Universal protection structure with independent wire harness, functional wire harness and manufacturing method thereof

Abstract

The invention discloses a universal protection structure with independent wire harnesses, a functional wire harness and a manufacturing method of the functional wire harness, the universal protection structure comprises the independent wire harnesses arranged side by side and a hollow pipe used for integrating a functional wire harness bus, and an injection molding rubber sleeve is integrally formed outside the independent wire harnesses and the hollow pipe in an injection molding mode. According to the universal anti-expansion structure with the independent wire harnesses, the hollow pipe and the independent wire harnesses are injection-molded into a whole directly through the injection mold, and then the wire harnesses needing to be combined are randomly arranged in the hollow pipe in a penetrating manner according to requirements, so that the universal design is realized, any combination of different wire harnesses can be met, and any combination of wires of different specifications can be realized; the method is high in flexibility, low in cost, good in stability and high in quality.

Description

Technical Field

[0001] The invention relates to the technical field of automobile cables, and in particular to a universal protective structure with an independent wiring harness and a functional wiring harness and a manufacturing method thereof. Background Art

[0002] With the continuous development of automobile intelligence, more and more control systems are needed, and more and more functional wiring harnesses are needed. The wires and signal harnesses inside the car body need to be led out to different parts, such as the anti-lock braking system ABS harness, the body height sensor harness, the EPB harness, the wear plug alarm harness, the electronic brake force distribution EBD harness, the dynamic adaptive chassis control system DCC harness, the brake pad wear status prompt system BVA harness, the automobile xenon headlight GDL harness, the dynamic adaptive chassis control system DCC and the automobile brake friction pad friction alarm system BVA harness, etc. In the process of leading out, in order to prevent the lead-out part from rubbing against the automobile sheet metal, a flared sheath will be set at the connection for protection, so as to avoid the vibration of the car during driving, which will cause the cable at the lead-out part to be damaged and broken, reduce safety hazards, and improve the reliability of the car.

[0003] In order to prevent the wear of the wiring harness and resist external chemical corrosion, make the product more solid, prevent it from falling off due to the vibration of the vehicle during driving, and avoid confusion caused by the lead-out of many wiring harnesses, it is usually adopted to pass all the wiring harnesses into a hollow tube, and then inject a bell-mouth protective cover on the outside of the hollow tube.

[0004] However, during the manufacturing process of the above technical solution, when multiple wire harnesses are directly injected through the PUR tube, there is a gap between the PUR tube and the wire harnesses. During the injection molding, the outer surface of the PUR is filled with glue. During the filling process, the PUR tube is easily subjected to the injection molding pressure, which may cause the outer surface of the PUR tube to dent, making the product scrapped, resulting in a low yield and high production cost.

[0005] Moreover, more importantly, this method can only meet the production of wiring harnesses with the same function at one time, and cannot meet the one-time production of functional wiring harnesses with different functions of different specifications, and cannot form the requirements of universal design.

[0006] In view of the above-mentioned problems in the prior art, it is necessary to design a product that can not only solve the problem of product scrapping caused by stress deformation of PUR tube during injection molding, but also meet the problem of arbitrary combination of wiring harnesses and realize universal design. Different wiring harnesses can be arranged according to product requirements to make various combinations of wiring harnesses. It can also prevent wear of the wires and resist external chemical corrosion, making the product more firm and preventing it from falling off due to vibration during driving of the vehicle. Summary of the invention

[0007] The purpose of the present invention is to solve the problems of low yield rate in the production process of the existing electronic parking wire and inability to meet the universal design requirements of different wiring harnesses, and to provide a universal protective structure and functional wiring harness with independent wiring harnesses, which has high stability and excellent quality, does not have the problem of damage to the hollow PUR tube by the rubber during injection molding, and can meet the universal design requirements of different wiring harness combinations, can realize arbitrary combination of wires of different specifications, has high flexibility, and has low cost, and a manufacturing method thereof.

[0008] The technical solution adopted by the present invention to achieve the first invention purpose is: a universal protection structure with independent wiring harnesses, including independent wiring harnesses arranged side by side and a hollow tube for integrating a functional wiring harness bus, and an injection-molded rubber sleeve is integrally injection-molded on the outside of the independent wiring harness and the hollow tube. The universal anti-expansion structure with independent wiring harnesses can select one of the special, important or complex wiring harnesses as an independent wiring harness as an injection-molded insert and injection-molded together with the hollow tube according to the needs of the automobile wiring and control system settings, and the injection-molded rubber sleeve is molded on the outside to achieve protection during the docking process with the automobile sheet metal, thereby avoiding damage to the wiring harness during the movement of the automobile. At the same time, in order to avoid the problem of damage to the hollow tube and poor stability caused by inserting all the wire cores of the functional combination into the hollow tube before injection molding, the core wire is not inserted into the hollow tube in advance, but the hollow tube and the independent wire harness are directly injection molded into one through an injection mold, and then the wire harness to be combined is arbitrarily inserted into the hollow tube as needed, thereby realizing a universal design that can meet the requirements of any combination of different wire harnesses and any combination of wires of different specifications, with high flexibility and low cost. In addition, the independent line has a universal anti-expansion structure with good stability and high quality.

[0009] Preferably, the injection-molded rubber sleeve comprises an integrally formed bell-mouth portion and a clamping portion, the bell-mouth portion is provided with a bell-mouth clamping slot for clamping with the body sheet metal penetration opening on the outside, a docking cavity is provided inside the bell-mouth portion, and a plurality of positioning grooves are provided on the outside of the clamping portion. The injection-molded rubber sleeve is integrally formed with the bell-mouth portion and the clamping portion by injection molding, the bell-mouth portion is provided to facilitate the penetration of the bus and the docking with the automobile sheet metal penetration opening, thereby protecting the wiring harness, and the clamping portion is provided to protect the wiring harness and facilitate the fixation of the position, and the positioning groove can realize flexible positioning.

[0010] Preferably, the two ends of the hollow tube extend to the outside of the injection-molded rubber sleeve respectively. As a preferred solution, both ends of the hollow tube can extend outside the injection-molded rubber sleeve to achieve the combined threading of the wire harness. When in use, the hollow tube is supported inside and outside the opening of the automobile sheet metal, which is convenient for the threading of the wire harness and can also play an effective strength support role.

[0011] Preferably, one end of the hollow tube toward the clamping portion extends out of the injection cavity sleeve, and one end of the hollow tube toward the bell mouth portion is arranged inside the bell mouth. As another preferred solution, the hollow tube may have only one end extending outside the injection cavity sleeve, and one end toward the bell mouth portion is arranged inside the bell mouth, thereby achieving flexible docking between the bell mouth and the through-hole of the automobile sheet metal, and avoiding affecting flexibility due to the presence of the hollow tube.

[0012] Preferably, the hollow tube is a hollow polyurethane tube or a thermoplastic polyurethane elastomer rubber tube. The hollow tube can be made of different materials as needed, as long as it can meet the needs.

[0013] The technical solution adopted by the present invention to achieve the second invention purpose is: a functional wiring harness, including the universal protection structure with independent wiring harnesses, and a functional wiring harness bus is integrated inside the hollow tube. Since the independent wiring harnesses have been pre-formed, the functional wiring harness can form an integrated functional wiring harness with different functions by freely combining other functional wiring harnesses according to design requirements, which is easy to operate, flexible in combination, and has good versatility.

[0014] Preferably, the functional harness bus is any one or a combination of vehicle height sensor harness, anti-lock braking system harness, electronic brake force distribution harness, electronic parking brake system harness, dynamic adaptive chassis control system harness, brake pad wear status prompt system harness, automobile xenon headlight harness, dynamic adaptive chassis control system harness, automobile brake friction pad friction alarm system harness. The functional harness assembly can be assembled arbitrarily according to the needs of the automobile harness, and can be one or more, with flexible combination, which greatly reduces the difficulty and cost of making different harness assemblies.

[0015] The technical solution adopted by the present invention to achieve the third invention object is: a method for making a functional wiring harness, comprising the following steps: Step 1: Select the cables and a certain length of hollow tube as independent wiring harnesses; Step 2: Place the independent wire harness and hollow tube as inserts into a special mold for injection molding; Step 3: Insert a core rod that matches the inner diameter of the hollow tube into the hollow interior to support and position the hollow tube; Step 4: mold closing and injection molding; Step 5: Forming a universal protective structure with independent wiring harness; Step 6: According to the function setting requirements, select the single-core wires with corresponding combined functions to form a bus, and insert the bus from the bell mouth into the hollow tube of the universal protection structure in step 5; Step 7: Functionally branch the bus that passes through the hollow tube to form a corresponding functional wiring harness.

[0016] The method for making the functional wiring harness adopts the method of integrally injecting the independent wiring harness and the hollow tube side by side, and injecting the special, complex or important cables that are considered to need to form an independent wiring harness as inserts together with the hollow tube. The independent wiring harness does not need to be set up later, and only needs to pass the core wires that need to be combined with the independent wiring harness to form different functions through the hollow tube for bundle setting, so that any combination and integration of wiring harnesses with various functions can be realized, the number of molds is reduced, the production cost is reduced, the product quality is improved, the number of scrapped products is reduced, and a universal design is realized, which can meet the needs of the rapid development of automobile intelligence.

[0017] Preferably, the mold in step 2 includes an upper mold, a lower mold, a mold cavity, and a wire harness positioning cavity arranged inside the mold cavity for realizing independent wire harness positioning, a tube cavity for realizing hollow tube positioning, and a sheath molding cavity is arranged outside the wire harness positioning cavity and the tube cavity. The mold is designed according to the specific structure of the independent wire harness and the hollow tube, so as to facilitate the integrated injection molding of the injection rubber sleeve with good stability and high quality outside the independent wire harness and the hollow tube arranged side by side.

[0018] Preferably, the independent wiring harness is any one of a vehicle height sensor wiring harness, an anti-lock braking system wiring harness, an electronic brake force distribution wiring harness, an electronic parking brake system wiring harness, a dynamic adaptive chassis control system wiring harness, a brake pad wear status prompt system wiring harness, an automobile xenon headlight wiring harness, a dynamic adaptive chassis control system wiring harness, and an automobile brake friction pad friction warning system wiring harness. The independent wiring harness can be selected arbitrarily according to production needs.

[0019] The beneficial effects of the present invention are as follows: the universal anti-expansion structure with an independent wiring harness is directly injection-molded into one piece by a hollow tube and an independent wiring harness through an injection mold, and then the wiring harness to be combined is arbitrarily inserted into the hollow tube as needed, thereby achieving a universal design that can meet any combination of different wiring harnesses and any combination of wires of different specifications, with high flexibility, low cost, good stability and high quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a structural schematic diagram of a universal protective structure with an independent wiring harness of the present invention.

[0021] Figure 2 It is a front view of the universal protection structure with independent wiring harness of the present invention.

[0022] Figure 3 yes Figure 2 Middle AA section view.

[0023] Figure 4 It is a structural schematic diagram of a universal protection structure with an independent wiring harness in Example 2 of the present invention.

[0024] Figure 5 This is the main view of the universal protection structure with independent wiring harness in Example 2 of the present invention.

[0025] Figure 6 yes Figure 5 Middle BB section view.

[0026] Figure 7 It is a schematic diagram of an application structure of the universal protection structure with an independent wiring harness of the present invention.

[0027] Figure 8 It is a structural schematic diagram of the mold in the present invention.

[0028] Fig. 9 It is a structural schematic diagram of the mold cavity in the present invention.

[0029] Fig.10 It is a schematic diagram of the manufacturing process of the universal protective structure with an independent wiring harness of the present invention.

[0030] Fig.11 It is a schematic structural diagram of the universal protective structure with an independent wiring harness after molding of the present invention.

[0031] In the figure: 1. Independent wiring harness; 2. Hollow pipe, 21. Inlet straight pipe section, 22. Arc-shaped curved pipe section, 23. Outlet straight pipe section; 3. injection-molded rubber sleeve, 31. bell mouth portion, 32. clamping portion, 33. bell mouth clamping groove, 34. docking cavity, 35. positioning groove; 4. mold, 41. upper mold, 42. lower mold, 43. mold cavity, 44. harness positioning cavity, 45. tube cavity, 46. sheath forming cavity, 47. vertical cavity section, 48. arc cavity section, 49. mandrel positioning cavity; 5. Mandrel, 6. Positioning groove for pressing piece; 10. Vehicle height sensor wiring harness, 20. ABS wiring harness, 30. EPB wiring harness, 40. Grinding plug alarm wiring harness, 50. Straight sheath, 60. Straight casing, 70. First three-in-one sheath, 80. Second three-in-one sheath, 100. Bus. DETAILED DESCRIPTION

[0032] The various aspects of the present invention are described in detail below through specific embodiments in conjunction with the accompanying drawings.

[0033] Embodiment 1: exist Figure 1 , Figure 2 , Figure 3In the embodiment shown, a universal protective structure with an independent wiring harness includes an independent wiring harness 1 arranged side by side and a hollow tube 2 for integrating a functional wiring harness bus, and an injection-molded rubber sleeve 3 that is integrally molded and coated on the outside of the independent wiring harness 1 and the hollow tube 2. The hollow tube 2 can be a hollow PUR (polyurethane elastomer) tube or a hollow TPU (thermoplastic polyurethane elastomer rubber) tube. In this embodiment, the hollow tube 2 is a hollow PUR (polyurethane elastomer) tube.

[0034] The injection-molded rubber sleeve 3 is used to connect with the docking interface of the vehicle body, and the injection-molded rubber sleeve 3 is a trumpet-shaped structure.

[0035] The independent wire harness 1 is arranged side by side with the hollow tube 2. In this embodiment, the independent wire harness 1 is arranged in an arc shape with the injection-molded rubber sleeve 3 to facilitate connection with the vehicle body at a certain angle during use, thereby avoiding bending of the independent wire harness, thereby affecting the service life.

[0036] The hollow tube 2 is provided with an outlet straight tube section 23. The outlet straight tube section 23 has a tube opening connected to the bell mouth of the injection-molded rubber sleeve 3, so as to facilitate the wire harness to penetrate into the hollow tube from the bell mouth.

[0037] The injection-molded rubber sleeve 3 includes an integrally formed bell-mouth portion 31 and a clamping portion 32. The bell-mouth portion 31 is provided with a bell-mouth clamping groove 33 for clamping with the body sheet metal outside, and a docking cavity 34 is provided inside the bell-mouth portion 31. The clamping portion 32 is provided with a plurality of positioning grooves 35 outside. The independent wiring harness 1 and the hollow tube 2 extend out of the bell-mouth portion and the clamping portion, respectively.

[0038] like Fig.10 , Fig.11 As shown, a method for manufacturing a universal protective structure with an independent wiring harness comprises the following steps: Step 1: Select the cable as an independent wiring harness and a certain length of hollow PUR tube as the hollow tube; Step 2: Place the independent wiring harness and the hollow PUR tube as inserts into a special mold 4 for injection molding; Step 3: insert a core rod 5 that matches the inner diameter of the hollow PUR tube into the hollow PUR tube to support and position the hollow PUR tube; Step 4: mold closing and injection molding; Step 5: Forming a universal protective structure with independent wiring harnesses.

[0039] like Figure 8 , Fig. 9As shown, the special mold 4 in step 2 includes an upper mold 41, a lower mold 42, a mold cavity 43, and a wire harness positioning cavity 44 arranged inside the mold cavity 43 for realizing independent wire harness positioning, a tube cavity 45 for realizing hollow PUR tube positioning, and a sheath molding cavity 46 is arranged outside the wire harness positioning cavity 44 and the tube cavity 45.

[0040] The harness positioning cavity 44 and the tube cavity 45 are arranged in parallel. The harness positioning cavity 44 includes two vertical cavity sections 47 and an arcuate cavity section 48 connecting the two vertical cavity sections. The ends of the two vertical cavity sections 47 are arranged on two adjacent side surfaces of the lower mold. The arcuate cavity section 48 of the harness positioning cavity is arranged around the outside of the tube cavity 45. The tube cavity 45 is arranged inside the arcuate cavity section 48. The tube cavity is arranged parallel to one of the vertical cavity sections of the harness positioning cavity 44. A core rod positioning cavity 49 is arranged at one end of the tube cavity 45 close to the arcuate cavity section 48. During injection molding, the core rod is inserted into the hollow tube and abuts against the core rod positioning cavity 49. The hollow PUR tube is supported and limited by the core rod 5.

[0041] A clamping piece positioning groove 6 is provided on both sides of the tube cavity 45 and the vertical cavity section 47. After the independent wiring harness and the hollow PUR tube are placed in, the clamping piece is pressed on the outside of the independent wiring harness and the hollow PUR tube to realize positioning of the independent wiring harness and the hollow PUR tube, thereby avoiding displacement of the independent wiring harness and the hollow PUR tube during the injection molding process.

[0042] During injection molding, the independent wire harness 1 is placed as an insert into the wire harness positioning cavity 44 . The independent wire harness 1 is placed from one of the vertical cavity segments 47 , passes through the arc cavity segment 48 , and then extends from the other vertical cavity segment 47 .

[0043] The hollow PUR tube is placed in the tube cavity 45 , and then a core rod 5 matching the inner diameter of the hollow PUR tube is inserted into the hollow PUR tube, and the inner end of the core rod abuts against the core rod positioning cavity 49 to achieve positioning.

[0044] The independent wire harness 1 and the hollow PUR tube are positioned, then molded and cast to form an integrated universal wire harness protection structure.

[0045] This universal protection structure with independent wiring harness is widely used in various combined wiring harnesses such as anti-lock braking system ABS+electronic brake force distribution EBD wiring harness, anti-lock braking system ABS+electronic parking brake system EPB+dynamic adaptive chassis control system DCC wiring harness, anti-lock braking system ABS+brake pad wear status prompt system BVA wiring harness, anti-lock braking system ABS+automobile xenon headlight GDL wiring harness, anti-lock braking system ABS+dynamic adaptive chassis control system DCC+automobile brake friction pad friction alarm system BVA wiring harness.

[0046] The independent wiring harness 1 may be a sheathed electric wire or a sheathed system wiring harness.

[0047] The universal protective structure with independent wiring harnesses avoids the situation where multiple wires are inserted into a PUR tube before injection molding. Due to the gap between the PUR tube and the wires, the outer surface of the PUR is filled with glue during injection molding, and the injection pressure causes the outer surface of the PUR to sag, resulting in product scrapping.

[0048] The universal protective structure with independent wiring harness adopts the method of injection molding universal or special wiring harness as an independent wiring harness together with a hollow PUR tube to form a trumpet-shaped sheath on the outside, which can not only protect the independent wiring harness, but also can arbitrarily pass the single-core wires that need to be combined inside the hollow PUR tube as needed. According to product requirements, multiple single-core wires can be passed through, such as 4, 6, 8 or other N single-core wires of different specifications, and then combined and branched. The combination is flexible, the operation is more convenient, the yield rate is high, and the cost is low.

[0049] Embodiment 2: exist Figure 7 In the illustrated embodiment, a functional wiring harness includes a universal protective structure with an independent wiring harness, and a functional wiring harness bus 100 is integrated inside the hollow tube.

[0050] The functional wiring harness bus 100 is any one or a combination of a vehicle height sensor wiring harness, an anti-lock braking system wiring harness, an electronic brake force distribution wiring harness, an electronic parking brake system wiring harness, a dynamic adaptive chassis control system wiring harness, a brake pad wear status prompt system wiring harness, an automobile xenon headlight wiring harness, a dynamic adaptive chassis control system wiring harness, and an automobile brake friction pad friction alarm system wiring harness.

[0051] A method for making a functional wiring harness comprises the following steps: Step 1: Select the cables and a certain length of hollow tube as independent wiring harnesses; Step 2: Place the independent wire harness and hollow tube as inserts into a special mold for injection molding; Step 3: Insert a core rod that matches the inner diameter of the hollow tube into the hollow interior to support and position the hollow tube; Step 4: mold closing and injection molding; Step 5: Forming a universal protective structure with independent wiring harness; Step 6: According to the function setting requirements, select the single-core wires with corresponding combined functions to form a bus, and insert the bus from the bell mouth into the hollow tube of the universal protection structure in step 5; Step 7: Functionally branch the bus that passes through the hollow tube to form a corresponding functional wiring harness.

[0052] In this embodiment, the vehicle height sensor wiring harness is used as an independent wiring harness, and then the ABS wiring harness, EPB wiring harness, and grinding insert alarm wiring harness are integrated to form an integrated wiring harness assembly of ABS wiring harness + EPB wiring harness + vehicle height sensor wiring harness + grinding insert alarm wiring harness.

[0053] Specifically, the vehicle height sensor harness 10 has 6 shielded wires inside, and a wire sheath is provided outside the 6 shielded wires. The vehicle height sensor harness 10 is used as an independent harness and is placed in the harness positioning cavity as an insert. Then select a hollow PUR tube that can pass through the ABS harness 20, the EPB harness 30 and the grinding insert alarm harness 40, put the hollow PUR tube into the tube cavity, and insert a matching core rod into the hollow PUR tube to limit the position.

[0054] The independent wire harness and the hollow PUR tube are positioned, molded, and cast to form an integrated universal wire harness protection structure.

[0055] After the injection molding is completed, the core wires used to form the ABS wiring harness 20, the EPB wiring harness 30, and the grinding insert alarm wiring harness 40 are integrated to form a bus 100, on which a plastic shell and a terminal are integrated. The core wires in the bus 100 are wrapped with a tape for a section, and then the bus 100 is inserted into the hollow PUR tube from one end of the bell mouth and passed out at the other end of the hollow PUR tube. A straight sheath 50 is set at the passing end of the hollow PUR tube, and a straight sleeve 60 is connected to the straight sheath 50. After the bus 100 passes through the straight sheath 50, it passes through the straight sleeve 60. The other end of the straight sleeve 60 is provided with a first three-in-one sheath 70. The bus is first branched at the first three-in-one sheath 70, one of which is set for the EPB wiring harness, and the other continues to extend as needed, and then it is branched through the second three-in-one sheath 80 to form an ABS wiring harness branch and a grinding insert alarm wiring harness branch, respectively. Thereby, the core wires are arranged in accordance with the layout requirements of the ABS wiring harness, EPB wiring harness, and grinding plug alarm wiring harness.

[0056] This functional wiring harness avoids the situation where multiple wires are inserted into a PUR tube before injection molding. Due to the gap between the PUR tube and the wires, the outer surface of the PUR is filled with glue during injection molding, and the injection pressure causes the outer surface of the PUR to sag, resulting in product scrapping.

[0057] This functional wiring harness uses a universal or special wiring harness as an independent wiring harness and is injection molded together with a hollow PUR tube to form a trumpet-shaped sheath on the outside, which can not only protect the independent wiring harness, but also can arbitrarily pass the single-core wires that need to be combined inside the hollow PUR tube as needed. According to product requirements, multiple single-core wires can be passed through, such as 4, 6, 8, etc. N single-core wires of different specifications, and then combined and branched. The combination is flexible, the operation is more convenient, the yield rate is high, and the cost is low.

[0058] Embodiment 3: exist Figure 4 , Figure 5 , Figure 6 In the embodiment shown, a universal protective structure with an independent wiring harness includes an independent wiring harness 1 and a hollow tube 2 that are integrally injection molded, and an injection-molded rubber sleeve 3 that is integrally injection molded and covers the independent wiring harness 1 and the hollow tube 2. In this embodiment, the hollow tube 2 is a hollow PUR (polyurethane elastomer) tube.

[0059] The hollow tube 2 is a hollow tube with an arc-shaped transition section, including an inlet straight tube section 21 , an arc-shaped curved tube section 22 and an outlet straight tube section 23 .

[0060] The injection-molded rubber sleeve 3 is used to connect with the docking interface of the vehicle body, and the injection-molded rubber sleeve 3 is a trumpet-shaped structure.

[0061] The independent wire harness 1 is arranged side by side with the hollow tube 2. In this embodiment, the independent wire harness 1 and the hollow tube 2 are arranged in an arc shape with the injection-molded rubber sleeve 3 to facilitate connection with the vehicle body at a certain angle during use, thereby avoiding bending of the independent wire harness, which affects the service life.

[0062] The injection-molded rubber sleeve 3 includes an integrally formed bell-mouth portion 31 and a clamping portion 32. The bell-mouth portion 31 is provided with a bell-mouth clamping groove 33 for clamping with the body sheet metal outside, and a docking cavity 34 is provided inside the bell-mouth portion 31. The clamping portion 32 is provided with a plurality of positioning grooves 35 outside. The independent wiring harness 1 and the hollow tube 2 extend out of the bell-mouth portion and the clamping portion, respectively.

[0063] A method for manufacturing a universal protective structure with an independent wiring harness comprises the following steps: Step 1: Select the cable as an independent wiring harness and a certain length of hollow PUR tube as the hollow tube; Step 2: Place the independent wiring harness and the hollow PUR tube as inserts into a special mold 4 for injection molding; Step 3: insert a core rod 5 that matches the inner diameter of the hollow PUR tube into the hollow PUR tube to support and position the hollow PUR tube; Step 4: mold closing and injection molding; Step 5: Forming a universal protective structure with independent wiring harnesses.

[0064] The special mold 4 in step 2 includes an upper mold 41, a lower mold 42, a mold cavity 43, and a wire harness positioning cavity 44 arranged inside the mold cavity 43 for realizing independent wire harness positioning, a tube cavity 45 for realizing hollow PUR tube positioning, and a sheath molding cavity 46 is arranged outside the wire harness positioning cavity 44 and the tube cavity 45.

[0065] The harness positioning cavity 44 and the tube cavity 45 are arranged in parallel, and the harness positioning cavity 44 includes two vertical cavity sections 47 and an arcuate cavity section 48 connecting the two vertical cavity sections. The ends of the two vertical cavity sections 47 are arranged on two adjacent side surfaces of the lower mold, and the arcuate cavity section 48 of the harness positioning cavity is arranged around the outside of the tube cavity 45. The tube cavity 45 is arranged inside the arcuate cavity section 48, and the shape of the tube cavity is arranged in parallel with the harness positioning cavity 44 to form a consistent structure. During injection molding, the core rod is inserted into the hollow tube, and the hollow PUR tube is supported and limited by the core rod.

[0066] A clamping piece positioning groove 6 is provided on both sides of the tube cavity 45 and the vertical cavity section 47. After the independent wiring harness and the hollow PUR tube are placed in, the clamping piece 7 is pressed on the outside of the independent wiring harness and the hollow PUR tube to realize positioning of the independent wiring harness and the hollow PUR tube, thereby avoiding displacement of the independent wiring harness and the hollow PUR tube during the injection molding process.

[0067] During injection molding, the independent wire harness 1 is placed as an insert into the wire harness positioning cavity 44 . The independent wire harness 1 is placed from one of the vertical cavity segments 47 , passes through the arc cavity segment 48 , and then extends from the other vertical cavity segment 47 .

[0068] The hollow PUR tube is placed in the tube cavity 45, and then a core rod 5 matching the inner diameter of the hollow PUR tube is inserted into the hollow PUR tube to achieve positioning, with both ends of the core rod extending to the outside of the tube cavity respectively.

[0069] The independent wire harness 1 and the hollow PUR tube are positioned, then molded and cast to form an integrated universal wire harness protection structure.

[0070] This universal protection structure with independent wiring harness is widely used in various combined wiring harnesses such as anti-lock braking system ABS+electronic brake force distribution EBD wiring harness, anti-lock braking system ABS+electronic parking brake system EPB+dynamic adaptive chassis control system DCC wiring harness, anti-lock braking system ABS+brake pad wear status prompt system BVA wiring harness, anti-lock braking system ABS+automobile xenon headlight GDL wiring harness, anti-lock braking system ABS+dynamic adaptive chassis control system DCC+automobile brake friction pad friction alarm system BVA wiring harness.

[0071] The independent wiring harness 1 may be a sheathed electric wire or a sheathed system wiring harness.

[0072] In this embodiment, the ABS wiring harness is used as an independent wiring harness, and then the EPB wiring harness and the dynamic adaptive chassis control system DCC wiring harness are integrated to form an integrated wiring harness assembly of the ABS wiring harness + EPB wiring harness + dynamic adaptive chassis control system DCC wiring harness.

[0073] Specifically, the ABS wire harness is treated as an independent wire harness and placed in the wire harness positioning cavity as an insert; Then select a hollow PUR tube that can meet the requirements of the EPB wiring harness + dynamic adaptive chassis control system DCC wiring harness, place the hollow PUR tube into the tube cavity, and insert a matching core rod into the hollow PUR tube to limit it.

[0074] The independent wire harness and the hollow PUR tube are positioned, molded, and cast to form an integrated universal wire harness protection structure.

[0075] After the injection molding is completed, the core wires used to form the EPB harness + dynamic chassis control system DCC harness are integrated to form a bus 100. A plastic shell and a terminal are integrated on the bus 100. The core wires in the bus 100 are wrapped with a tape for a section, and then the bus 100 is inserted into the hollow PUR tube from one end of the bell mouth and passed out from the other end of the hollow PUR tube. A straight sheath 50 is set at the end of the hollow PUR tube, and a straight sleeve 60 is connected to the straight sheath 50. After the bus 100 passes through the straight sheath 50, it passes through the straight sleeve 60. The other end of the straight sleeve 60 is provided with a first three-in-one sheath 70. The bus is first divided in the first three-in-one sheath 70, one of which is set for the EPB harness and the other forms the dynamic chassis control system DCC harness. In this way, the core wires are arranged according to the layout requirements of the ABS harness, EPB harness, and dynamic chassis control system DCC harness.

[0076] The universal protective structure and functional wiring harness with independent wiring harnesses avoids the situation where multiple wires are inserted into a PUR tube before injection molding. Due to the gap between the PUR tube and the wires, the outer surface of the PUR is filled with glue during injection molding, and the injection pressure causes the outer surface of the PUR to sag, resulting in product scrapping.

[0077] The universal protective structure and functional wiring harness with independent wiring harness adopts the method of injection molding universal or special wiring harness as an independent wiring harness together with a hollow PUR tube to form a trumpet-shaped sheath on the outside, which can not only protect the independent wiring harness, but also can arbitrarily pass the single-core wires that need to be combined inside the hollow PUR tube as needed. According to product requirements, multiple single-core wires can be passed through, such as 4, 6, 8 or other N single-core wires of different specifications, and then combined and branched. The combination is flexible, the operation is more convenient, the yield rate is high, and the cost is low.

[0078] The universal protective structure and functional wiring harness with an independent wiring harness places a special or complex cable with a certain outer diameter as an independent wiring harness and a hollow tube passed through a core rod into the mold cavity. Since the cable is solid, it will not be damaged by pressure during injection molding, and the hollow tube is hollow. Therefore, the core rod is passed through the inside of the hollow tube to ensure that the hollow tube is not damaged by pressure during the injection molding process, so that an injection-molded rubber sleeve is integrally injection-molded on the outside of the independent wiring harness and the hollow tube to achieve docking with the body sheet metal to facilitate the lead-out of other cables.

[0079] The universal protective structure and functional wiring harness with independent wiring harness effectively solve the problem in the prior art of passing multiple wires through a hollow tube and then directly injection molding a sheath on the outside of the hollow tube. Since there is a gap between the hollow tube and the wires, the outer surface of the hollow tube is easily dented due to the injection pressure during injection molding, resulting in product scrapping.

[0080] The universal protective structure and functional wiring harness with independent wiring harnesses realizes universal design, avoids the problem that each combination of wiring harnesses needs to be molded separately, and the cost is high. The independent wiring harness is injected together with the hollow tube. After the hollow tube is inserted into the core rod and placed in the mold cavity, the injection molding process is highly stable and of excellent quality. There is no damage to the hollow tube by the rubber during injection molding. The inside of the injection molding hollow tube is still hollow, and multiple wires, such as 4, 6, 8 and other wires of different specifications, can be passed through according to product requirements, and can be flexibly combined according to the specific layout. It has a wide range of applications, high versatility and practicality. It greatly improves production efficiency and reduces production costs and operating difficulties.

[0081] It can be widely used in various functional wiring harnesses of automobiles, such as anti-lock braking system ABS+electronic brake force distribution EBD wiring harness, anti-lock braking system ABS+electronic parking brake system EPB+dynamic adaptive chassis control system DCC wiring harness, anti-lock braking system ABS+brake pad wear status prompt system BVA wiring harness, anti-lock braking system ABS+automobile xenon headlight GDL wiring harness, anti-lock braking system ABS+dynamic adaptive chassis control system DCC+automobile brake friction pad friction alarm system BVA wiring harness and other combined wiring harnesses.

[0082] The above specific implementation modes / embodiments are specific implementation modes of the present invention, which are used to illustrate the concept of the present invention, are explanatory and exemplary, and should not be interpreted as limiting the implementation modes of the present invention and the scope of the present invention. In addition to the embodiments described herein, those skilled in the art can also adopt other obvious technical solutions based on the contents disclosed in the claims and the specification of this application, and these technical solutions include any obvious replacement and modification of the embodiments described herein, which are within the protection scope of the present invention.

Claims

1. A universal protective structure with an independent wiring harness, characterized in that: The invention comprises independent wiring harnesses (1) arranged side by side and a hollow tube (2) for integrating a functional wiring harness bus, wherein an injection-molded rubber sleeve (3) is integrally injection-molded outside the independent wiring harness (1) and the hollow tube (2).

2. The universal protective structure with independent wiring harness according to claim 1, characterized in that: The injection-molded rubber sleeve (3) comprises an integrally formed bell-mouth portion (31) and a clamping portion (32); the bell-mouth portion (31) is provided with a bell-mouth clamping groove (33) for clamping with a through-hole of a vehicle body sheet metal on the outside; a docking cavity (34) is provided inside the bell-mouth portion (31); and the clamping portion (32) is provided with a plurality of positioning grooves (35) on the outside.

3. The universal protective structure with independent wiring harness according to claim 2, characterized in that: Both ends of the hollow tube (2) extend to the outside of the injection-molded rubber sleeve (3) respectively.

4. The universal protective structure with independent wiring harness according to claim 2, characterized in that: One end of the hollow tube (2) facing the clamping portion (32) extends out of the injection molding cavity sleeve (3), and one end of the hollow tube (2) facing the bell mouth portion (31) is arranged inside the bell mouth.

5. The universal protective structure with independent wiring harness according to any one of claims 1 to 4, characterized in that: The hollow tube (2) is a hollow polyurethane tube or a thermoplastic polyurethane elastomer rubber tube.

6. A functional wiring harness, characterized in that: The universal protective structure with an independent wiring harness comprises any one of claims 1 to 5, wherein a functional wiring harness bus is integrated inside the hollow tube.

7. The functional wiring harness according to claim 6, characterized in that: The functional wiring harness bus is any one or a combination of the following: vehicle height sensor wiring harness, anti-lock braking system wiring harness, electronic brake force distribution wiring harness, electronic parking brake system wiring harness, dynamic adaptive chassis control system wiring harness, brake pad wear status prompt system wiring harness, automobile xenon headlight wiring harness, dynamic adaptive chassis control system wiring harness, and automobile brake friction pad friction alarm system wiring harness.

8. A method for manufacturing a functional wiring harness according to claim 6 or 7, characterized in that The following steps are involved: Step 1: Select the cables and a certain length of hollow tube as independent wiring harnesses; Step 2: Place the independent wire harness and hollow tube as inserts into a special mold for injection molding; Step 3: Insert a core rod that matches the inner diameter of the hollow tube into the hollow interior to support and position the hollow tube; Step 4: mold closing and injection molding; Step 5: Forming a universal protective structure with independent wiring harness; Step 6: According to the function setting requirements, select the single-core wires with corresponding combined functions to form a bus, and insert the bus from the bell mouth into the hollow tube of the universal protection structure in step 5; Step 7: Functionally branch the bus that passes through the hollow tube to form a corresponding functional wiring harness.

9. The method for making a functional wiring harness according to claim 8, characterized in that: The mold in step 2 includes an upper mold (41), a lower mold (42), a mold cavity (43), and a wire harness positioning cavity (44) arranged inside the mold cavity (43) for realizing independent wire harness positioning, a tube cavity (45) for realizing hollow tube positioning, and a sheath molding cavity (46) is arranged outside the wire harness positioning cavity (44) and the tube cavity (45).

10. The method for making a functional wiring harness according to claim 8, characterized in that: The independent wiring harness is any one of a vehicle height sensor wiring harness, an anti-lock braking system wiring harness, an electronic braking force distribution wiring harness, an electronic parking brake system wiring harness, a dynamic adaptive chassis control system wiring harness, a brake pad wear status prompt system wiring harness, an automobile xenon headlight wiring harness, a dynamic adaptive chassis control system wiring harness, and an automobile brake friction pad friction alarm system wiring harness.

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