Anti-fracture wire harness and manufacturing method thereof

Abstract

The invention relates to the technical field of wire harnesses, and discloses an anti-fracture wire harness and a manufacturing method thereof.The wire core mechanism comprises a communication core wire used for electric signal transmission and a core wire sheath, the communication core wire is fixedly arranged in the core wire sheath, and the sheath mechanism comprises a shielding net sleeve, a first sheath and a second sheath; the shielding net sleeve, the first sheath and the second sheath are arranged outside the core wire sheath in a wrapping mode, the anti-cracking interlayer is fixedly arranged between the first sheath and the second sheath, the communication core wires are arranged in a separated mode, the communication core wires are wrapped through the soft core wire sheath, the power supply safety of the wire harness is improved, and the service life of the wire harness is prolonged. The core wire sheath is arranged between the first sheath and the second sheath, the shielding net sleeve is arranged outside the core wire sheath, the anti-interference capability of the wire harness can be improved, the anti-cracking interlayer is arranged between the first sheath and the second sheath, and the anti-cracking interlayer is formed by processing tensile fibers through a rotary weaving process, so that the overall tensile capability of the sheath can be improved while the anti-bending capability is considered.

Description

Technical Field

[0001] The invention relates to the technical field of wire harnesses, in particular to an anti-fracture wire harness and a manufacturing method thereof. Background Art

[0002] The wiring harness is composed of multiple groups of metal wires tied together. It is a connecting harness that conducts signals and power between devices. It is mainly used for the transmission of electrical signals. At present, the wiring harness has been widely used in various fields. For example, in the medical field, when examining the patient's stomach, it is necessary to insert a gastroscope into the patient's stomach to achieve an imaging examination of the patient's stomach. In order to transmit electronic images and power the electronic equipment at the end of the gastroscope, a signal transmission harness is provided inside the gastroscope.

[0003] When the wire harness is working, some of the wire harnesses need to be bent repeatedly due to the need for use. For example, the wire harness in the above-mentioned gastroscope needs to be bent multiple times inside the patient's body when working. In order to prevent the wire harness from breaking during bending and to protect the outside of the wire harness, a flexible protective layer is provided on the outside of the existing wire harness during processing, which can provide elastic buffering for the wires inside the wire harness when the wire harness is bent to prevent the wires from breaking due to excessive bending. The material of the protective layer is mostly rubber or PVC, which has good softness but limited tensile strength. When the wire harness is subjected to strong bending or stretching, due to different deformation resistance, the metal wires inside the wire harness will break first and have poor tensile protection characteristics. Summary of the invention

[0004] The object of the present invention is to provide a breakage-resistant wire harness and a manufacturing method thereof to solve the problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: an anti-fracture wire harness, comprising a wire harness body, the wire harness body comprising a wire core mechanism and a sheath mechanism, the wire core mechanism being wrapped and arranged inside the sheath mechanism;

[0006] The wire core mechanism includes a communication core wire and a core wire sheath for transmitting electrical signals. The communication core wire is fixedly arranged inside the core wire sheath. The sheath mechanism includes a shielding mesh, a first sheath and a second sheath. The shielding mesh, the first sheath and the second sheath are all wrapped around the outside of the core wire sheath. An anti-cracking interlayer is fixedly arranged between the first sheath and the second sheath.

[0007] Preferably, the communication core wires are provided in a plurality of groups, the plurality of groups of communication core wires are not in contact with each other, and the plurality of groups of communication core wires are all fixedly wrapped and connected inside the core wire sheath.

[0008] Preferably, the shielding mesh sleeve is arranged outside the core wire sheath, and the shielding mesh sleeve is arranged in a braided mesh sleeve structure, and the shielding mesh sleeve is fixedly wrapped around the outside of the core wire sheath.

[0009] Preferably, the first sheath is arranged on the outside of the shielding mesh sleeve, and the first sheath is fixedly wrapped and connected to the outside of the shielding mesh sleeve by a hot-melt process.

[0010] Preferably, the anti-cracking interlayer is arranged on the outside of the first sheath, the first sheath is arranged in a woven mesh structure, and the first sheath is fixedly connected to the outside of the first sheath by wrapping and weaving.

[0011] Preferably, the second sheath is arranged on the outside of the anti-cracking interlayer, the second sheath is fixedly wrapped and connected to the outside of the anti-cracking interlayer through a hot melt process, and the anti-cracking interlayer is fixedly wrapped and connected between the first sheath and the second sheath.

[0012] Preferably, the communication core wire is a copper thin wire, an insulating sheath is provided on the outside of the thin wire, and the inner core of a single thin wire is composed of a plurality of copper thin filaments.

[0013] Preferably, the shielding mesh is made of a metal material with shielding properties, the anti-cracking interlayer is made of a fiber material with tensile properties, and both the shielding mesh and the anti-cracking interlayer are woven by winding and weaving equipment.

[0014] The present invention also provides a method for manufacturing a fracture-resistant wiring harness, comprising the following steps:

[0015] S1, core wire processing, a plurality of copper wires are braided into a bundle to form the inner core of the communication core wire, and then the outer part of the inner core is wrapped with molten resin, and the molten resin is solidified by mold cooling to form an insulating outer skin to form the communication core wire;

[0016] S2, sheath processing, when processing the core wire sheath, multiple groups of communication core wires are loaded and transported, and the outside of the multiple groups of communication core wires is wrapped with molten rubber, and the molten rubber is solidified by extrusion die shaping and cooling to form the core wire sheath;

[0017] S3, shielding layer processing, when processing the shielding mesh, the communication core wire after the sheath processing is loaded on the upper part of the winding and braiding equipment, and the metal filaments are braided on the outside of the core wire sheath through winding and braiding to form a shielding mesh;

[0018] S4. External sheath processing. After the shielding layer processing is completed, the outside of the shielding mesh is wrapped with molten polyethylene, and the molten polyethylene is solidified by extrusion die shaping and cooling to form a first sheath. Then the communication core wire covered with the first sheath is loaded on the upper part of the winding and braiding equipment. The fiber filaments are woven on the outside of the first sheath through winding and braiding to form an anti-cracking interlayer. Then, the outside of the anti-cracking interlayer is wrapped with secondary molten polyethylene, and the molten polyethylene is solidified by mold cooling to form a second sheath.

[0019] Compared with the prior art, the present invention adopts the above technical solution and has the following technical effects:

[0020] 1. The wiring harness adopts a composite sheath structure, adopts a separated setting for the communication core wire, and wraps the communication core wire with a soft core wire sheath. While ensuring the flexibility of the communication core wire, it can reduce the probability of short circuit and sparking of the communication core wire, thereby improving the power supply safety of the wiring harness.

[0021] 2. A shielding mesh sleeve is arranged outside the core wire sheath, and the communication core wire is protected by the electromagnetic shielding effect of the shielding mesh sleeve, which can improve the anti-interference ability of the wire harness and improve the stability of the signal transmission of the wire harness.

[0022] 3. An anti-cracking interlayer is arranged between the first sheath and the second sheath. The anti-cracking interlayer is made of tensile-resistant fiber through a rotary weaving process and is fixed between the first sheath and the second sheath. It can prevent the metal wire core in the wiring harness from breaking due to external stretching, and can improve the overall tensile strength of the sheath while taking into account the bending resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0024] Figure 1 It is a schematic diagram of the main structure of the wiring harness of the present invention;

[0025] Figure 2 It is a schematic diagram of the structure of the end portion of the wiring harness body of the present invention;

[0026] Figure 3 For the present invention Figure 2 Schematic diagram of the structure of the middle A area;

[0027] Figure 4 It is a schematic diagram of the cross-sectional structure of the wiring harness body of the present invention;

[0028] Figure 5 It is a schematic diagram of the anti-cracking sandwich structure of the present invention.

[0029] Explanation of the accompanying drawings: 1. Wire harness body; 2. Wire core mechanism; 3. Sheath mechanism; 4. Communication core wire; 5. Core wire sheath; 6. Shielding mesh sleeve; 7. First sheath; 8. Anti-cracking interlayer; 9. Second sheath. DETAILED DESCRIPTION

[0030] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the conditions under which this application can be implemented. Therefore, they have no substantive technical significance. Any structural modification, change in proportional relationship or adjustment of size should still fall within the scope of the technical content disclosed in this application without affecting the effects and purposes that can be achieved by this application.

[0032] Example

[0033] See also Figure 1-5 The present invention provides a technical solution: an anti-fracture wire harness, comprising a wire harness body 1, wherein the wire harness body 1 comprises a wire core mechanism 2 and a sheath mechanism 3, wherein the sheath mechanism 3 is arranged in a composite structure and can provide comprehensive protection for the wire core mechanism 2.

[0034] The wire core mechanism 2 is wrapped and arranged inside the sheath mechanism 3. The wire core mechanism 2 includes a communication core wire 4 and a core wire sheath 5 for transmitting electrical signals. The communication core wire 4 is fixedly arranged inside the core wire sheath 5. The communication core wire 4 is a copper thin wire. An insulating leather sheath is arranged on the outside of the thin wire. The inner core of a single thin wire is composed of a plurality of copper filaments and has good conductivity and anti-bending properties. There are multiple groups of communication core wires 4, and the multiple groups of communication core wires 4 do not contact each other, which can reduce the probability of short circuit and sparking of the communication core wires 4 and improve the power supply safety of the wiring harness. The multiple groups of communication core wires 4 are fixedly wrapped and connected to the inside of the core wire sheath 5. The core wire sheath 5 is made of flexible rubber material and is wrapped on the outside of the communication core wire 4 through melting processing. The communication core wire 4 is wrapped by the soft core wire sheath 5 to ensure that the communication core wire 4 has good flexibility.

[0035] The sheath mechanism 3 includes a shielding mesh 6, a first sheath 7 and a second sheath 9. The shielding mesh 6, the first sheath 7 and the second sheath 9 are all wrapped and arranged on the outside of the core wire sheath 5. The shielding mesh 6 is arranged on the outside of the core wire sheath 5. The shielding mesh 6 is a braided mesh structure. The shielding mesh 6 is made of a metal material with shielding properties. The shielding mesh 6 can be made of tinned metal filaments and is woven by winding and braiding equipment. The shielding mesh 6 is fixedly wrapped on the outside of the core wire sheath 5 to form an electromagnetic shielding layer. The electromagnetic shielding effect of the shielding mesh 6 protects the communication core wire 4, which can improve the anti-interference ability of the wiring harness and improve the stability of the wiring harness signal transmission.

[0036] The first sheath 7 is arranged on the outside of the shielding mesh sleeve 6, and the first sheath 7 and the second sheath 9 are both made of polyethylene. The first sheath 7 is fixedly wrapped and connected to the outside of the shielding mesh sleeve 6 through a hot melt process, and the second sheath 9 is arranged on the outside of the anti-cracking interlayer 8. The second sheath 9 is fixedly wrapped and connected to the outside of the anti-cracking interlayer 8 through a hot melt process, which can improve the waterproof and wear-resistant protection capabilities of the outside of the wiring harness.

[0037] An anti-cracking interlayer 8 is fixedly arranged between the first sheath 7 and the second sheath 9. The anti-cracking interlayer 8 is made of a fiber material with tensile properties. The anti-cracking interlayer 8 is made of Kevlar fiber and is woven from Kevlar fiber filaments by winding and weaving equipment. The anti-cracking interlayer 8 is arranged on the outside of the first sheath 7. The first sheath 7 is a woven mesh structure. The first sheath 7 is fixedly connected to the outside of the first sheath 7 by winding and weaving, and is fixed between the first sheath 7 and the second sheath 9. This can prevent the metal wire core in the wiring harness from breaking due to external stretching, and can improve the overall tensile strength of the sheath while taking into account the bending resistance.

[0038] Working principle or structural principle, when processing the wire harness, the core wire is first processed, and multiple copper wires are braided into a bundle to form the inner core of the communication core wire 4, and then the outer part of the inner core is wrapped with molten resin, and the molten resin is solidified by mold cooling to form an insulating outer skin to form the communication core wire 4;

[0039] Then, the sheath is processed. When the core wire sheath 5 is processed, multiple groups of communication core wires 4 are loaded and transported, and the outside of the multiple groups of communication core wires 4 is wrapped with molten rubber, and the molten rubber is solidified by the extrusion die to form the core wire sheath 5 after being shaped and cooled;

[0040] After completion, the shielding layer is processed. When the shielding mesh sleeve 6 is processed, the communication core wire 4 after the sheath processing is loaded on the upper part of the winding and braiding equipment, and the metal filaments are braided on the outside of the core wire sheath 5 by winding and braiding to form the shielding mesh sleeve 6;

[0041] Finally, the outer protective layer is processed. After the shielding layer is processed, the outside of the shielding mesh 6 is wrapped with molten polyethylene, and the molten polyethylene is solidified by the extrusion mold through shaping and cooling to form a first sheath 7. Then the communication core wire 4 covered with the first sheath 7 is loaded on the upper part of the winding and weaving equipment, and the fiber filaments are woven on the outside of the first sheath 7 through winding and weaving to form an anti-cracking interlayer 8. Then, the outside of the anti-cracking interlayer 8 is wrapped with secondary molten polyethylene, and the molten polyethylene is solidified by mold cooling to form a second sheath 9. Before processing the second sheath 9, the outside of the communication core wire 4 with the anti-cracking interlayer 8 needs to be preheated, and the heating temperature is controlled between 190°C and 200°C. The preheating treatment can facilitate the fusion of the second sheath 9 and the first sheath 7 and the fixation of the anti-cracking interlayer 8.

[0042] In summary, the wiring harness adopts a sheath mechanism 3 with a composite structure, adopts a separated setting for the communication core wire 4, and wraps the communication core wire 4 with a soft core wire sheath 5. While ensuring that the communication core wire 4 has flexibility, the probability of short circuit and sparking of the communication core wire 4 can be reduced, thereby improving the power supply safety of the wiring harness. A shielding mesh sleeve 6 is arranged on the outside of the core wire sheath 5. The communication core wire 4 is protected by the electromagnetic shielding effect of the shielding mesh sleeve 6, thereby improving the anti-interference ability of the wiring harness and the stability of the signal transmission of the wiring harness. In addition, an anti-cracking interlayer 8 is arranged between the first sheath 7 and the second sheath 9. The anti-cracking interlayer 8 is made of tensile-resistant fiber through a rotary weaving process and is fixed between the first sheath 7 and the second sheath 9. It can prevent the metal wire core in the wiring harness from breaking due to external stretching, while taking into account the anti-bending ability and improving the overall tensile strength of the sheath.

[0043] The present invention also provides a method for manufacturing a fracture-resistant wiring harness, comprising the following steps:

[0044] S1, core wire processing, a plurality of copper wires are braided into a bundle to form the inner core of the communication core wire 4, and then the outer part of the inner core is wrapped with molten resin, and the molten resin is solidified by mold cooling to form an insulating outer sheath to form the communication core wire 4;

[0045] S2, sheath processing, when processing the core wire sheath 5, multiple groups of communication core wires 4 are loaded and transported, and the outside of the multiple groups of communication core wires 4 is wrapped with molten rubber, and the molten rubber is solidified by shaping and cooling through an extrusion die to form the core wire sheath 5;

[0046] S3, shielding layer processing, when processing the shielding mesh 6, the communication core wire 4 after the sheath processing is loaded on the upper part of the winding and braiding equipment, and the metal filaments are braided on the outside of the core wire sheath 5 by winding and braiding to form the shielding mesh 6;

[0047] S4, external sheath processing, after completing the shielding layer processing, the outside of the shielding mesh 6 is wrapped with molten polyethylene, and the molten polyethylene is solidified by the extrusion die to form a first sheath 7 through shaping and cooling. Then, the communication core wire 4 covered with the first sheath 7 is loaded on the upper part of the winding and weaving equipment, and the fiber filaments are woven on the outside of the first sheath 7 through winding and weaving to form an anti-cracking interlayer 8. Then, the outside of the anti-cracking interlayer 8 is wrapped with secondary molten polyethylene, and the molten polyethylene is solidified by mold cooling to form a second sheath 9.

[0048] So far, the embodiments of the present invention have been described in detail in conjunction with the accompanying drawings. It should be noted that the implementation methods not shown or described in the drawings or the body of the specification are all forms known to ordinary technicians in the relevant technical field and are not described in detail. In addition, the above definitions of each component are not limited to the various specific structures, shapes or methods mentioned in the embodiments, and ordinary technicians in the field can simply change or replace them.

[0049] It will be appreciated by those skilled in the art that the features described in the various embodiments and / or claims of the present invention may be combined and / or combined in various ways, even if such combinations and / or combinations are not explicitly described in the present invention. In particular, the features described in the various embodiments and / or claims of the present invention may be combined and / or combined in various ways without departing from the spirit and teachings of the present invention. All of these combinations and / or combinations fall within the scope of the present invention.

[0050] The specific embodiments described above further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A break-proof wire harness, comprising a wire harness body (1), characterized in that: The wire harness body (1) comprises a wire core mechanism (2) and a sheath mechanism (3), wherein the wire core mechanism (2) is wrapped and arranged inside the sheath mechanism (3); The wire core mechanism (2) comprises a communication core wire (4) and a core wire sheath (5) for transmitting electrical signals, wherein the communication core wire (4) is fixedly arranged inside the core wire sheath (5), and the sheath mechanism (3) comprises a shielding mesh sheath (6), a first sheath (7) and a second sheath (9), wherein the shielding mesh sheath (6), the first sheath (7) and the second sheath (9) are all wrapped around the outside of the core wire sheath (5), and an anti-cracking interlayer (8) is fixedly arranged between the first sheath (7) and the second sheath (9).

2. The anti-fracture wire harness according to claim 1, characterized in that: The communication core wires (4) are provided in a plurality of groups, the plurality of groups of communication core wires (4) do not contact each other, and the plurality of groups of communication core wires (4) are all fixedly wrapped and connected to the inside of the core wire sheath (5).

3. The anti-fracture wire harness according to claim 2, characterized in that: The shielding mesh sleeve (6) is arranged outside the core wire sheath (5); the shielding mesh sleeve (6) is arranged in a braided mesh sleeve structure; the shielding mesh sleeve (6) is fixedly wrapped around the outside of the core wire sheath (5).

4. The anti-fracture wire harness according to claim 3, characterized in that: The first sheath (7) is arranged on the outside of the shielding mesh sleeve (6), and the first sheath (7) is fixedly wrapped and connected to the outside of the shielding mesh sleeve (6) through a hot-melt process.

5. The anti-fracture wire harness according to claim 4, characterized in that: The anti-cracking interlayer (8) is arranged outside the first sheath (7); the first sheath (7) is arranged in a woven mesh structure; the first sheath (7) is fixedly connected to the outside of the first sheath (7) by wrapping and weaving.

6. The anti-fracture wire harness according to claim 5, characterized in that: The second sheath (9) is arranged outside the anti-cracking interlayer (8), and the second sheath (9) is fixedly wrapped and connected to the outside of the anti-cracking interlayer (8) through a hot-melt process, and the anti-cracking interlayer (8) is fixedly wrapped and connected between the first sheath (7) and the second sheath (9).

7. The anti-fracture wire harness according to claim 2, characterized in that: The communication core wire (4) is a copper thin wire, the outside of which is provided with an insulating sheath, and the inner core of a single thin wire is composed of a plurality of copper thin filaments.

8. The anti-fracture wire harness according to claim 6, characterized in that: The shielding mesh sleeve (6) is made of a metal material with shielding properties, the anti-cracking interlayer (8) is made of a fiber material with tensile strength, and both the shielding mesh sleeve (6) and the anti-cracking interlayer (8) are woven by winding and weaving equipment.

9. A method for manufacturing an anti-fracture harness according to any one of claims 1 to 8, characterized in that: The following steps are involved: S1, core wire processing, a plurality of copper wires are braided into a bundle to form an inner core of the communication core wire (4), and then the outer part of the inner core is wrapped with molten resin, and the molten resin is solidified by mold cooling to form an insulating outer sheath to form the communication core wire (4); S2, sheath processing, when processing the core wire sheath (5), multiple groups of communication core wires (4) are loaded and transported, and the outside of the multiple groups of communication core wires (4) are wrapped with molten rubber, and the molten rubber is solidified by shaping and cooling through an extrusion die to form the core wire sheath (5); S3, shielding layer processing, when processing the shielding mesh sleeve (6), the communication core wire (4) after the sheath processing is loaded on the upper part of the winding and weaving equipment, and the metal filaments are woven on the outside of the core wire sheath (5) through winding and weaving to form the shielding mesh sleeve (6); S4, external sheath processing, after the shielding layer processing is completed, the outside of the shielding mesh (6) is wrapped with molten polyethylene, and the molten polyethylene is solidified by extrusion die shaping and cooling to form a first sheath (7), and then the communication core wire (4) covered with the first sheath (7) is loaded on the upper part of the winding and braiding equipment, and the fiber filaments are woven on the outside of the first sheath (7) through winding and braiding to form an anti-cracking interlayer (8), and then the outside of the anti-cracking interlayer (8) is wrapped with a secondary molten polyethylene, and the molten polyethylene is solidified by mold cooling to form a second sheath (9).

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