Automobile high-voltage wire harness and method for manufacturing the same

Abstract

The present invention relates to the field of automotive high-voltage wire harnesses, and relates to an automotive high-voltage wire harness and a method for manufacturing the same. The automotive high-voltage wire harness of the present invention comprises a mother body and a connector. The mother body comprises a wire core layer, an insulating layer, a shielding layer, a sheath layer and an outer sheath arranged in sequence from the inside out. The wire core layer is composed of the following weight percentages: 60-75% copper, 20-30% aluminum, 0.5-2% tin, 0.5-2% nickel and 0.1-1% silicon. The insulating layer is composed of the following weight percentages: 50-70% nanocomposite polymer, 20-40% high-temperature cross-linked fluoroplastic and 10-20% modified polyimide. The shielding layer comprises an aluminum foil layer, a conductive solvent-cured layer and a silicon oxide dielectric layer arranged in sequence outward. The combination of the nanocomposite polymer, high-temperature cross-linked fluoroplastic and modified polyimide adopted in the insulating layer provides excellent electrical insulation performance. The aluminum foil layer, the conductive solvent-cured layer and the silicon oxide dielectric layer of the shielding layer provide good electromagnetic compatibility for the wire harness.

Description

Technical Field

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

[0002] With the development of new energy vehicle technology, high-voltage wiring harness systems are playing an increasingly important role in electric vehicles. High-voltage wiring harnesses are responsible for transmitting high voltage and high current to drive the vehicle's various electrical devices. While these systems play a crucial role in new energy vehicles, they also have some shortcomings and potential problems. The following are some of the main shortcomings of high-voltage wiring harnesses: High-voltage wiring harnesses carry high voltage and high current, easily generating electromagnetic radiation and electromagnetic interference, which can adversely affect the vehicle's electrical system, such as signal interference and equipment malfunction. To reduce electromagnetic radiation and interference, high-voltage wiring harnesses require effective shielding and grounding, which increases the complexity of design and production. Due to the high voltage, high-voltage wiring harnesses place extremely high demands on insulation performance, requiring a multi-layer composite structure to enhance insulation strength and withstand voltage rating. However, even with this, the insulation layer can still break down over time or under certain conditions (such as high temperature and humid environments), leading to safety hazards such as leakage or short circuits.

[0003] Therefore, in order to solve the deficiencies in the prior art, it is necessary to design a high-voltage wiring harness for automobiles with a simple structure and a method for manufacturing the high-voltage wiring harness. Summary of the Invention

[0004] In order to solve the problems of the prior art, the present invention provides an automobile high-voltage wire harness and a method for manufacturing the high-voltage wire harness.

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

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

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

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

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

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

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

[0012] S2: The annealed monofilaments are then twisted into a strand to form a core layer;

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

[0014] S4: Shielding layer manufacturing: An aluminum foil layer is fixed on the surface of the insulating layer, a conductive solvent is coated on the surface of the aluminum foil layer to form a conductive solvent solidified layer, a conductive dielectric is sprayed on the surface of the conductive solvent to form a silicon oxide dielectric layer, and the treated layer is placed in an oven for baking to fully solidify the conductive solvent solidified layer and the silicon oxide dielectric layer;

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

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

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

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

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

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

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

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

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

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

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

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

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

[0028] In the description of the present invention, it should be noted that, unless otherwise specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0029] Below with reference to the embodiment and the attached Figures 1-2 , further elaborating on the technical solution of the present invention.

[0030] Example 1

[0031] A high-voltage automotive wiring harness comprises a wiring harness body 1 and a connector 2. The wiring harness body 1 comprises, arranged in sequence from the inside out, a core layer 11, an insulating layer 12, a shielding layer 13, a sheath layer 14, and an outer sheath 15. The core layer 11 is composed of the following weight percentages: 60-75% copper, 20-30% aluminum, 0.5-2% tin, 0.5-2% nickel, and 0.1-1% silicon. The insulating layer 12 is composed of the following weight percentages: 50-70% nanocomposite polymer, 20-40% high-temperature cross-linked fluoroplastic, and 10-20% modified polyimide. The shielding layer 13 comprises an aluminum foil layer 131, a conductive solvent-cured layer 132, and a silicon oxide dielectric layer 133, arranged in sequence outward.

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

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

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

[0035] S2: The annealed monofilaments are then twisted into a strand to form a core layer 11;

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

[0037] S4: Manufacturing the shielding layer: An aluminum foil layer 131 is fixed on the surface of the insulating layer 12, a conductive solvent is coated on the surface of the aluminum foil layer 131 to form a conductive solvent solidified layer 132, a conductive dielectric is sprayed on the surface of the conductive solvent to form a silicon oxide dielectric layer 133, and the treated layer is placed in an oven for baking to fully solidify the conductive solvent solidified layer 132 and the silicon oxide dielectric layer 133;

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

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

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

[0041] Precise control of the melting and mixing processes ensures uniform alloy composition, resulting in consistent physical and electrical properties. Optimized wire drawing speeds and annealing treatments ensure consistent wire diameter, improving the mechanical properties and flexibility of the wiring harness. A layer-by-layer coating and baking process ensures the shielding layer is cured and adheres, enhancing the harness's anti-interference capabilities. Connectors utilize LV, USCAR, or Japanese standard connectors. LV standard connectors have the highest circulation in the domestic market and boast relatively complete process standards. They are suitable for a variety of electrical connection needs and offer excellent versatility. They are widely used in key components such as battery packs and motor controllers in new energy vehicles. USCAR standard connectors are internationally standardized connectors with high compatibility and reliability. Designed to meet the stringent requirements of the automotive industry, they ensure stable operation in harsh environments and are primarily used in new energy vehicles from international brands to meet global market demand. Japanese standard connectors are designed according to Japanese standards, emphasizing refinement and high performance. These connectors are compact and offer superior electrical performance.

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

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

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

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

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

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

[0048] As a further preferred embodiment, the thickness of the conductive solvent solidified layer 132 in step S4 is 0.01 mm to 0.05 mm. This thickness range provides good conductivity and shielding effect while maintaining the flexibility of the wiring harness. The thickness of the silicon monoxide dielectric layer 133 is 0.05 mm to 0.1 mm. This thickness range ensures that the dielectric layer can effectively protect the wires while not excessively increasing the outer diameter of the wiring harness. This improves the protective performance and shielding effect of the shielding layer.

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

[0050] The above describes in detail the preferred embodiments of the present invention. It should be understood that those skilled in the art can make numerous modifications and variations based on the concepts of the present invention without inventive effort. Therefore, any technical solutions that can be derived by those skilled in the art through logical analysis, reasoning, or limited experimentation based on the concepts of the present invention and the prior art should be within the scope of protection defined by the claims.

Claims

1. An automotive high-voltage wire harness, characterized in that: The invention comprises a wiring harness mother body and a connector. The wiring harness mother body comprises a wire core layer, an insulating layer, a shielding layer, a sheath layer and an outer sheath arranged in sequence from the inside to the outside. The wire core layer is composed of the following weight percentages: 60-75% copper, 20-30% aluminum, 0.5-2% tin, 0.5-2% nickel and 0.1-1% silicon. The insulating layer is composed of the following weight percentages: 50-70% nanocomposite polymer, 20-40% high-temperature cross-linked fluoroplastic and 10-20% modified polyimide. The shielding layer comprises an aluminum foil layer, a conductive solvent solidified layer and a silicon oxide dielectric layer arranged in sequence outward. The nanocomposite polymer is composed of a basic polymer matrix and a nanoscale filler, wherein the nanoscale filler is nanoclay, carbon nanotube or graphene. At least one of the above, and the amount of nano-scale filler added is 1-5% of the weight of the polymer matrix; the high-temperature cross-linked fluoroplastic is at least one of polytetrafluoroethylene or polyvinylidene fluoride and has been cross-linked; the jacket layer is composed of the following weight percentages: 40-60% thermoplastic elastomer, 20-40% cross-linked polyethylene and 10-30% chlorosulfonated polyethylene; the outer jacket is composed of the following weight percentages: 30-50% polyurethane, 20-40% polyvinyl chloride (PVC) and 10-30% polytetrafluoroethylene; the conductive solvent solidified layer is 20%-40% by mass, and the silicon oxide dielectric layer is 60%-80% by mass, and the conductive solvent solidified layer includes xylene, butanone and polyvinyl alcohol; The following manufacturing steps are also included: S1: Wire drawing: The raw materials copper, aluminum, tin, nickel and silicon are melted in a furnace and mixed evenly to form an alloy melt. The alloy melt is drawn into a single wire of the required diameter through a wire drawing machine, and then annealed; S2: The annealed monofilaments are then twisted into a strand to form a core layer; S3: Insulation treatment: Nanocomposite polymer, high-temperature cross-linked fluoroplastic and modified polyimide insulation materials are mixed and placed into an extruder. The extruder evenly coats the insulation material on the surface of the wire core layer, and after cooling and solidification, a solid insulation layer is formed; S4: Shielding layer manufacturing: An aluminum foil layer is fixed on the surface of the insulating layer, a conductive solvent is coated on the surface of the aluminum foil layer to form a conductive solvent solidified layer, a conductive dielectric is sprayed on the surface of the conductive solvent to form a silicon oxide dielectric layer, and the treated layer is placed in an oven for baking to fully solidify the conductive solvent solidified layer and the silicon oxide dielectric layer; S5: Sheath layer manufacturing: Thermoplastic elastomer, cross-linked polyethylene and chlorosulfonated polyethylene are mixed and placed into an extruder. The extruder evenly coats the insulating material on the surface of the insulation layer to form the sheath layer; S6: Outer sheath manufacturing: polyurethane, polyvinyl chloride (PVC) and polytetrafluoroethylene are mixed and placed into an extruder, and the extruder evenly coats the outer sheath on the surface of the sheath layer to make the outer sheath; S7: Connector installation: The connectors at both ends of the high-voltage wire harness are manufactured using precision machining and injection molding technology.

2. An automotive high-voltage wire harness according to claim 1, characterized in that: In the step S1, the melting temperature of the alloy melt is controlled at 1200° C. to 1400° C., the wire drawing speed is 10 m / s to 30 m / s, and the mixing time of the alloy melt in the step S1 is not less than 60 minutes.

3. An automotive high-voltage wire harness according to claim 1, characterized in that: In the step S3, the temperature of the extruder is controlled at 180° C. to 250° C., and the extrusion speed is 0.5 m / s to 1.5 m / s; in the step S4, the baking temperature is 120° C. to 180° C., and the baking time is 30 minutes to 60 minutes.

4. An automotive high-voltage wire harness according to claim 1, characterized in that: In the step S4, the thickness of the conductive solvent solidified layer is 0.01 mm to 0.05 mm, and the thickness of the silicon monoxide dielectric layer is 0.05 mm to 0.1 mm.

5. An automotive high-voltage wire harness according to claim 1, characterized in that: In step S5, the ratio of the die diameter of the extruder to the diameter of the wire core layer is 1.2 to 1.5; in step S6, the surface of the outer sheath is coated with a wear-resistant coating or subjected to ultraviolet curing treatment; in step S7, the manufacture of the connector includes an electroplating process, wherein the electroplating layer is nickel or gold.

Images