixing part 30, and the space of the second through hole 42 of the outer casing 40 is larger than the volume of the connector 20. Gaps exist between the connector 20, the portion of the wire harness 10, the portion of the fixing part 30, and the outer casing 40. The outer casing 40 can be made of plastic or other materials. In this embodiment, the outer casing 40 is made of plastic. A plastic outer casing 40 is not only easier to manufacture, but also allows for stronger adhesion between the outer casing 40 and the waterproof part 50.

[0043] The waterproof portion 50 has multiple protrusions 51 of different shapes, which are used to seal the gaps between the connector portion 20, part of the wire harness 10, part of the fixing portion 30, and the housing 40. Preferably, the protrusions 51 on the waterproof portion 50 match the gaps on the housing 40. The waterproof portion 50 can be connected to the housing 40 with sealant to achieve a seal between the waterproof portion 50 and the housing 40, or it can be injection molded onto the housing 40. In this embodiment, the waterproof portion 50 is preferably made of a fusible plastic material, and injection molding the waterproof portion 50 onto the housing 40 allows for a tighter connection between the waterproof portion 50 and the housing 40, more thorough filling of gaps, and thus improved waterproof performance of the wire harness.

[0044] In one specific embodiment, the outer casing 40 is provided with one or more recesses 43. The recesses 43 are preferably evenly distributed on the outer casing 40. The shape of the recesses 43 can be cylindrical, cuboid, or other irregular shapes. The waterproof part 50 is provided with one or more corresponding protrusions 52, the shape of which matches the shape of the recesses 43. When the waterproof part 50 is connected to the outer casing 40, the protrusions 52 are inserted into the recesses 43. This improves the adhesion between the waterproof part 50 and the outer casing 40, preventing the wiring harness from losing its sealing performance when subjected to external impact. The recesses 43 are preferably shaped with an inward-opening structure from the inside out. When the protrusions 52 are placed in the recesses 43, they are less likely to fall out, thereby increasing the adhesion between the waterproof part 50 and the outer casing 40.

[0045] In one specific embodiment, the outer shell 40 is provided with a slot 44, and the fixing part 30 is provided with a corresponding step 32. Part of the step 32 is engaged in the slot 44 to restrict the movement of the fixing part 30, so as to prevent the fixing part 30 from swaying back and forth or left and right relative to the outer shell 40 during the production process, which facilitates production, improves production efficiency, and also improves the yield of products.

[0046] As a preferred embodiment, the fixing part 30 is further provided with a positioning post 33. The positioning post 33 can be a cylinder, a cuboid, or other shapes. In this embodiment, the positioning post 33 is approximately cylindrical. A third through hole 53 is correspondingly provided on the waterproof part 50, and the positioning post 33 is fitted into the third through hole 53. This increases the contact area between the fixing part 30 and the waterproof part 50, thereby improving the adhesion between them. Furthermore, during the production process, especially during injection molding, the injection mold first abuts against the positioning post 33 to restrict the movement of the fixing part 30, preventing the fixing part 30 from wobbling relative to the outer shell 40 during production, thus improving production efficiency and further increasing the product yield. The fixing part 30 is also provided with a fourth through hole 54, and part of the fixing part 30 is inserted into the fourth through hole 54. The fixing part 30 and the fourth through hole 54 are matched, and a sealed connection is formed between the fixing part 30 and the fourth through hole 54.

[0047] In one specific embodiment, a snap-fit ​​structure 45 is provided on each of the two sides of the outer casing 40. The snap-fit ​​structure 45 has a snap-fit ​​surface 451, a first protrusion 452, and a second protrusion 453. The first protrusion 452 and the second protrusion 453 are disposed on the snap-fit ​​surface 451. The first protrusion 452 is approximately triangular prism-shaped, and the second protrusion 453 is approximately annular. When the wire harness is connected to other components, the snap-fit ​​structure 45 can tightly connect the wire harness to the other components. Preferably, the snap-fit ​​structure 45 is an elastic component, which can further improve the connection strength between the wire harness and other components, and also facilitate the separation of the wire harness from other components.

[0048] Reference Figure 6 The method for manufacturing a wire harness according to the present invention, used to manufacture a wire harness according to any one of the above, includes steps S1-S3.

[0049] Step S1: Set the connector 20 and the fixing part 30 on the wire harness 10 to form a semi-finished product.

[0050] Specifically, before step S1, multiple wires 11 are bundled together to form a wire bundle 10. One end of each wire 11 is connected to a connector 20, and the electrical connection between the wire 11 and the connector 20 can be achieved by welding, pressing, or other methods. A fixing part 30 can be directly formed on the wire bundle 10, or a pre-formed fixing part 30 can be fitted onto the wire bundle 10. Finally, the fixing part 30 is fitted onto one end of the wire bundle 10 near the connector 20, forming a semi-finished product.

[0051] Step S2: Install the semi-finished product processed in step S1 onto the outer casing 40 and form a gap.

[0052] Specifically, the semi-finished product processed in step S1 is installed onto the outer casing 40. Part of the wire harness 10 and part of the fixing part 30 are placed in the groove 41 of the outer casing 40, and the connector part 20 is placed in the second through hole 42. The space of the groove 41 of the outer casing 40 is larger than the volume of part of the wire harness 10 and part of the fixing part 30, and the space of the second through hole 42 of the outer casing 40 is larger than the volume of the connector part 20. Finally, there is a gap between part of the wire harness 10, part of the fixing part 30 and connector part 20 and the outer casing 40.

[0053] Step S3: Fill the gaps after step S2 by injection molding to form a waterproof part 50.

[0054] Specifically, the outer shell 40 after step S2 is placed into the mold. The raw material for making the waterproof part 50 is plastic material. The plastic material is molten by heating. The heating temperature can be adjusted according to the actual production situation. No special requirements are made again, as long as the plastic material can be molten. The molten plastic material is then injected onto the outer shell 40 and fills the gap after step S2. Finally, the molten plastic material is cooled to form the waterproof part 50.

[0055] As a preferred embodiment, the fixing part 30 is also provided with a positioning post 33, the outer shell 40 is provided with a slot 44, and the fixing part 30 is correspondingly provided with a step 32. In step S3, during the injection molding process, the mold abuts against the positioning post 33 on the fixing part 30 to restrict the fixing part 30 from moving in the vertical direction, and part of the step 32 is engaged in the slot 44 to restrict the fixing part 30 from moving in the front, back, left, and right directions. This can prevent the fixing part 30 from shaking during the injection molding process, thereby improving production efficiency and also improving the product yield.

[0056] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the invention without departing from the principles and spirit of the invention, and all such changes should fall within the protection scope of the claims of the present invention.

Claims

1. A wiring harness characterized by, The application relates to a wire harness, which comprises: a wire harness having a plurality of wires, each wire having a conductor and an insulating covering layer covering the outer periphery of the conductor; a joint part to which one end of the wire harness is connected; a fixing part having a first through hole, the fixing part being sleeved on one end of the wire harness close to the joint part through the first through hole; a shell having a plurality of recesses of different shapes and a second through hole, part of the wire harness and part of the fixing part being arranged in the recesses of the shell, and the joint part being arranged in the second through hole; a waterproof part arranged on the shell, the waterproof part having a plurality of protrusions of different shapes, the protrusions being used for sealing the gaps between the joint part, part of the wire harness and part of the fixing part and the shell; wherein one or more recesses are arranged on the shell, one or more corresponding protrusions are arranged on the waterproof part, the protrusions are inserted into the recesses, a clamping groove is arranged on the shell, part of the steps arranged on the fixing part are clamped in the clamping groove, a positioning column is further arranged on the fixing part, a third through hole is arranged on the waterproof part in correspondence with the positioning column, and the positioning column is sleeved in the third through hole.

2. The wire harness of claim 1, wherein, One clamping structure is arranged on each side of the shell, the clamping structure has a clamping surface, a first protrusion and a second protrusion, and the first protrusion and the second protrusion are arranged on the clamping surface.

3. The wire harness of claim 2, wherein, The clamping structure is an elastic part.

4. The wire harness of claim 1, wherein, Each wire has one or more conductors. The number of joint parts is one or more.

5. The wire harness of claim 1, wherein, The wire harness further comprises a protective shell for covering the wires.

6. A method of manufacturing a wire harness for manufacturing the wire harness according to any one of claims 1 to 5, characterized by, The application further relates to a manufacturing method of the wire harness, which comprises the following steps: S1: arranging the joint part and the fixing part on the wire harness to form a semi-finished product; S2: mounting the semi-finished product processed in step S1 on the shell to form a gap; S3: filling the gap processed in step S2 by injection molding to form a waterproof part.

7. The method of manufacturing a wire harness according to claim 6, wherein The fixing part further has a positioning column, the shell has a clamping groove, part of the steps arranged on the fixing part are clamped in the clamping groove, and in step S3, the mold abuts against the positioning column on the fixing part during the injection molding process to limit the movement of the fixing part.

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