Wire harness cable side outlet potting processing method

Abstract

The invention relates to a wire harness cable conductor side outlet potting processing method. The method is characterized by comprising the following steps: step 1, determining the position of a wire harness to be processed; the method comprises the following steps of: a, manufacturing a tail wire bundle (2) of a connector (1) which needs to be laterally discharged and encapsulated according to cable forming direction and angle parameter requirements; b, pre-installing a side-out tail cover or a side-out filling and sealing mold (6), determining an outlet position on the wire bundle (2) of the side-out tail cover or the side-out filling and sealing mold (6), and making a mark I (4) at the outlet position on the wire bundle (2); then taking down the side-out type filling and sealing mold (6); the pouring sealant overflow problem is solved, the application range is wide, the process standardization is high, operation and quality guarantee are standardized, and the production efficiency and the product stability are improved.

Description

Technical Field

[0001] The present invention relates to a method for side-out potting treatment of a wire harness cable. More specifically, the present invention studies a method which, by sealing the cable that needs side-out potting, ensures that the potting glue does not overflow from the side during side-out potting, guaranteeing the reliability of cable potting and avoiding the problem of excess material caused by glue overflow. Background Art

[0002] In order to enable the cable to meet the harsh external environment and enhance the cable sealing performance, for the cable connector 1, a method of using potting glue to seal the root of the connector 1 and the root wire harness is often adopted for treatment. This treatment method is called potting. Potting can be divided into straight-out potting of the wire and side-out potting of the wire according to the wire outlet direction (as Figure 1 shown).

[0003] In the actual operation process, the root of the connector 1 is often surrounded by designing a potting mold, and then potting glue is poured into the potting mold until the glue solidifies to complete the potting treatment. In many cases, due to the product structure requirements, the cable needs to be subjected to side-out potting. In side-out potting, since space needs to be left on the side for placing the wire harness, when performing potting treatment, the glue will overflow from the gaps between the cable and the potting mold and between the cable wires, which not only affects the appearance but also poses quality hazards such as easy adhesion of cable wires and formation of excess glue.

[0004] As the electrical connection relationship of aerospace products becomes more and more complex and the number of signals to be transmitted increases. At the same time, aerospace products are developing towards miniaturization and lightweight, and it is impossible to equip each electrical device with a separate wire cable. Therefore, in actual products, wire short-circuit and parallel connection are often carried out in the wire harness cable wires to introduce the required electrical signals into each electrical device. The reliability of wire parallel connection is directly related to the quality and reliability of aerospace products. Summary of the Invention

[0005] The purpose of the present invention is to provide a method for side-out potting treatment of a wire harness cable, which is applicable to side-out potting molds and side-out connector tail cover potting. By performing process treatment on the cable and simultaneously applying silicone rubber to fill the gaps, the problem of side overflow of potting glue caused by side-out potting can be perfectly solved.

[0006] A method for side-out potting treatment of a wire harness cable wire, characterized in that:

[0007] Step 1: Determine the position of the wire harness to be processed

[0008] a. Fabricate the tail wire harness 2 of the connector 1 that needs side-out potting according to the requirements of the cable forming direction and angle parameters;

[0009] b. Pre-install the side-out tail cover or side-out potting mold 6, determine the outlet position on the wire harness 2 of the side-out tail cover or side-out potting mold 6, and make a mark Ⅰ4 at the outlet position on the wire harness 2; then remove the side-out potting mold 6; then set distances before and after the mark Ⅰ4 and make marks Ⅱ5 and mark Ⅲ3 respectively; the part between the mark Ⅱ5 and the mark Ⅲ3 is the area that needs to be processed technologically;

[0010] Step 2: Process the wire harness 2

[0011] a. Manually separate the wire harness 2 between the mark Ⅱ5 and the mark Ⅲ3 sufficiently;

[0012] b. Apply one-component silicone rubber between the wires of the wire harness 2 to make the silicone rubber fully fill the wire harness 2;

[0013] c. At the front end of the mark Ⅱ5 and the rear end of the mark Ⅲ3, use cotton thread or brocade silk thread for binding and fixing respectively to form a wire harness binding position Ⅰ8 and a wire harness binding position Ⅱ9; let the cable stand still until the applied silicone rubber solidifies;

[0014] Step 3: Binding of the cable sheath

[0015] a. Place the port of the cable sheath 11 at the wire harness binding position Ⅰ8 in front of the mark Ⅱ5 until it completely covers the wire harness binding position Ⅰ8;

[0016] b. Use the binding wire 10 to tightly bind the cable sheath 11. The binding 10 starts from the port of the cable sheath 11 until it covers the entire area between the mark Ⅱ5 and the mark Ⅲ3;

[0017] c. Apply one-component silicone rubber to the gaps between the binding port of the cable sheath 11 and the wires and the gaps between the binding wires;

[0018] Step 4: Install the side-out tail cover or side-out potting mold

[0019] a. Install the side-out tail cover or side-out potting mold 6, and at the same time, wind the tape 12 at the outlet of the side-out tail cover or the side outlet of the side-out potting mold 6 until there is no gap;

[0020] Step 5: Plugging leaks

[0021] a. Apply one-component silicone rubber again to the gaps between the wire harness 2 and the outlet of the side-out tail cover or side-out potting mold 6 and the gaps between the tail cover structures or the side-out potting mold structures;

[0022] b. Let the tooling and the cable stand still until the silicone rubber completely solidifies;

[0023] Step 6: Cable potting

[0024] a. From the top of the potting mold 6, slowly pour the glue solution using a syringe until the process requirements are met;

[0025] b. Let the tooling and the cable stand still until the potting glue has completely solidified;

[0026] Step Seven: Remove the potting tooling

[0027] After the potting glue has completely solidified, remove the silicone rubber used for plugging leaks, and remove the potting mold 6. The side-out potting is completed.

[0028] The cable harness can be a round harness or a flat harness.

[0029] At the positions before and after the mark Ⅰ4 in the steps described, make mark Ⅱ5 and mark Ⅲ3 respectively at set distances; the set distance is 3 mm to 5 mm; the area between mark Ⅱ5 and mark Ⅲ3 is used as the internal leak plugging area of the harness;

[0030] In the second step described, at the front end of mark Ⅱ5 and the rear end of mark Ⅲ3, use cotton thread or brocade silk thread for tying and fixing respectively, and the tying width is not less than 3 mm.

[0031] In the third step, a. Place the port of the cable sheath 11 at the harness tying position Ⅰ8 at the front end of mark Ⅱ5 until it completely covers the harness tying position Ⅰ8; and make the front end of the cable sheath 11 exceed mark Ⅱ5 by a distance of more than 5 mm, and tie the port of the cable sheath 11 at the front end of mark Ⅱ5; and apply one-component silicone rubber again at the gap between the cable sheath 11 and the wire harness 2 to seal the gap between the cable sheath 11 and the wire harness 2 and prevent the potting glue from oozing out from this gap.

[0032] In the fourth step, the tying port of the sheath is inside the side-out tail cover or the side-out potting mold 6, and the tying length covers the entire area from mark Ⅱ5 to mark Ⅲ3.

[0033] The tying operation method described meets the wiring harness tying specifications for aerospace products.

[0034] After the potting is completed, promptly clean the excess silicone rubber at the leak plugging and sealing parts; and conduct a foreign object inspection on the cable to prevent quality problems.

[0035] Beneficial effects:

[0036] 1. Solve the problem of potting glue overflow:

[0037] Most of the existing wire and cable potting is straight-out potting, that is, the wire outlet direction is the same as the wire welding direction. For the side-out potting scenario, the traditional technology lacks an effective solution. In the existing side-out potting, the potting adhesive is likely to overflow from the gaps between the cable and the potting mold and between the cable wires, which not only affects the appearance but also poses quality hazards such as cable wire adhesion and formation of redundant adhesive substances. Through multi-step process treatment of the cable, such as determining the treatment area, applying silicone rubber, tying multiple times, and plugging leaks, etc., the present invention can perfectly solve the problem of side overflow of the potting adhesive, avoid quality problems caused by redundant substances, and ensure the reliability of cable potting.

[0038] 2. Wide range of applications:

[0039] The existing technology may have limitations in aspects such as the applicable cable types and potting molds. The method of the present invention is applicable to side-out potting molds and side-out connector tail cover potting, and the cable harness can be either a round harness or a flat harness, expanding the scope of application.

[0040] 3. Strong process standardization:

[0041] In the actual operation of the existing technology, the potting process often lacks a unified standard, and quality problems are likely to occur due to improper operation. The present invention details the operation process of each step, including the setting of the marking position, the application of silicone rubber, the standardization of the tying operation, etc. This standardized process flow can ensure the consistency and accuracy of the operation and reduce quality problems caused by human factors.

[0042] 4. Standardized operation and quality assurance:

[0043] The operation details and parameters of each step are clarified, such as the set distance of the marking, the tying width, the requirements for the position of the cable sheath, etc. It is also required that the tying operation method meets the cable harness tying standard for aerospace products. After potting, the redundant silicone rubber is cleaned and the redundant substances are inspected to ensure standardized operation and product quality. This process treatment method that meets aerospace standards can effectively improve the application value of the cable in the aerospace field.

[0044] 5. Improve production efficiency and product stability:

[0045] In the context of the complex electrical connections of aerospace products and the trend towards miniaturization and lightweight, the reliability of wire parallel connection is related to product quality. The method of the present invention reduces the possibility of adhesive overflow and wire adhesion through multiple leak plugging and sealing treatments, thereby reducing the incidence of quality problems. This optimized process treatment method can effectively improve the overall quality of the cable, ensure its reliability in actual applications, and guarantee the quality and stability of aerospace products. Description of the Drawings

[0047] Figure 1, Schematic diagrams of direct-out potting and side-out potting in the prior art;

[0048] Figure 2 , Schematic diagram of the pre-installation position of the side-out potting mold 6 of the present invention;

[0049] Figure 3 , Schematic diagram of the position of the silicone rubber 7 between the wire harnesses of the present invention;

[0050] Figure 4 , Schematic diagram of the wire harness binding position of the present invention;

[0051] Figure 5 , Schematic diagram of the position of the cable sheath 11 of the present invention;

[0052] Figure 6 , Schematic diagram of the overall binding 10 outside the sheath of the present invention

[0053] Figure 7 , Schematic diagram of the winding position of the external tape 12 and the filling position of the leak-proof silicone rubber 13 of the present invention.

[0054] Among them, 1 is a connector, 2 is a wire harness, 3 is Mark Ⅲ, 4 is Mark Ⅰ, 5 is Mark Ⅱ, 6 is a potting mold, 7 is the silicone rubber between the wire harnesses, 8 is the wire harness binding position Ⅰ, 9 is the wire harness binding position Ⅱ, 10 is a binding wire, 11 is a cable sheath, 12 is a tape, and 13 is a silicone rubber. Detailed implementation method

[0055] Example 1:

[0056] A method for side-out potting treatment of a wire harness cable, comprising the following steps:

[0057] The first step is to determine the position of the wire harness to be processed

[0058] a. The tail wires of the connector that need side-out potting are fabricated according to the parameters such as the direction and angle of the cable forming.

[0059] b. The side-out tail cover or the side-out potting mold is pre-installed, and the wire outlet position of the side-out tail cover or the side-out potting mold is determined. Mark Ⅰ 4 is made on the wire harness; then Mark Ⅱ 5 and Mark Ⅲ 3 are made respectively before and after Mark Ⅰ 4. (As Figure 2 shown)

[0060] c. The part between Mark Ⅱ 5 and Mark Ⅲ 3 is the area that needs to be processed by the process.

[0061] The second step is to perform process treatment on the wire harness cable

[0062] d. The wires between Mark Ⅱ 5 and Mark Ⅲ 3 are separated sufficiently by hand;

[0063] e. Apply one-component silicone rubber and make it fully fill the cable harness.

[0064] At the front end of Mark Ⅱ5 and the rear end of Mark Ⅲ3, perform binding and fixing respectively; use one-component silicone rubber to apply to the gaps between the binding ports of the cable sheath 11 and the conductors and the gaps between the binding wires; let the cable stand still until the applied silicone rubber solidifies. (As Figure 3 shown)

[0065] The third step: Binding of the cable sheath

[0066] f. Place the cable sheath port at the binding wire at the front end of Mark Ⅱ5 until the binding wire is completely covered.

[0067] g. Use binding wire to bind the sheath. The binding starts from the sheath port, and the binding length covers the entire area from Mark Ⅱ5 to Mark Ⅲ3.

[0068] The fourth step: Install the side-out tail cover or side-out potting mold

[0069] h. Install the side-out tail cover or side-out potting mold. At the same time, at the outlet of the side-out tail cover or the side outlet of the side-out

[0070] potting mold, wind the tape to fill until there is no gap.

[0071] The fifth step: Leakage prevention

[0072] i. Use one-component silicone rubber again to apply to the gap between the wire harness cable and the outlet of the side-out tail cover or side-out potting mold.

[0073] j. Let the tooling and the cable stand still until the silicone rubber completely solidifies.

[0074] The sixth step: Cable potting

[0075] k. From the top of the potting mold, slowly inject the glue solution with a syringe until the process requirements are met.

[0076] l. Let the tooling and the cable stand still until the potting glue completely solidifies.

[0077] The seventh step: Remove the potting tooling

[0078] After the potting glue completely solidifies, remove the silicone rubber used for leakage prevention and remove the potting mold.

[0079] The following takes a certain side-out tail cover cable as an example to illustrate the cable side-out potting treatment method:

[0080] The first step: Determine the position of the wire harness to be processed

[0081] a) Fabricate the conductors at the tail of the connector that needs side-out potting according to the parameters such as the direction and angle of the cable forming.

[0082] b) For the pre-installed side-out tail cover, determine the wire outlet position of the side-out tail cover or the side-out potting mold, and make a mark Ⅰ4 on the wire harness; then make marks Ⅱ5 and Ⅲ3 respectively before and after the mark Ⅰ4. c) The part between the mark Ⅱ5 and the mark Ⅲ3 is the area that needs to be processed technologically.

[0083] The second step is to process the wire harness cable technologically

[0084] d) Manually separate the wires between the mark Ⅱ5 and the mark Ⅲ3 sufficiently;

[0085] e) Apply one-component silicone rubber to fully fill it in the cable harness;

[0086] f) Fix it by tying at the front end of the mark Ⅱ5 and the rear end of the mark Ⅲ3 respectively; Let the cable stand still until the applied silicone rubber solidifies.

[0087] The third step is to tie the cable sheath

[0088] g) Place the cable sheath port at the tying wire at the front end of the mark Ⅱ5 until it completely covers the tying wire;

[0089] h) Use tying wire to tie the sheath. The tying starts from the sheath port, and the tying length covers the entire area from the mark Ⅱ5 to the mark Ⅲ3.

[0090] The fourth step is to install the side-out tail cover or the side-out potting mold

[0091] i) Install the side-out tail cover, and at the same time, at the outlet of the side-out tail cover, wind the tape to fill it until there is no

[0092] gap;

[0093] The fifth step is to plug the leak

[0094] j) Use one-component silicone rubber again to apply to the gap between the wire harness cable and the outlet of the side-out tail cover or the side-out potting mold.

[0095] k) Let the tooling and the cable stand still until the silicone rubber completely solidifies.

[0096] The sixth step is to pot the cable

[0097] l) Use a syringe to pour the glue solution from the top screw hole of the side-out tail cover until it meets the process requirements.

[0098] m) Let the tooling and the cable stand still until the potting glue completely solidifies.

[0099] The seventh step is to remove the potting tooling. After the potting glue completely solidifies, remove the silicone rubber used for plugging the leak and remove the potting mold.

Claims

1. A method for potting treatment of a wire harness cable with side-out wires at the conductor side, characterized in that: Step 1: Determine the position of the wire harness to be treated a. The wire bundle (2) at the tail of the connector (1) that needs to be potted with side-out wires is fabricated according to the requirements of the direction and angle parameters of the cable forming. b. A side-out tail cover or a side-out potting mold (6) is pre-installed, and the outlet position on the wire bundle (2) of the side-out tail cover or the side-out potting mold (6) is determined, and a mark Ⅰ (4) is made at the outlet position on the wire bundle (2); then the side-out potting mold (6) is removed; marks Ⅱ (5) and Ⅲ (3) are respectively made at set distances before and after the mark Ⅰ (4); the part between the mark Ⅱ (5) and the mark Ⅲ (3) is the area that needs to be processed by the process. Step 2: Perform process treatment on the wire bundle (2) a. Manually separate the wire bundle (2) between the mark Ⅱ (5) and the mark Ⅲ (3) sufficiently. b. Apply one-component silicone rubber between the wires of the wire bundle (2) so that the silicone rubber fully fills the wire bundle (2). c. At the front end of the mark Ⅱ (5) and the rear end of the mark Ⅲ (3), cotton threads or brocade silk threads are respectively used for tying and fixing to form a wire harness tying position Ⅰ (8) and a wire harness tying position Ⅱ (9); the cable is left stationary until the applied silicone rubber solidifies. Step 3: Tying of the cable sheath a. Place the port of the cable sheath (11) at the wire harness tying position Ⅰ (8) in front of the mark Ⅱ (5) until the wire harness tying position Ⅰ (8) is completely covered. b. Use a tying wire (10) to tightly tie the cable sheath (11), and the tying (10) starts from the port of the cable sheath (11) until the entire area between the mark Ⅱ (5) and the mark Ⅲ (3) is covered. c. Apply one-component silicone rubber to the gaps between the tying port of the cable sheath (11) and the wires and the gaps between the tying wires. Step 4: Install the side-out tail cover or the side-out potting mold a. Install the side-out tail cover or the side-out potting mold (6), and at the same time, wrap the tape (12) at the outlet of the side-out tail cover or the side outlet of the side-out potting mold (6) until there are no gaps. Step 5: Plugging leaks a. Apply one-component silicone rubber again to the gaps between the wire bundle (2) and the outlet of the side-out tail cover or the side-out potting mold (6) and the gaps between the tail cover structures or the side-out potting mold structures. b. Leave the tooling and the cable stationary until the silicone rubber completely solidifies. Step 6: Cable potting a. Slowly pour the glue from the top of the potting mold (6) using a syringe until the process requirements are met. b. Leave the tooling and the cable stationary until the potting glue completely solidifies. Step 7: Remove the potting tooling After the potting glue completely solidifies, remove the silicone rubber used for plugging leaks and remove the potting mold (6), and the side-out potting is completed.

2. A wire harness cable conductor side-out potting treatment method according to claim 1, characterized in that, The cable wire harness can be a round wire harness or a flat wire harness.

3. A wire harness cable conductor side-out potting treatment method according to claim 1, characterized in that, The marks Ⅱ (5) and Ⅲ (3) are respectively made at set distances before and after the mark Ⅰ (4) in the steps described; the set distance is 3 mm to 5 mm; the area between the mark Ⅱ (5) and the mark Ⅲ (3) is used as the internal leak plugging area of the wire harness.

4. A wire harness cable conductor side-out potting treatment method according to claim 1, characterized in that In the second step described above, at the front end of the marker II (5) and the rear end of the marker III (3), cotton threads or brocade silk threads are respectively used for binding and fixing, and the binding width is not less than 3 mm.

5. A wire harness cable conductor side-out potting treatment method according to claim 1, characterized in that, In the third step, a. Place the port of the cable sheath (11) at the wire harness binding position I (8) at the front end of the marker II (5) until the wire harness binding position I (8) is completely covered; and make the front end of the cable sheath (11) exceed the marker II (5) by more than 5 mm, and bind the port of the cable sheath (11) at the front end of the marker II (5); And apply one-component silicone rubber again at the gap between the cable sheath (11) and the wire harness (2) to seal the gap between the cable sheath (11) and the wire harness (2) and prevent the potting compound from leaking out from this gap.

6. A wire harness cable conductor side-out potting treatment method according to claim 1, characterized in that, In the fourth step, the sheath binding port is inside the side-out tail cover or the side-out potting mold (6), and the binding length covers the entire area from the marker II (5) to the marker III (3).

7. A wire harness cable wire side out potting treatment method according to claim 1, characterized in that The described binding operation method meets the cable wire harness binding specifications for aerospace products.

8. A wire harness cable conductor side-out potting treatment method according to claim 1, characterized in that, After potting is completed, promptly clean the excess silicone rubber at the leak plugging and sealing locations; and conduct a foreign object inspection on the cable to prevent quality problems.

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