Lightweight high-toughness automobile wire harness

Abstract

The invention discloses a lightweight high-toughness automobile wire harness, and relates to the technical field of new energy automobile wire harnesses, the lightweight high-toughness automobile wire harness comprises a cable, one end of the cable is provided with a charging plug, the cable comprises a conductor, the conductor is externally provided with an inner insulating layer, the inner insulating layer is externally provided with an inner shielding layer, and the inner shielding layer is externally provided with an outer shielding layer. The outer portion of the inner shielding layer is provided with a flame-retardant heat dissipation layer, the flame-retardant heat dissipation layer is composed of a flame-retardant base material layer and a heat dissipation enhancement layer, the outer portion of the flame-retardant heat dissipation layer is provided with a composite anti-interference layer, the composite anti-interference layer is composed of a shielding base material layer and a shielding net layer, and the outer portion of the composite anti-interference layer is provided with an outer sheath. And the outer sheath is composed of a lightweight base material layer, a high-toughness enhancement layer, a fireproof layer and a wear-resistant layer. The problems that the new energy automobile wire harness is inconvenient to use due to large weight and is easy to damage during bending are solved.

Description

Technical Field

[0001] The invention relates to the technical field of new energy automobile wiring harnesses, and in particular to a lightweight and high-toughness automobile wiring harness. Background Art

[0002] The wiring harness for new energy vehicle charging guns is an indispensable key component in the electric vehicle charging system, and is designed to meet the needs of modern electric vehicles for efficient and safe charging. This wiring harness uses high-purity oxygen-free copper as a conductor material, with excellent conductivity and low resistance characteristics, which can ensure efficient transmission of electric energy, reduce energy loss, support a variety of charging modes from home slow charging to public fast charging, and is compatible with mainstream electric vehicle charging interface standards at home and abroad. The outer layer of the wiring harness is made of environmentally friendly flame-retardant PVC or TPU material. At the same time, the wiring harness is equipped with multiple safety protection mechanisms, including overcurrent protection, short circuit protection and temperature monitoring functions, to ensure that even if an abnormal situation occurs during the charging process, it can respond quickly to ensure the safety of users and vehicles. It is also equipped with an intelligent identification chip, which can seamlessly connect with the charging gun and the vehicle charging management system to achieve intelligent matching and optimization of charging parameters, and further improve charging efficiency and user experience. The wiring harness for new energy vehicle charging guns has become an important support for promoting the popularization and development of electric vehicles with its excellent performance, wide compatibility and high safety.

[0003] For example, the Chinese authorized patent "A New Energy Vehicle Wiring Harness" with announcement number CN115257582B includes a harness tube, which is set to an arc shape bent at any angle. The harness tube is composed of multiple harness rings, and each two harness rings are connected by multiple connecting belts; each harness ring includes a main half ring, which is connected to a secondary half ring through a connecting mechanism, a slot is provided on the main half ring, and the secondary half ring is inserted into the slot, and a plurality of matching latches and limit teeth are fixed on the surface of the secondary half ring and the inner wall of the slot, respectively, and a limiting mechanism is provided in the harness ring, and the limiting mechanism includes two fixing belts, which are fixed on the inner wall of the main half ring, and the other ends of the two fixing belts are fixed with harness belts; a latch groove corresponding to the connecting belt is provided on the main half ring, and the surface of the connecting belt is provided with a latch structure, and the connecting belt can only go in but not out after being inserted into the latch groove.

[0004] The temperature inside the wiring harness will continue to rise during power transmission in the above-mentioned prior art. If the internal heat is difficult to discharge, it will not only affect the service life of the wiring harness, but may also cause serious accidents due to cable overheating or fire. In addition, in order to meet the power transmission effect, the prior art wraps more wire cores, resulting in an increase in overall weight. Not only is it difficult to move during use, but it is also prone to damage during bending. Therefore, it does not meet existing needs. In this regard, we propose a lightweight and high-toughness automotive wiring harness. Summary of the invention

[0005] The purpose of the present invention is to provide a lightweight and high-toughness automobile wiring harness to solve the problem that the new energy automobile wiring harness proposed in the above background technology is inconvenient to use due to its large weight and is easily damaged during bending.

[0006] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: A lightweight and high-toughness automotive wiring harness, comprising a cable, a charging plug being installed at one end of the cable, the cable comprising a conductor, an inner insulating layer being arranged on the outside of the conductor, an inner shielding layer being arranged on the outside of the inner insulating layer, a flame retardant and heat dissipation layer being arranged on the outside of the inner shielding layer, the flame retardant and heat dissipation layer being composed of a flame retardant base material layer and a heat dissipation enhancement layer, a composite anti-interference layer being arranged on the outside of the flame retardant and heat dissipation layer, the composite anti-interference layer being composed of a shielding base material layer and a shielding mesh layer, an outer sheath being arranged on the outside of the composite anti-interference layer, the outer sheath being composed of a lightweight base material layer, a high-toughness enhancement layer, a fireproof layer and a wear-resistant layer.

[0007] Preferably, the conductor is formed by twisting multiple strands of ultra-fine soft copper wires, the inner insulating layer is wrapped around the outside of the conductor by extrusion equipment, the inner shielding layer is woven in a mesh shape around the outside of the inner insulating layer, and the conductor, inner insulating layer and inner shielding layer constitute the core structure of the cable.

[0008] Preferably, the flame retardant substrate layer is fixed to the inner shielding layer and the composite anti-interference layer by a thermoplastic adhesive, an annularly distributed cavity is provided inside the flame retardant substrate layer, and the heat dissipation enhancement layer is filled inside the flame retardant substrate layer.

[0009] Preferably, the shielding substrate layer is coated on the outside of the flame-retardant heat dissipation layer by a thermoplastic adhesive, and the shielding mesh layer is woven in a mesh shape on the outside of the shielding substrate layer.

[0010] Preferably, the lightweight substrate layer is coated on the outside of the composite anti-interference layer through a foaming device, the high-toughness reinforcement layer is spirally wound on the outside of the lightweight substrate layer, the fireproof layer is wrapped on the outside of the high-toughness reinforcement layer through an extrusion device, and the wear-resistant layer is wrapped on the outside of the fireproof layer through an extrusion device.

[0011] Preferably, a coil spring wire is embedded in one side of the outer sheath, and the coil spring wire makes the cable present a spiral structure.

[0012] Preferably, a halogen-free flame retardant is added to the flame-retardant substrate layer, and the halogen-free flame retardant includes aluminum hydroxide and magnesium hydroxide.

[0013] Preferably, a thermoplastic adhesive is provided between the shielding substrate layer and the shielding mesh layer, and flame-retardant particles are added to the thermoplastic adhesive of the layer to form a composite heat-insulating layer.

[0014] Preferably, rubber wheels are installed on the upper and lower parts of the front end of the charging plug, and the rubber wheels are connected to the charging plug through a rotating shaft, and limiting slide grooves are provided on the upper and lower parts of the rear end of the charging plug, and the limiting slide grooves are staggered front and back, and a water baffle is slidably installed inside the limiting slide groove, a driving pulley is fixedly installed at one end of the rubber wheel shaft, a rack plate is provided on one side of the water baffle, and a driven gear is provided at the lower end of one side of the rack plate, the shaft of the driven gear is rotatably connected to the charging plug, and the driven gear is meshed with the rack plate, a transmission gear is meshedly installed on one side of the driven gear, a driven pulley is fixedly installed on the shaft at one end of the transmission gear, and the driven pulley and the driving pulley are connected by a belt.

[0015] Preferably, a plug block is provided above the middle position of the charging plug.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] 1. The present invention significantly reduces the overall weight of the cable by adopting lightweight materials and foaming technology, which is in line with the development trend of lightweight new energy vehicles, helps to reduce vehicle energy consumption and improve endurance. The addition of a high-toughness reinforcement layer significantly improves the tensile strength and bending resistance of the cable, making the cable more durable and able to withstand greater mechanical stress. The provision of a fireproof layer ensures that the cable can maintain a certain structural integrity under extreme conditions such as fire, reduces the risk of fire spread, and improves safety. The addition of a wear-resistant layer improves the cable's resistance to the external environment and reduces cable damage and performance degradation caused by wear. By designing a composite outer sheath and combining the selection of materials with lightweight, high toughness, flame retardant and wear-resistant properties, the overall performance of the new energy vehicle charging gun cable can be significantly improved, providing a strong guarantee for the safe and efficient charging of new energy vehicles.

[0018] 2. The present invention is provided with a composite anti-interference layer. The flame-retardant anti-interference substrate layer and the shielding mesh layer work together to significantly improve the anti-interference ability of the cable and reduce the impact of external electromagnetic interference on signal transmission. The flame-retardant anti-interference substrate layer and the flame-retardant material in the bonding and insulation layer work together to further improve the flame retardant grade of the cable and ensure the safety performance of the cable under extreme conditions such as fire. By reducing external electromagnetic interference, the composite anti-interference layer can ensure that the power transmission in the charging gun cable of the new energy vehicle is more stable and clear, and improve the reliability and efficiency of the charging process. Although the composite anti-interference layer is added, by selecting lightweight substrate and shielding materials, and optimizing the layer structure design, it can ensure that the overall weight of the cable remains at a low level, which is in line with the development trend of lightweight new energy vehicles.

[0019] 3. The present invention is provided with a composite flame-retardant heat dissipation layer. The flame-retardant substrate layer and the flame retardant work together to significantly improve the flame retardant level of the cable and reduce the risk of fire. The heat dissipation enhancement layer can effectively conduct the heat inside the cable by heat conduction or increasing the heat dissipation area, thereby reducing the operating temperature of the cable and extending the service life of the cable. The flame retardant and heat dissipation performance of the lightweight and high-toughness cable is improved, which helps to reduce accidents caused by overheating or fire of the cable and improve the safety of new energy vehicles. The use of halogen-free flame retardants and environmentally friendly adhesives can reduce environmental pollution during the production and use of cables, which is in line with the current environmental protection trend.

[0020] 4. The present invention provides movable water baffles at the upper and lower parts of the rear end of the charging plug. When the user connects the charging plug to the new energy charging port, as the charging plug is continuously inserted, the new energy charging port squeezes the rubber wheel and drives the rubber wheel to rotate through friction. The shaft at one end of the rubber wheel drives the driving pulley to rotate, and the driven pulley rotates under the transmission of the belt. The driven pulley drives the transmission gear to rotate, and drives the driven gear to rotate under the meshing action. The rotational motion is converted into linear motion when it engages with the rack plate, driving the water baffle to extend from the inside of the limiting slide groove to the outside until it blocks the new energy charging port, thereby preventing external rainwater from penetrating into the new energy charging port to cause circuit failure, and the protectiveness is further improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is an overall stereogram of the present invention;

[0022] Figure 2 It is a side view of the overall structure of the present invention;

[0023] Figure 3 A three-dimensional diagram of the internal structure of the cable of the present invention;

[0024] Figure 4 It is a schematic diagram of the internal structure of the cable of the present invention;

[0025] Figure 5 It is a schematic diagram of the structure of the flame retardant heat dissipation layer of the present invention;

[0026] Figure 6 It is a schematic diagram of the structure of the composite anti-interference layer of the present invention;

[0027] Figure 7 It is a schematic diagram of the outer sheath structure of the present invention;

[0028] Figure 8 It is a schematic diagram of the water baffle transmission structure of the present invention.

[0029] In the figure: 1. cable; 2. charging plug; 3. water baffle; 4. plug-in block; 5. rubber wheel; 6. conductor; 7. inner insulation layer; 8. inner shielding layer; 9. flame retardant heat dissipation layer; 901. flame retardant base material layer; 902. heat dissipation enhancement layer; 10. composite anti-interference layer; 1001. shielding base material layer; 1002. shielding mesh layer; 11. outer sheath; 1101. lightweight base material layer; 1102. high toughness enhancement layer; 1103. fireproof layer; 1104. wear-resistant layer; 12. spiral spring wire; 13. rack plate; 14. limit slide; 15. driven gear; 16. transmission gear; 17. driven pulley; 18. belt; 19. driving pulley. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0031] See also Figure 1-8 An embodiment of the present invention is as follows: a lightweight and high-toughness automotive wiring harness comprises a cable 1, a charging plug 2 is installed at one end of the cable 1, a plug block 4 is arranged above the middle position of the charging plug 2, the cable 1 comprises a conductor 6, an inner insulating layer 7 is arranged outside the conductor 6, an inner shielding layer 8 is arranged outside the inner insulating layer 7, a flame retardant heat dissipation layer 9 is arranged outside the inner shielding layer 8, the flame retardant heat dissipation layer 9 is composed of a flame retardant base material layer 901 and a heat dissipation enhancement layer 902, a composite anti-interference layer 10 is arranged outside the flame retardant heat dissipation layer 9, the composite anti-interference layer 10 is composed of a shielding base material layer 1001 and a shielding mesh layer 1002, an outer sheath 11 is arranged outside the composite anti-interference layer 10, and the outer sheath 11 is composed of a lightweight base material layer 1101, a high-toughness enhancement layer 1102, a fireproof layer 1103 and a wear-resistant layer 1104.

[0032] See also Figure 3 and Figure 4 The conductor 6 is formed by twisting multiple strands of ultra-fine soft copper wires, the inner insulating layer 7 is wrapped on the outside of the conductor 6 by an extrusion device, and the inner shielding layer 8 is woven in a mesh shape on the outside of the inner insulating layer 7. The conductor 6, the inner insulating layer 7 and the inner shielding layer 8 constitute the core structure of the cable 1. The conductor 6 is a plurality of strands of ultra-fine soft copper wires, which is responsible for transmitting current. It is twisted by twisting multiple strands of ultra-fine soft copper wires, which can not only ensure the current transmission efficiency, but also reduce the diameter and weight of the cable; the inner insulating layer 7 is a thermoplastic elastomer, which not only has good insulation properties, but also provides excellent wear resistance and oil resistance; the inner shielding layer 8 is a tinned copper braided layer, which helps to improve the stability and anti-interference ability of signal transmission.

[0033] See also Figure 3 , Figure 4 and Figure 5The flame retardant substrate layer 901 is fixed to the inner shielding layer 8 and the composite anti-interference layer 10 by a thermoplastic adhesive. The interior of the flame retardant substrate layer 901 is provided with an annular cavity, and the heat dissipation enhancement layer 902 is filled in the interior of the flame retardant substrate layer 901. Halogen-free flame retardants are added to the flame retardant substrate layer 901901, and the halogen-free flame retardants include aluminum hydroxide and magnesium hydroxide. The flame retardant substrate layer adopts flame retardant polyolefin (such as flame retardant PP, flame retardant PE), and halogen-free flame retardants (such as aluminum hydroxide and magnesium hydroxide) are added to improve the flame retardant effect and environmental protection performance; the heat dissipation enhancement layer 902 is a thermally conductive graphite material, which is used to enhance the heat dissipation efficiency of the cable; the adhesive layer is a thermoplastic adhesive, which has excellent bonding properties and temperature resistance, and can ensure the firm bonding between the layers of materials.

[0034] See also Figure 3 , Figure 4 and Figure 6 The shielding substrate layer 1001 is coated on the outside of the flame retardant heat dissipation layer 9 by a thermoplastic adhesive, and the shielding mesh layer 1002 is mesh-woven on the outside of the shielding substrate layer 1001. A thermoplastic adhesive is provided between the shielding substrate layer 1001 and the shielding mesh layer 1002, and flame retardant particles are added to the thermoplastic adhesive of this layer to form a composite thermal insulation layer. The shielding substrate layer 1001 is a flame retardant polyimide film, which not only has excellent flame retardant properties, but also has a certain electromagnetic shielding effect. In order to enhance the anti-interference ability, conductive fibers or nanoparticles can be added to the substrate to form a conductive network to improve the electromagnetic shielding efficiency of the material; the shielding mesh layer 1002 is a silver-plated copper woven mesh with good conductivity and shielding effect, which can effectively block external electromagnetic interference.

[0035] See also Figure 3 , Figure 4 and Figure 7 The lightweight substrate layer 1101 is coated on the outside of the composite anti-interference layer 10 through a foaming device, the high-toughness reinforcement layer 1102 is spirally wound on the outside of the lightweight substrate layer 1101, the fireproof layer 1103 is wrapped on the outside of the high-toughness reinforcement layer 1102 through an extrusion device, and the wear-resistant layer 1104 is wrapped on the outside of the fireproof layer 1103 through an extrusion device. The lightweight substrate layer 1101 uses low-density polyethylene, which has a lower density and higher mechanical strength, and can reduce the overall weight of the cable. The foaming technology is used to make the substrate The layers form a microporous structure to reduce the material density; the high-toughness reinforcement layer 1102 is aramid fiber, which can significantly improve the tensile strength and bending resistance of the cable; the fireproof layer 1103 is flame-retardant PP, which provides basic flame retardant properties to ensure that the cable can maintain a certain structural integrity under extreme conditions such as fire; the wear-resistant layer 1104 is polyurethane, which has good wear resistance and anti-aging properties and can resist erosion from the external environment. In order to further improve the wear resistance, wear-resistant particles or fibers, such as silicon carbide, aluminum oxide, etc., can be added to the wear-resistant layer.

[0036] See also Figure 4 A spiral spring wire 12 is embedded in one side of the outer sheath 11 , and the spiral spring wire 12 makes the cable 1 present a spiral structure.

[0037] See also Figure 1 and Figure 8 , rubber wheels 5 are installed at the upper and lower parts of the front end of the charging plug 2, and the rubber wheel 5 is connected to the charging plug 2 through a rotating shaft, and limiting slide grooves 14 are arranged at the upper and lower parts of the rear end of the charging plug 2, and the limiting slide grooves 14 are staggered front and back, and a water baffle plate 3 is slidably installed inside the limiting slide groove 14, a driving pulley 19 is fixedly arranged at one end of the rotating shaft of the rubber wheel 5, a rack plate 13 is arranged on one side of the water baffle plate 3, and a driven gear 15 is arranged at the lower end of one side of the rack plate 13, the shaft of the driven gear 15 is rotatably connected with the charging plug 2, and the driven gear 15 is meshed with the rack plate 13, and a transmission gear 16 is meshedly installed on one side of the driven gear 15, and a driven pulley 17 is fixedly installed on the shaft at one end of the transmission gear 16, and the driven pulley 17 is connected to the driving pulley 19 through a belt 18.

[0038] Working principle: When in use, when the user connects the charging plug 2 to the new energy charging port, as the charging plug 2 continues to enter, the new energy charging port squeezes the rubber wheel 5 and drives the rubber wheel 5 to rotate through friction. The shaft at one end of the rubber wheel 5 drives the active pulley 19 to rotate, and the driven pulley 17 rotates under the transmission of the belt 18. The driven pulley 17 drives the transmission gear 16 to rotate, and drives the driven gear 15 to rotate under the meshing action. When the meshing with the rack plate 13 descends, the rotational motion is converted into linear motion, driving the water baffle 3 to extend from the inside of the limiting slide groove 14 to the outside until it forms a blockage for the new energy charging port, thereby preventing external rainwater from seeping into the new energy charging port and causing circuit failure.

[0039] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A lightweight and high-toughness automotive wiring harness, comprising a cable (1); characterized in that: A charging plug (2) is installed at one end of the cable (1). The cable (1) comprises a conductor (6). An inner insulating layer (7) is arranged outside the conductor (6). An inner shielding layer (8) is arranged outside the inner insulating layer (7). A flame retardant heat dissipation layer (9) is arranged outside the inner shielding layer (8). The flame retardant heat dissipation layer (9) is composed of a flame retardant base material layer (901) and a heat dissipation enhancement layer (902). A composite anti-interference layer (10) is arranged outside the flame retardant heat dissipation layer (9). The composite anti-interference layer (10) is composed of a shielding base material layer (1001) and a shielding mesh layer (1002). An outer sheath (11) is arranged outside the composite anti-interference layer (10). The outer sheath (11) is composed of a lightweight base material layer (1101), a high-toughness enhancement layer (1102), a fireproof layer (1103) and a wear-resistant layer (1104).

2. A lightweight and high-toughness automotive wiring harness according to claim 1, characterized in that: The conductor (6) is formed by twisting a plurality of strands of ultra-fine soft copper wires; the inner insulating layer (7) is wrapped around the outside of the conductor (6) by an extrusion device; the inner shielding layer (8) is woven in a mesh shape around the outside of the inner insulating layer (7); the conductor (6), the inner insulating layer (7) and the inner shielding layer (8) constitute a wire core structure of the cable (1).

3. A lightweight and high-toughness automotive wiring harness according to claim 1, characterized in that: The flame retardant substrate layer (901) is fixed to the inner shielding layer (8) and the composite anti-interference layer (10) via a thermoplastic adhesive, an annularly distributed cavity is provided inside the flame retardant substrate layer (901), and the heat dissipation enhancement layer (902) is filled inside the flame retardant substrate layer (901).

4. A lightweight and high-toughness automotive wiring harness according to claim 1, characterized in that: The shielding substrate layer (1001) is coated on the outside of the flame-retardant heat dissipation layer (9) by means of a thermoplastic adhesive, and the shielding mesh layer (1002) is woven in a mesh shape on the outside of the shielding substrate layer (1001).

5. The lightweight and high-toughness automotive wiring harness according to claim 1, characterized in that: The lightweight substrate layer (1101) is coated on the outside of the composite anti-interference layer (10) through a foaming device, the high-toughness reinforcement layer (1102) is spirally wound on the outside of the lightweight substrate layer (1101), the fireproof layer (1103) is wrapped on the outside of the high-toughness reinforcement layer (1102) through an extrusion device, and the wear-resistant layer (1104) is wrapped on the outside of the fireproof layer (1103) through an extrusion device.

6. A lightweight and high-toughness automotive wiring harness according to claim 1, characterized in that: A spiral spring wire (12) is embedded in one side of the inner part of the outer sheath (11), and the spiral spring wire (12) enables the cable (1) to have a spiral structure.

7. A lightweight and high-toughness automotive wiring harness according to claim 3, characterized in that: A halogen-free flame retardant is added to the flame-retardant substrate layer (901), and the halogen-free flame retardant includes aluminum hydroxide and magnesium hydroxide.

8. A lightweight and high-toughness automotive wiring harness according to claim 4, characterized in that: A thermoplastic adhesive is provided between the shielding substrate layer (1001) and the shielding mesh layer (1002), and flame-retardant particles are added to the thermoplastic adhesive of the layer to form a composite heat-insulating layer.

9. A lightweight and high-toughness automotive wiring harness according to claim 1, characterized in that: The front end of the charging plug (2) is provided with a rubber wheel (5) at the top and bottom, and the rubber wheel (5) is connected to the charging plug (2) via a rotating shaft. The rear end of the charging plug (2) is provided with a limit slide groove (14) at the top and bottom, and the limit slide grooves (14) are staggered front to back. A water baffle (3) is slidably installed inside the limit slide groove (14). A driving pulley (19) is fixedly installed at one end of the rotating shaft of the rubber wheel (5). A rack plate (19) is provided on one side of the water baffle (3). 3), a driven gear (15) is provided at the lower end of one side of the rack plate (13), the shaft of the driven gear (15) is rotatably connected to the charging plug (2), and the driven gear (15) is meshed with the rack plate (13), a transmission gear (16) is meshedly installed on one side of the driven gear (15), a driven pulley (17) is fixedly installed on the shaft at one end of the transmission gear (16), and the driven pulley (17) is connected to the driving pulley (19) through a belt (18).

10. A lightweight and high-toughness automotive wiring harness according to claim 9, characterized in that: A plug-in block (4) is arranged above the middle position of the charging plug (2).

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