Easily-bent branch wire harness connection structure and manufacturing method thereof

Abstract

The invention discloses an easy-to-bend bifurcated wire harness connection structure and a manufacturing method thereof, relates to the technical field of engine cables, and aims to solve the problems of poor bending performance, insufficient oil resistance and weak anti-electromagnetic interference capability of a wire harness in the prior art. The wire harness comprises the wire, the wave-proof sleeve and the nitrile rubber sheath, after sleeving, the wire harness can be tightly hooped to prevent the internal wire from moving, trace gaps are reserved to assist bending, and the flexibility of the wire harness is improved. The middle section of the wire harness is provided with the forked injection molding assembly, the forked position is fixed through the forked injection molding layer and the forked epoxy glue layer, and firm connection is ensured through wire core bundle welding and fuse binding. The end part of the wire harness is provided with a tail-attached injection molding assembly, and the wire harness is fixedly connected with the connector and the tail-attached injection molding assembly through a tail-attached injection molding layer and a tail-attached epoxy glue layer. Particularly, one end of the reinforced wave-proof sleeve is sleeved at the connecting end part of the wave-proof sleeve, the other end of the reinforced wave-proof sleeve is turned outwards to the outer side of the connector tail attachment, and 360-degree shielding layer shell connection is realized through wire core bundle welding, so that the anti-electromagnetic interference performance is remarkably improved.

Description

Technical Field

[0001] The invention relates to the technical field of engine cables, and in particular to a bifurcated wire harness connection structure that is easy to bend. Background Art

[0002] In modern military equipment, especially tanks, the stability and reliability of their electrical systems are crucial. As an important part of the electrical system, the tank wiring harness not only needs to withstand the mechanical stress during vehicle operation, but also needs to have good weather resistance and anti-electromagnetic interference performance to ensure normal operation in various complex environments. However, the existing tank wiring harness has the following problems: Poor bending performance: The outermost layer of traditional tank wiring harnesses is usually protected by heat shrink tubing. Although heat shrink tubing can provide certain protection, in actual applications, the overall flexibility of the wiring harness is reduced because the heat shrink tubing fits too closely with the internal anti-wave sleeve after shrinkage, making it difficult to adapt to frequent bending and vibration, which can easily cause the wiring harness to break or be damaged.

[0003] Insufficient oil resistance: Although heat shrink tubing and double-wall heat shrink tubing can resist the influence of the external environment to a certain extent, their oil resistance is poor, which will accelerate the aging and failure of the heat shrink tubing, shorten the service life of the wiring harness, and increase maintenance costs.

[0004] Weak anti-electromagnetic interference performance: In the prior art, when the wiring harness is connected to the connector, the wave-proof sleeve at the connection end usually needs to be broken up and tied to the outside of the connector tail. This practice destroys the original structural integrity of the wave-proof sleeve, causing the connection part between the wave-proof sleeve and the connector tail to lose its effective shielding effect, and cannot meet the strict electromagnetic compatibility requirements, especially in a high-density electromagnetic interference environment, which may affect the normal operation of the vehicle electrical system. Summary of the invention

[0005] In order to make up for the above shortcomings, the present invention provides an easy-to-bend forked wire harness connection structure. The first purpose is to solve the problem of poor bending and oil resistance of the wire harness, and the second purpose is to solve the problem of poor anti-electromagnetic interference performance of the connection part between the wire harness and the connector tail.

[0006] The present invention is realized by the following technical scheme: a forked wire harness connection structure that is easy to bend, comprising a wire harness, a connector connected to both ends of the wire harness and a connector tail attached to the connector, characterized in that: the wire harness comprises a wire, a wave-proof sleeve sleeved on the outside of the wire and a nitrile rubber sheath sleeved on the outside of the wave-proof sleeve; a forked injection molding component for dividing the wire harness into a plurality of wire harnesses is arranged at the middle section of the wire harness; the ends of the wire harness are connected and fixed to the connector tail attachment through the tail attachment injection molding component; The bifurcated injection molding component comprises a bifurcated injection molding layer, a bifurcated epoxy adhesive layer embedded inside the bifurcated injection molding layer; the wave-proof sleeve inside the bifurcated epoxy adhesive layer is sleeved on the outside of the wave-proof sleeve of the bifurcated wiring harness, and connected by welding the wire core; a fuse is tied to the nitrile rubber sheath inside the bifurcated epoxy adhesive layer; The tail attachment injection molding assembly includes a tail attachment injection molding layer and a tail attachment epoxy glue layer potted inside the tail attachment injection molding layer; a reinforcement anti-wave sleeve is also provided on the inner side of the tail attachment epoxy glue layer, one end of the reinforcement anti-wave sleeve is sleeved on the connecting end of the anti-wave sleeve, and the other end is turned outward and sleeved on the outer side of the connector tail; wire cores for reinforcing the connection are respectively welded on the outer sides of both ends of the reinforcement anti-wave sleeve; a fuse is tied on the outer side of the nitrile rubber sheath at the connecting end; and epoxy glue is potted inside the connector tail.

[0007] Furthermore, the manufacturing method of the easily bendable bifurcated wire harness connection structure comprises the following steps: Wiring: Use shielded wires for wiring according to electrical principles; Installation of anti-wave sleeve: Put the anti-wave sleeve on the outside of the wire; Installation of nitrile rubber sheath: Put the nitrile rubber sheath on the outside of the wave-proof sheath, making sure that the sheath and the wire harness are basically in close contact, but not completely tight, leaving a slight gap to assist in bending the wire harness; Production of forked injection molding components: Use wire cores to weld and fix the wave-proof sleeve at the position where forking is required; Use a fuse to tie and fix the nitrile rubber sheath; use DG-3S epoxy glue for potting to form a bifurcated epoxy glue layer; perform injection molding on the bifurcated position to form a bifurcated injection molding layer; Wire end welding: weld the end of the wire into the connector and blow heat shrink tubing at the welding position for protection; Installation of reinforced anti-wave sleeve: put the reinforced anti-wave sleeve on the anti-wave sleeve at the wire access end, and fix it by welding the wire core; Connector tail installation: Install the connector tail and use GMX-351 epoxy glue to potting inside the connector tail to fix the connected wires and surge protector to the connector tail; Reinforced wave-proof sleeve turned outward: turn the reinforced wave-proof sleeve outward to the outside of the connector tail, and use the wire core to connect the turned-out reinforced wave-proof sleeve to the connector tail to achieve the purpose of 360° shielding layer connection to the shell; Tail-attached injection molding assembly production: Use a fuse to tie and fix the nitrile rubber sheath; use GMX-351 epoxy glue for potting to form a tail-attached epoxy glue layer; injection mold the connecting end to form a tail-attached injection molding layer. Compared with the prior art, the invention has the following beneficial effects and features: Adopt nitrile rubber sheath: replace the traditional heat shrink tube, nitrile rubber has excellent elasticity and oil resistance, can ensure the flexibility of the wire harness while effectively resisting oil erosion and extending the service life of the wire harness.

[0008] Reinforced anti-wave sleeve design: By adding a layer of reinforced anti-wave sleeve between the anti-wave sleeve and the connector tail, a 360° fully enclosed shielding layer connection is achieved, which significantly improves the anti-electromagnetic interference performance and ensures the stable operation of the wiring harness in a high-density electromagnetic interference environment.

[0009] Optimized manufacturing process: The introduction of epoxy potting and injection molding processes ensures a firm connection between components, while improving the overall protection performance of the wiring harness, enabling it to adapt to a variety of complex working conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 It is a cross-sectional schematic diagram of the bifurcated injection molding component part of the present invention; Figure 3 It is a cross-sectional schematic diagram of the tail-attached injection molding component part of the present invention.

[0011] Explanation of the main component numbers in the figure: 1. Wire harness; 101. Wire; 102. Wave-proof sleeve; 103. Nitrile rubber sheath; 104. Wire core; 105. Fuse; 2. Forked injection molding assembly; 201. Forked injection molding layer; 202. Forked epoxy adhesive layer; 3. Tail-attached injection molding assembly; 301. Tail-attached injection molding layer; 302. Tail-attached epoxy adhesive layer; 303. Reinforced wave-proof sleeve; 304. Epoxy adhesive; 4. Connector; 401. Connector tail.

[0012] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. The other drawings obtained are all within the protection scope required by the present invention. DETAILED DESCRIPTION

[0013] The following combination Figure 1-3 , the contents of the present invention are described in detail through specific embodiments. Example

[0014] The easy-to-bend bifurcated wire harness connection structure comprises a wire harness 1, a connector 4 connected to both ends of the wire harness, and a connector tail 40 arranged on the connector, wherein: the wire harness comprises a wire 101, a wave-proof sleeve 102 sleeved on the outside of the wire, and a nitrile rubber sheath 103 sleeved on the outside of the wave-proof sleeve; a bifurcated injection molding component 2 for dividing the wire harness into a plurality of wire harnesses is arranged at the middle section of the wire harness; the ends of the wire harness are connected and fixed to the connector tail through a tail injection molding component 3; The bifurcated injection molding assembly includes a bifurcated injection molding layer 201, a bifurcated epoxy adhesive layer 202 embedded inside the bifurcated injection molding layer; the wave-proof sleeve inside the bifurcated epoxy adhesive layer is sleeved on the outside of the wave-proof sleeve of the bifurcated wiring harness, and is connected by welding the wire core 104; the nitrile rubber sheath inside the bifurcated epoxy adhesive layer is tied with a fuse 105; The tail attachment injection molding component includes a tail attachment injection molding layer 301, and a tail attachment epoxy glue layer 302 potted inside the tail attachment injection molding layer; a reinforcement wave-proof sleeve 303 is also arranged on the inner side of the tail attachment epoxy glue layer, one end of the reinforcement wave-proof sleeve is sleeved on the connecting end of the wave-proof sleeve, and the other end is turned outward and sleeved on the outer side of the connector tail; wire cores for reinforcing the connection are respectively welded on the outer sides of the two ends of the reinforcement wave-proof sleeve; a fuse is tied on the outer side of the nitrile rubber sheath at the connecting end; and epoxy glue 304 is potted inside the connector tail.

[0015] Preferably, the manufacturing method of the easily bendable bifurcated wire harness connection structure comprises the following steps: 1. Material selection and preparation Wire 101: Use shielded wire that meets military standards, which has good conductivity and anti-interference performance.

[0016] Wave-proof sleeve 102: Made of metal woven mesh or metal foil, it has excellent electromagnetic shielding effect.

[0017] Nitrile rubber sheath 103: Nitrile rubber material with good elasticity and oil resistance is selected to ensure that the wire harness can still maintain flexibility and protective performance in harsh environments.

[0018] Epoxy glue: DG-3S epoxy glue is used for potting of the bifurcated injection molding layer and the tail injection molding layer, and GMX-351 epoxy glue is used to reinforce the anti-wave sleeve and the potting inside the connector tail. These two epoxy glues have fast curing, high strength and good chemical corrosion resistance.

[0019] Fuse 105: Use high-strength, high-temperature resistant metal wire to bind and fix the nitrile rubber sheath to ensure its firmness at the bifurcation position.

[0020] Reinforced wave-proof sleeve 303: Choose a metal braided mesh made of the same material as the wave-proof sleeve. The length should be sufficient to cover the outside of the connector tail and leave enough margin for outward turning processing.

[0021] 2. Wire harness routing and assembly 2.1 Wire routing Use shielded wires for wiring according to the electrical schematics. Make sure the wires are arranged neatly to avoid crossing and entanglement to reduce signal interference and mechanical stress.

[0022] 2.2 Installation of wave shield The wave-proof sleeve 102 is sequentially sleeved on the outside of the wire 101, and the length of the wave-proof sleeve is ensured to be sufficient to cover the length of the entire wire harness. Sufficient space should be reserved at both ends of the wave-proof sleeve for subsequent bifurcation and connection operations.

[0023] 2.3 Installation of Nitrile Rubber Sheath Put the nitrile rubber sheath 103 on the outside of the anti-wave sheath 102, and ensure that the sheath is basically fitted to the wire harness, but not completely tight, leaving a slight gap to assist the bending of the wire harness. The length of the sheath should cover the outer surface of the entire wire harness, and leave appropriate processing allowances at the fork position and the connector tail.

[0024] 3. Fabrication of bifurcated injection molding components 3.1 The bifurcation position of the wave-proof sleeve is fixed At the position where bifurcation is required, the wave-proof sleeve 102 is welded and fixed with the wire core 104 to ensure that the connection between the branch wire harnesses after bifurcation is firm and to prevent the wave-proof sleeve from loosening or slipping off.

[0025] 3.2 Nitrile rubber sheath fork position fixed At the bifurcation position, the nitrile rubber sheath 103 is tied and fixed with a fuse 105 to ensure that the sheath does not move at the bifurcation position. When tying, attention should be paid to moderate strength to ensure the fixing effect without damaging the sheath.

[0026] 3.3 Epoxy potting At the bifurcation position, DG-3S epoxy glue is used for potting to ensure that the wave-proof sleeve and the nitrile rubber jacket are firmly connected and form a bifurcation epoxy glue layer 202. During potting, the epoxy glue should be evenly distributed to avoid bubbles and gaps.

[0027] 3.4 Forked Injection Molding After potting is completed, the bifurcated position is injection molded to form a bifurcated injection molding layer 201. The injection molding material should be compatible with the nitrile rubber sheath to ensure good bonding between the injection molding layer and the sheath. After injection molding, wait for the epoxy glue and the injection molding material to be completely cured to complete the production of the bifurcated injection molding component.

[0028] 4. Production of tail-attached injection molding components 4.1 Wire end welding The end of the wire 101 is welded to the connector 4 to ensure that the welding point is firm and reliable. After welding is completed, a heat shrink tube is blown on the welding position for protection to prevent the welding point from being affected by the external environment.

[0029] 4.2 Reinforcement of wave-proof sleeve installation The reinforcing wave-proof sleeve 303 is put on the wave-proof sleeve 102 at the wire access end, and fixed by welding the wire core 104 to ensure that the connection between the reinforcing wave-proof sleeve and the wave-proof sleeve is firm. The length of the reinforcing wave-proof sleeve should be enough to cover the outside of the connector tail 401, and leave enough margin for external turning.

[0030] 4.3 Connector tail installation Install the connector tail 401 and use GMX-351 epoxy glue to potting inside the connector tail to fix the connected wires and wave shield to the connector tail. When potting, ensure that the epoxy glue is evenly distributed to avoid bubbles and gaps.

[0031] 4.4 Reinforced anti-wave cover eversion The reinforced anti-wave sleeve 303 is turned outward to the outside of the connector tail 401, and the turned outward reinforced anti-wave sleeve is connected to the connector tail using the wire core 104, so as to achieve the purpose of 360° connection of the wire harness shielding layer to the shell and provide overall electromagnetic shielding.

[0032] 4.5 Nitrile rubber sheath fixing At the connection end, the nitrile rubber sheath 103 is tied and fixed with a fuse 105 to ensure that the sheath does not move at the end of the connector. When tying, attention should be paid to moderate strength to ensure the fixing effect without damaging the sheath.

[0033] 4.6 Epoxy potting At the connection end, GMX-351 epoxy glue is used for potting to ensure that the connection between the reinforced wave-proof sleeve, the nitrile rubber sleeve and the connector tail is firm, and to form a tail epoxy glue layer 302. During potting, the epoxy glue should be evenly distributed to avoid bubbles and gaps.

[0034] 4.7 Tail Injection Molding After potting is completed, the connection end is injection molded to form a tail-attached injection molding layer 301. The injection molding material should be compatible with the nitrile rubber sheath to ensure good bonding between the injection molding layer and the sheath. After injection molding, wait for the epoxy glue and the injection molding material to be completely cured to complete the production of the tail-attached injection molding assembly.

Claims

1. A forked wire harness connection structure that is easy to bend, comprising a wire harness, a connector connected to both ends of the wire harness, and a connector tail attached to the connector, characterized in that; The wiring harness comprises a wire, a wave-proof sleeve sleeved on the outside of the wire, and a nitrile rubber sheath sleeved on the outside of the wave-proof sleeve; A bifurcated injection molding component for dividing the wiring harness into several wiring harnesses is provided at the middle section of the wiring harness; the ends of the wiring harness are connected and fixed to the connector tail attachment through the tail attachment injection molding component; The bifurcated injection molding component comprises a bifurcated injection molding layer, a bifurcated epoxy adhesive layer embedded inside the bifurcated injection molding layer; the wave-proof sleeve inside the bifurcated epoxy adhesive layer is sleeved on the outside of the wave-proof sleeve of the bifurcated wiring harness, and connected by welding the wire core; a fuse is tied to the nitrile rubber sheath inside the bifurcated epoxy adhesive layer; The tail attachment injection molding assembly includes a tail attachment injection molding layer and a tail attachment epoxy glue layer potted inside the tail attachment injection molding layer; a reinforcement anti-wave sleeve is also provided on the inner side of the tail attachment epoxy glue layer, one end of the reinforcement anti-wave sleeve is sleeved on the connecting end of the anti-wave sleeve, and the other end is turned outward and sleeved on the outer side of the connector tail; wire cores for reinforcing the connection are respectively welded on the outer sides of both ends of the reinforcement anti-wave sleeve; a fuse is tied on the outer side of the nitrile rubber sheath at the connecting end; and epoxy glue is potted inside the connector tail.

2. The easily bendable bifurcated wire harness connection structure according to claim 1, wherein the manufacturing method thereof comprises the following steps: Wiring: Use shielded wires for wiring according to electrical principles; Installation of anti-wave sleeve: Put the anti-wave sleeve on the outside of the wire; Installation of nitrile rubber sheath: Put the nitrile rubber sheath on the outside of the wave-proof sheath, making sure that the sheath and the wire harness are basically in close contact, but not completely tight, leaving a slight gap to assist in bending the wire harness; Production of forked injection molding components: Use wire cores to weld and fix the wave-proof sleeve at the position where forking is required; Use a fuse to tie and fix the nitrile rubber sheath; use DG-3S epoxy glue for potting to form a bifurcated epoxy glue layer; perform injection molding on the bifurcated position to form a bifurcated injection molding layer; Wire end welding: weld the end of the wire into the connector and blow heat shrink tubing at the welding position for protection; Installation of reinforced anti-wave sleeve: put the reinforced anti-wave sleeve on the anti-wave sleeve at the wire access end, and fix it by welding the wire core; Connector tail installation: Install the connector tail and use GMX-351 epoxy glue to potting inside the connector tail to fix the connected wires and surge protector to the connector tail; Reinforced wave-proof sleeve turned outward: turn the reinforced wave-proof sleeve outward to the outside of the connector tail, and use the wire core to connect the turned-out reinforced wave-proof sleeve to the connector tail to achieve the purpose of 360° shielding layer connection to the shell; Tail attachment injection molding assembly production: Use fuse to tie and fix the nitrile rubber sheath; Use GMX-351 epoxy glue for potting to form a tail-attached epoxy glue layer; The connection end is injection molded to form a tail injection molding layer.

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