Manufacturing method of wire harness plug

Abstract

A manufacturing method of a wire harness plug comprises the following steps: S100, adding a high-elasticity rubber ring to a wire rod of a wire harness: sleeving the surface of the wire rod with the high-elasticity rubber ring in advance; s200, cutting the wires, exposing conductor parts of the wires, and arranging the wires; s300, the wire and the connector are welded; s400, the welding reliability is tested; after reliable welding is confirmed, the next step is carried out; if the welding is poor, reworking and re-welding; s500, performing internal mold injection molding at the welding position to form an internal mold wrapping the wire; s600, the high-elasticity rubber ring is moved to be tightly attached to the end face of the inner mold; and S700, outer mold injection molding is conducted, and the high-elasticity rubber ring and the inner mold which are tightly attached are wrapped in the outer mold. The invention has the following beneficial effects: 1, the high-elasticity rubber ring and the outer mold are integrated through injection molding, and the silica gel ring is hermetically combined with the wire sheath and the inner mold, so that the waterproof effect is good; 2, the silicone rubber has good elasticity, and the waterproof requirement of the plug above IPX8 can be met no matter how the wire harness is bent and swings;

Description

Technical Field

[0001] The present application relates to the field of electronic technology, and in particular to a method for manufacturing a wiring harness plug. Background Art

[0002] The wiring harness plug molding consists of inner mold (PE material) molding and outer mold (PVC). During production, the inner mold is first injection molded and then the outer mold is added to the inner mold. After this production process, the inner mold at the tail and the outer core wire are peeled off during the use of the product by consumers, resulting in failure to seal. There is a gap between the inner mold and the outer mold. When the external environment is soaked with rain, the rainwater will penetrate into the inner core wire along the outer core wire, causing the product to have a short circuit risk and fail to achieve a waterproof effect.

[0003] Therefore, it is urgent to develop a manufacturing method of a wiring harness plug that can make the wiring harness plug have a waterproof function. Summary of the invention

[0004] The present invention aims to solve one of the above technical problems at least to a certain extent.

[0005] Therefore, an object of the present invention is to provide a method for manufacturing a wiring harness plug, which can make the wiring harness plug have a waterproof function.

[0006] To achieve the above-mentioned purpose, the embodiment of the present application discloses a manufacturing method of a wiring harness plug, comprising the following steps: S100: adding a high elastic rubber ring to the wiring harness wire: pre-sleeve the high elastic rubber ring on the surface of the wire; S200: cutting the wire, exposing the conductor part of the wire, and arranging the wire; S300: welding the wire to the connector; S400: testing the reliability of the welding; after confirming that the welding is reliable, proceed to the next step; if the welding is poor, rework and re-weld; S500: performing inner mold injection molding at the welding position to form An inner mold for covering the wire; S600: moving the high elastic rubber ring to make it fit tightly with the end face of the inner mold; S700: performing outer mold injection molding to cover the tightly fitting high elastic rubber ring and the inner mold in the outer mold; through the above steps, a wiring harness plug is manufactured, including: a connector 1, a wiring harness 2 connected to the connector 1, an inner mold 3 covering the connection between the connector 1 and the wiring harness 2, a high elastic rubber ring 4 sleeved on the outside of the wiring harness 2 and tightly fitting at the end face of the inner mold 3, and an outer mold 5 covering the high elastic rubber ring 4 and the inner mold 3.

[0007] In addition, the manufacturing method of the wiring harness plug according to the above technical solution of the present application may also have the following additional technical features: Optionally, during the outer mold injection molding in step S700, the outer mold 5 further includes a plurality of mutually connected reinforcing rib rings 51 on one side of the wire.

[0008] Optionally, the high elastic rubber ring material has a hardness of 70A, a temperature resistance of more than 200°C, and a tensile strength greater than 5MPa.

[0009] Optionally, when the inner mold injection molding is performed in step S500, the inner mold 3 of the injection molding is in the shape of a circular ring sleeve.

[0010] Optionally, when the outer diameter of the wire harness 2 is A, the inner diameter of the high-elastic rubber ring 4 is A-1 mm, and the outer diameter is A+3 mm.

[0011] Optionally, the outer diameter of the highly elastic rubber ring 4 after assembly is A+2.5 mm, and the outer diameter of the end surface where the inner mold 3 is connected to the highly elastic rubber ring 4 is 1.1*(A+2.5) mm.

[0012] The beneficial effects of the present application are: 1. Since the high-elastic rubber ring is injection-molded into one piece with the outer mold, the silicone ring is sealed with the outer sheath of the wire and the SR end plane of the inner mold, and the waterproof effect is good; 2. Silicone rubber has good elasticity, and no matter how the wire harness is bent and swayed, the plug can meet the IPX8 or above waterproof requirements. The production and assembly are convenient, the cost is low, and the production efficiency and cost advantages are obvious. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 is a cross-sectional view of a wiring harness plug provided by an embodiment of the present application; Figure 2 This is a schematic diagram of the structure of a wiring harness plug provided by an embodiment of the present application after the outer mold is removed; Figure 3 It is a schematic diagram of the dimensions of a wiring harness plug provided by one embodiment of the present application; Figure 4 This is a test report of a wiring harness plug provided by an embodiment of the present application.

[0015] Reference numerals: 1-connector, 2-wiring harness, 3-inner mold, 4-high elastic rubber ring, 5-outer mold, 51-reinforcement rib ring. DETAILED DESCRIPTION

[0016] The embodiments of the present application are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or components / elements with the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present application, and should not be construed as limiting the present application.

[0017] The following describes a molding method of a manufacturing method of a wiring harness plug according to an embodiment of the present application in conjunction with the accompanying drawings.

[0018] Figure 1is an AA cross-sectional view of a wiring harness plug provided by an embodiment of the present application; Figure 2 1 is a schematic diagram of the structure of a wiring harness plug provided by an embodiment of the present application after removing the outer mold. Figure 1-2 As shown: the manufacturing method of the wiring harness plug includes the following steps: S100: adding a high elastic rubber ring to the wiring harness wire: pre-sleeve the high elastic rubber ring on the surface of the wire; S200: cutting the wire, exposing the conductor part of the wire, and arranging the wire; S300: welding the wire and the connector; S400: testing the reliability of the welding; after confirming that the welding is reliable, proceed to the next step; if the welding is poor, rework and re-weld; S500: performing inner mold injection molding at the welding position to form an inner mold covering the wire; S600: moving the high elastic rubber ring to make it fit tightly against the end face of the inner mold; S700: performing outer mold injection molding to cover the tightly fitting high elastic rubber ring and the inner mold in the outer mold; through the above steps, a wiring harness plug is manufactured, including: a connector 1, a wiring harness 2 connected to the connector 1, an inner mold 3 covering the connection between the connector 1 and the wiring harness 2, a high elastic rubber ring 4 sleeved on the outside of the wiring harness 2 and tightly fitting against the end face of the inner mold 3, and an outer mold 5 covering the high elastic rubber ring 4 and the inner mold 3.

[0019] Specifically, this solution adopts mixed injection molding with the addition of silicone rubber rings. One side of the high-elastic rubber ring is close to the side of the inner membrane molding, and the inside is close to the surface of the outer sheath of the wire harness. The outer mold injection molding is used for positioning and pressure compression to achieve the ideal waterproof effect. No matter how the wire harness swings, rain from the outside cannot enter the inside of the wire. The main features of the injection molding production process of wire harness products: The wire harness plug is injected with a high-elastic rubber ring twice to achieve a waterproof level of IPX8 or above. The wire is first inserted into a high-elastic rubber ring designed according to the size of the wire sheath, and the plug is welded to form the inner membrane. When designing the inner membrane, the plane of the SR end of the wire harness is designed to match the side of the high-elastic rubber ring. This plane should be larger than the outer diameter of the high-elastic rubber ring. The high-elastic rubber ring is close to this surface during the next molding process to achieve a lateral waterproof effect ( Figure 3 ), and then move the high-elastic rubber ring to the plane close to the SR end of the inner film, and then perform external mold mixed injection molding. The external mold injection molding fixes the wire and the high-elastic rubber ring, and the high-elastic rubber ring is close to the SR end of the inner mold. The external mold molding compression makes the high-elastic rubber ring close to the outer jacket of the wire harness. The three materials are closely matched to make the high-elastic rubber ring close in the horizontal and vertical directions. The elasticity of the high-elastic rubber ring makes the wiring harness plug waterproof even if it swings at will.

[0020] It should be noted that, combined with the influence of injection molding pressure, the high elastic rubber ring will be squeezed by the outer mold rubber during mixed injection molding and move. The inner mold "O"-shaped tail SR structure is designed (according to structural requirements or other shapes). This design prevents the high elastic rubber ring from moving during mixed injection molding. At the same time, due to the pressure movement, it better fits with the inner mold, perfectly sealing the gap between the inner mold and the wire.

[0021] It should also be noted that the attached drawings also provide a waterproof test report of the wiring harness plug produced according to the method of the present application, which shows that it can reach the IPX8 level and has a good waterproof effect.

[0022] High elastic rubber ring can be made of silicone rubber ring.

[0023] According to the manufacturing method of the wiring harness plug of the present application, a high-elastic rubber ring is inserted into the outer sheath of the wire and extruded into the outer mold of the product through injection molding. The high-elastic rubber ring is inserted into the outer sheath of the wire and is in sealing contact with the side of the inner mold of the wire. The outer mold molding and extrusion are completely and tightly matched to achieve a waterproof effect when the product is used.

[0024] According to an embodiment of the present application, during the outer mold injection molding in step S700, the outer mold 5 further includes a plurality of mutually connected reinforcing rib rings 51 on one side of the wire.

[0025] Specifically, the design of the reinforcing rib ring 51 can effectively prevent the wire from breaking at the ends of the outer mold and the inner mold, thereby causing the waterproof function to fail.

[0026] According to one embodiment of the present application, the high elastic rubber ring material has a hardness of 70A, a temperature resistance of more than 200°C, and a tensile strength greater than 5MPa.

[0027] Specifically, this material has high temperature resistance and is higher than the molding temperature of the outer mold material to meet the requirements of mixed injection molding.

[0028] According to an embodiment of the present application, when the inner mold injection molding is performed in step S500, the inner mold 3 of the injection molding is in the shape of a circular ring sleeve.

[0029] Specifically, the inner mold 3 is in the shape of a circular ring, which can make it more consistent with the high-elastic rubber ring 4, thereby ensuring the reliability of the waterproof function.

[0030] According to an embodiment of the present application, when the outer diameter of the wire harness 2 is A, the inner diameter of the high-elastic rubber ring 4 is A-1 mm, and the outer diameter is A+3 mm.

[0031] According to an embodiment of the present application, the outer diameter of the highly elastic rubber ring 4 after assembly is A+2.5 mm, and the outer diameter of the end surface where the inner mold 3 is connected to the highly elastic rubber ring 4 is 1.1*(A+2.5) mm.

[0032] Specifically, Figure 3 Schematic diagram of the dimensions of a wiring harness plug provided by an embodiment of the present application. Figure 3As shown, the dimensions of the high elastic rubber ring 4 and the inner mold 3 can be designed according to the dimensions of the wiring harness 2. This design dimension fully meets the requirements for preventing the position deviation of the silicone rubber ring from the mixed injection molding, so that the high elastic rubber ring can be elastically contracted after being assembled on the wire material, and the two materials are seamlessly combined to ensure reliable waterproof function, while meeting the appearance standard requirements of silicone rubber mixed injection molding products.

[0033] The above embodiments are preferred implementation schemes of the present application. In addition, the present application may also be implemented in other ways. Any obvious replacement without departing from the concept of the present application is within the protection scope of the present application.

Claims

1. A method for manufacturing a wiring harness plug, characterized in that: The following steps are involved: S100: Add high elastic rubber ring to the wire harness: Pre-slip the high elastic rubber ring on the wire surface; S200: Cut the wires, expose the conductor part of the wires, and organize the wires; S300: welding the wires to the connectors; S400: Testing the reliability of welding; after confirming that the welding is reliable, proceed to the next step; If the welding is bad, rework and re-weld; S500: performing inner mold injection molding at the welding position to form an inner mold covering the wire; S600: Move the high elastic rubber ring to make it fit tightly against the end surface of the inner mold; S700: Perform outer mold injection molding to enclose the tightly fitting high elastic rubber ring and inner mold in the outer mold; Through the above steps, a wiring harness plug is manufactured, comprising: a connector (1), a wiring harness (2) connected to the connector (1), an inner mold (3) covering the connection between the connector (1) and the wiring harness (2), a high elastic rubber ring (4) sleeved outside the wiring harness (2) and tightly fitted on the end surface of the inner mold (3), and an outer mold (5) covering the high elastic rubber ring (4) and the inner mold (3).

2. The method for manufacturing a wiring harness plug according to claim 1, characterized in that: During the external mold injection molding in step S700, the external mold (5) further comprises a plurality of mutually connected reinforcing rib rings (51) on one side of the wire material.

3. The method for manufacturing a wiring harness plug according to claim 1, characterized in that: The high elastic rubber ring material has a hardness of 70A, a temperature resistance of more than 200°C, and a tensile strength of more than 5MPa.

4. The method for manufacturing a wiring harness plug according to claim 1, characterized in that: When the inner mold injection molding is performed in step S500, the inner mold (3) for injection molding is in the shape of a circular ring sleeve.

5. The method for manufacturing a wiring harness plug according to claim 4, characterized in that: When the outer diameter of the wire harness (2) is A, the inner diameter of the high elastic rubber ring (4) is A-1 mm, and the outer diameter is A+3 mm.

6. The method for manufacturing a wiring harness plug according to claim 5, characterized in that: The outer diameter of the highly elastic rubber ring (4) after assembly is A+2.5 mm, and the outer diameter of the end surface where the inner mold (3) is connected to the highly elastic rubber ring (4) is 1.1*(A+2.5) mm.

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