A flexible bifurcated wire harness connection structure and method of making the same

Abstract

The application discloses a flexible 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 in the prior art. The wire harness comprises a wire, a wave-proof sleeve and a butyronitrile rubber sheath. After being sleeved, the wire harness is tightly buckled to prevent internal wires from moving, and a small gap is left to assist bending, so that the flexibility of the wire harness is improved. A bifurcated injection molding assembly is arranged in the middle section of the wire harness, the bifurcated position is fixed through a bifurcated epoxy glue layer and a bifurcated injection molding layer, wire core bundle welding and fuse binding are used to ensure firm connection. A tail-attached injection molding assembly is arranged at the end of the wire harness, the wire harness, a connector and a tail attachment thereof are fixed through a tail-attached epoxy glue layer and a tail-attached injection molding layer. In particular, one end of the reinforced wave-proof sleeve is sleeved at the connecting end of the wave-proof sleeve, the other end is turned outward to the outside of the tail attachment of the connector, and 360-degree shielding layer shell connection is realized through wire core bundle welding, so that the anti-electromagnetic interference performance is significantly improved.

Description

Technical Field

[0001] This invention relates to the field of engine cable technology, and in particular to a flexible branched wire harness connection structure. Background Technology

[0002] In modern military equipment, especially armored vehicles, the stability and reliability of their electrical systems are paramount. As a crucial component of the electrical system, armored vehicle wiring harnesses not only need to withstand the mechanical stresses of vehicle operation but also require excellent weather resistance and electromagnetic interference immunity to ensure normal operation in various complex environments. However, existing armored vehicle wiring harnesses suffer from the following problems: Poor bending performance: Traditional armored vehicle wiring harnesses typically use heat shrink tubing for outermost protection. Although heat shrink tubing can provide some protection, in practical applications, the excessively tight fit between the heat shrink tubing and the inner anti-wave sleeve after shrinking reduces the overall flexibility of the wiring harness, making it difficult to adapt to frequent bending and vibration, and easily causing 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. This will accelerate the aging and failure of the heat shrink tubing, shorten the service life of the wire harness, and increase maintenance costs.

[0004] Weak electromagnetic interference resistance: In existing technologies, when connecting wire harnesses to connectors, it is usually necessary to disassemble the anti-surge sleeve at the connection end and bind it to the outside of the connector tail. This practice destroys the original structural integrity of the anti-surge sleeve, causing the connection between the disassembled anti-surge sleeve and the connector tail to lose its effective shielding effect, failing to meet strict electromagnetic compatibility requirements. Especially in high-density electromagnetic interference environments, this may affect the normal operation of the vehicle's electrical system. Summary of the Invention

[0005] To overcome the above deficiencies, the present invention provides a flexible branched wire harness connection structure. The first objective is to solve the problems of poor wire harness flexibility and oil resistance, and the second objective is to solve the problem of poor electromagnetic interference resistance of the connection part between the wire harness and the connector tail.

[0006] This invention is achieved through the following technical solution: a bendable branched wire harness connection structure, comprising a wire harness, connectors connected to both ends of the wire harness, and connector tail attachments disposed on the connectors, characterized in that: the wire harness comprises a conductor, a wave-damping sleeve fitted over the conductor, and a nitrile rubber sheath fitted over the wave-damping sleeve; a branching injection molding assembly for dividing the wire harness into several wire harnesses is disposed at the middle section of the wire harness; the ends of the wire harness are connected and fixed to the connector tail attachments through the tail attachment injection molding assembly; The bifurcation injection molding assembly includes a bifurcation injection molding layer and a bifurcation epoxy layer encapsulated inside the bifurcation injection molding layer; a wave shield sleeve inside the bifurcation epoxy layer is fitted onto the outside of the wave shield sleeve of the bifurcation wiring harness and is connected by wire core bundling; a fuse is tied to the nitrile rubber sheath inside the bifurcation epoxy layer. The tail-attached injection molding assembly includes a tail-attached injection molding layer and a tail-attached epoxy layer encapsulated inside the tail-attached injection molding layer; a reinforcing anti-surge sleeve is also provided inside the tail-attached epoxy layer, one end of which is fitted onto the connecting end of the anti-surge sleeve, and the other end is fitted onto the outside of the connector tail-attached assembly after being folded outward; wire cores for reinforcing the connection are respectively welded to the outside of both ends of the reinforcing anti-surge sleeve; a fuse is tied to the outside of the nitrile rubber sheath at the connecting end; and epoxy is encapsulated inside the connector tail-attached assembly.

[0007] Furthermore, the manufacturing method of the aforementioned easily bendable branched wire harness connection structure includes the following steps: Wiring: Shielded wires are used for wiring according to electrical principles; Anti-surge sleeve installation: Place the anti-surge sleeve on the outside of the conductor; Nitrile rubber sheath installation: Put the nitrile rubber sheath on the outside of the anti-surge sleeve, ensuring that the sheath is basically in contact with the wire harness, but not completely tight, leaving a small gap to assist the bending of the wire harness; Split injection molding component fabrication: At the location where splitting is required, use wire cores to bundle and weld the anti-surge sleeve in place; Secure the nitrile rubber sheath with a fuse; pot it with DG-3S epoxy resin to form a bifurcation epoxy layer; and perform injection molding at the bifurcation location to form a bifurcation injection molding layer. Wire end soldering: Solder the end of the wire into the connector and protect the soldering position with heat shrink tubing; Installation of reinforced wave shield sleeve: The reinforced wave shield sleeve is placed on the wave shield sleeve at the conductor access end and fixed by welding the conductor cores together; Connector tail attachment installation: Install the connector tail attachment and pot the inside of the connector tail attachment with GMX-351 epoxy glue to fix the connected wires and anti-surge sleeve to the connector tail attachment. Reinforced anti-surge sleeve flipped outward: Flip the reinforced anti-surge sleeve outward to the outside of the connector tail attachment, and use the wire core to connect the flipped-out reinforced anti-surge sleeve to the connector tail attachment to achieve the purpose of 360° shielding layer shell; Tail-mounted injection molding assembly fabrication: A nitrile rubber sheath is secured using a fuse; GMX-351 epoxy resin is used for potting to form a tail-mounted epoxy layer; the connecting end is injection molded to form a tail-mounted injection molding layer. Compared with the prior art, the beneficial effects and features of this invention are as follows: Nitrile rubber sheath is used: replacing the traditional heat shrink tubing, nitrile rubber has excellent elasticity and oil resistance, which can effectively resist oil corrosion while ensuring the flexibility of the wire harness and extending the service life of the wire harness.

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

[0009] Optimized manufacturing process: The introduction of epoxy potting and injection molding processes ensures a strong connection between components and improves the overall protective performance of the wiring harness, enabling it to adapt to a variety of complex working conditions. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a cross-sectional schematic diagram of the bifurcated injection molding component in this invention; Figure 3 This is a cross-sectional schematic diagram of the tail-mounted injection molding component in this invention.

[0011] The main component numbers in the diagram are as follows: 1. Wiring harness; 101. Wire; 102. Anti-surge sleeve; 103. Nitrile rubber sheath; 104. Wire core; 105. Fuse; 2. Branch injection molding assembly; 201. Branch injection molding layer; 202. Branch epoxy layer; 3. Tail attachment injection molding assembly; 301. Tail attachment injection molding layer; 302. Tail attachment epoxy layer; 303. Reinforced anti-surge sleeve; 304. Epoxy adhesive; 4. Connector; 401. Connector tail attachment.

[0012] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, and the other drawings obtained are all within the protection scope claimed by the present invention. Detailed Implementation

[0013] The following combination Figure 1-3 The present invention will be described in detail through specific embodiments. Example

[0014] The easily bendable branched wire harness connection structure includes a wire harness 1, connectors 4 connected to both ends of the wire harness, and connector tail attachments 40 disposed on the connectors. The wire harness includes a conductor 101, a wave-damping sleeve 102 sleeved on the outside of the conductor, and a nitrile rubber sheath 103 sleeved on the outside of the wave-damping sleeve. A branching injection molding assembly 2 for dividing the wire harness into several wire harnesses is disposed in the middle section of the wire harness. The ends of the wire harness are connected and fixed to the connector tail attachments through the tail attachment injection molding assembly 3. The bifurcation injection molding assembly includes a bifurcation injection molding layer 201 and a bifurcation epoxy layer 202 encapsulated inside the bifurcation injection molding layer; a wave shield sleeve inside the bifurcation epoxy layer is fitted onto the outside of the wave shield sleeve of the bifurcation wiring harness and is connected by wire core 104; a fuse 105 is tied to the nitrile rubber sheath inside the bifurcation epoxy layer. The tail-attached injection molding assembly includes a tail-attached injection molding layer 301 and a tail-attached epoxy layer 302 encapsulated inside the tail-attached injection molding layer. A reinforcing anti-surge sleeve 303 is also provided inside the tail-attached epoxy layer. One end of the reinforcing anti-surge sleeve is fitted onto the connecting end of the anti-surge sleeve, and the other end is fitted onto the outside of the connector tail-attached assembly after being folded outward. Wire cores for reinforcing the connection are respectively welded to the outside of both ends of the reinforcing anti-surge sleeve. A fuse is tied to the outside of the nitrile rubber sheath at the connecting end. Epoxy resin 304 is encapsulated inside the connector tail-attached assembly.

[0015] The preferred method for manufacturing a bendable branched wire harness connection structure includes the following steps: 1. Material Selection and Preparation Wire 101: Shielded wire conforming to military standards is selected, which has good conductivity and anti-interference performance.

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

[0017] Nitrile rubber sheath 103: Made of nitrile rubber material with good elasticity and oil resistance, ensuring that the wire harness can maintain its flexibility and protective performance in harsh environments.

[0018] Epoxy Adhesives: DG-3S epoxy adhesive is selected for potting the bifurcation injection layer and the tail injection layer, and GMX-351 epoxy adhesive is used for potting the reinforcement of the anti-surge sleeve and the inside of the connector tail. Both of these epoxy adhesives have fast curing, high strength and good chemical corrosion resistance.

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

[0020] Reinforced anti-surge sleeve 303: Select a metal braided mesh of the same material as the anti-surge sleeve. The length should be sufficient to cover the outer side of the connector tail and leave enough slack for outward turning.

[0021] 2. Wire Harness Wiring and Assembly 2.1 Wiring Based on the electrical schematic, use shielded wires for wiring. Ensure the wires are neatly arranged, avoiding crossings and tangles to reduce signal interference and mechanical stress.

[0022] 2.2 Installation of the anti-surge sleeve Slide the anti-surge sleeve 102 onto the outside of the conductor 101 in sequence, ensuring that the length of the anti-surge sleeve is sufficient to cover the entire length of the wire harness. Sufficient space should be left at both ends of the anti-surge sleeve for subsequent branching and connection operations.

[0023] 2.3 Installation of Nitrile Rubber Sheath Fit the nitrile rubber sheath 103 onto the outside of the anti-surge sleeve 102, ensuring that the sheath fits snugly against the wire harness but is not completely taut, leaving a small gap to assist in bending the wire harness. The length of the sheath should cover the entire outer surface of the wire harness, with appropriate machining allowances at bifurcation points and connector tail attachments.

[0024] 3. Fabrication of bifurcated injection molded components 3.1 The bifurcation position of the wave-damping sleeve is fixed. At the location where branching is required, use wire core 104 to bundle and weld the anti-surge sleeve 102 to ensure that the connection between each branch harness after branching is firm and to prevent the anti-surge sleeve from loosening or slipping.

[0025] 3.2 Fixing the bifurcation position of the nitrile rubber sheath At the bifurcation point, use fuse 105 to secure the nitrile rubber sheath 103, ensuring that the sheath does not shift at the bifurcation. When securing, apply moderate force to ensure a secure hold without damaging the sheath.

[0026] 3.3 Epoxy potting At the bifurcation point, use DG-3S epoxy resin for potting to ensure a strong connection between the anti-surge sleeve and the nitrile rubber sheath, forming a bifurcation epoxy layer 202. During potting, ensure the epoxy resin is evenly distributed, avoiding air bubbles and voids.

[0027] 3.4 Split Injection Molding After potting, injection molding is performed at the bifurcation location to form the bifurcation injection molding layer 201. The injection molding material should be compatible with the nitrile rubber sheath to ensure good adhesion between the injection molding layer and the sheath. After injection molding, wait for the epoxy resin and injection molding material to fully cure to complete the fabrication of the bifurcation injection molding component.

[0028] 4. Fabrication of tail-mounted injection molded components 4.1 Welding of wire ends Solder the end of wire 101 into connector 4, ensuring a strong and reliable solder joint. After soldering, apply heat shrink tubing to the solder joint for protection, preventing it from being affected by the external environment.

[0029] 4.2 Installation of reinforced wave-damping sleeve The reinforced anti-surge sleeve 303 is fitted onto the anti-surge sleeve 102 at the wire inlet and secured by wire core 104, ensuring a firm connection between the reinforced anti-surge sleeves. The length of the reinforced anti-surge sleeve should be sufficient to cover the outer side of the connector tail 401, with enough slack for outward folding.

[0030] 4.3 Connector Tail Mounting Install connector tail 401 and pot the inside of the connector tail 401 with GMX-351 epoxy resin to secure the incoming wires and anti-surge sleeve to the connector tail 401. During potting, ensure the epoxy resin is evenly distributed, avoiding air bubbles and voids.

[0031] 4.4 Reinforce the outward-turning baffle sleeve The reinforced anti-surge sleeve 303 is flipped outward to the outside of the connector tail attachment 401, and the flipped-out reinforced anti-surge sleeve is connected to the connector tail attachment using the wire core 104, so as to achieve the purpose of 360° housing of the wire harness shielding layer and provide overall electromagnetic shielding.

[0032] 4.5 Fixing with nitrile rubber sleeve At the connection end, use fuse 105 to secure the nitrile rubber sheath 103, ensuring that the sheath does not shift at the connector tail. When securing, apply moderate force to ensure a secure hold without damaging the sheath.

[0033] 4.6 Epoxy potting At the connection end, use GMX-351 epoxy resin for potting to ensure a firm connection between the reinforced anti-surge sleeve, nitrile rubber sheath, and connector tail attachment, forming a tail attachment epoxy layer 302. During potting, ensure the epoxy resin is evenly distributed, avoiding air bubbles and voids.

[0034] 4.7 Tail-end injection molding After potting, injection molding is performed on the connecting ends to form the tail-attached injection molding layer 301. The injection molding material should be compatible with the nitrile rubber sheath to ensure good adhesion between the injection molding layer and the sheath. After injection molding, wait for the epoxy resin and injection molding material to fully cure to complete the fabrication of the tail-attached injection molding assembly.

Claims

1. A bendable branched wire harness connection structure, comprising a wire harness, connectors connected to both ends of the wire harness, and connector tail attachments disposed on the connectors, characterized in that; The wiring harness includes a conductor, a wave shield sleeve fitted over the outside of the conductor, and a nitrile rubber sheath fitted over the outside of the wave shield sleeve. A bifurcation injection molding assembly for dividing the wire harness into several wire harnesses is provided at the middle section of the wire harness; the ends of the wire harness are connected and fixed to the connector tail attachment via a tail attachment injection molding assembly. The bifurcation injection molding assembly includes a bifurcation injection molding layer and a bifurcation epoxy layer encapsulated inside the bifurcation injection molding layer; a wave shield sleeve inside the bifurcation epoxy layer is fitted onto the outside of the wave shield sleeve of the bifurcation wiring harness and is connected by wire core bundling; a fuse is tied to the nitrile rubber sheath inside the bifurcation epoxy layer. The tail-attached injection molding assembly includes a tail-attached injection molding layer and a tail-attached epoxy layer encapsulated inside the tail-attached injection molding layer. A reinforcing anti-surge sleeve is also provided inside the tail-attached epoxy layer. One end of the reinforcing anti-surge sleeve is fitted onto the connecting end of the anti-surge sleeve, and the other end is fitted onto the outside of the connector tail-attached assembly after being folded outward. Wire cores for reinforcing the connection are respectively welded to the outside of both ends of the reinforcing anti-surge sleeve. A fuse is tied to the outside of the nitrile rubber sheath at the connecting end. Epoxy resin is encapsulated inside the connector tail-attached assembly.

2. The easily bendable branched wire harness connection structure according to claim 1, its manufacturing method includes the following steps: Wiring: Shielded wires are used for wiring according to electrical principles; Anti-surge sleeve installation: Place the anti-surge sleeve on the outside of the conductor; Nitrile rubber sheath installation: Put the nitrile rubber sheath on the outside of the anti-surge sleeve, ensuring that the sheath is basically in contact with the wire harness, but not completely tight, leaving a small gap to assist the bending of the wire harness; Split injection molding component fabrication: At the location where splitting is required, use wire cores to bundle and weld the anti-surge sleeve in place; Secure the nitrile rubber sheath with a fuse; pot it with DG-3S epoxy resin to form a bifurcation epoxy layer; and perform injection molding at the bifurcation location to form a bifurcation injection molding layer. Wire end soldering: Solder the end of the wire into the connector and protect the soldering position with heat shrink tubing; Installation of reinforced wave shield sleeve: The reinforced wave shield sleeve is placed on the wave shield sleeve at the conductor access end and fixed by welding the conductor cores together; Connector tail attachment installation: Install the connector tail attachment and pot the inside of the connector tail attachment with GMX-351 epoxy glue to fix the connected wires and anti-surge sleeve to the connector tail attachment. Reinforced anti-surge sleeve flipped outward: Flip the reinforced anti-surge sleeve outward to the outside of the connector tail attachment, and use the wire core to connect the flipped-out reinforced anti-surge sleeve to the connector tail attachment to achieve the purpose of 360° shielding layer shell; Tail-mounted injection molded component fabrication: Use fuses to secure the nitrile rubber sheath; GMX-351 epoxy resin was used for potting to form a tail-attached epoxy layer; The connecting end is injection molded to form a tail-attached injection molded layer.

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