A new energy vehicle high-voltage wire harness with a self-healing insulation layer and a preparation method thereof

Abstract

The present application relates to the technical fields of new energy vehicle high-voltage wiring harness, and especially relates to a new energy vehicle high-voltage wiring harness with self-healing insulation layer and a preparation method thereof, in order to solve the problem that the self-healing effect is reduced due to the difficulty of the coating layer in penetrating into the internal insulation layer to repair deep cracks; the present application can release a low-viscosity repair agent when the internal insulation layer is damaged, fill the cracks by capillary action, and then combine with the internal insulation layer through self-curing to complete self-healing; when the external insulation layer is damaged, the outer surface PE composite film film kit is broken, and the internal self-repairing silicone rubber flows out; the siloxane chain triggers key recombination to fill the gap by stress and heat at the crack, and at the same time, the channel between the shielding layer and the aluminum alloy protective layer is blocked, gas is introduced through the air vent, and the protective layer is used for heat conduction to accelerate the solidification of the silicone rubber, so that the self-healing effect of the insulation layer of the wiring harness is improved through the double-layer self-healing function.

Description

Technical Field

[0001] This invention relates to the field of high-voltage wiring harness technology for new energy vehicles, and in particular to a high-voltage wiring harness for new energy vehicles with a self-healing insulation layer and its preparation method. Background Technology

[0002] High-voltage wiring harnesses in new energy vehicles are core conductive components that connect high-voltage components such as batteries, motors, and electronic controls to transmit high-voltage electrical energy. They need to stably transmit high voltage and high current while resisting corrosion from high and low temperatures, vibrations, and oil contamination in the engine compartment, and preventing electromagnetic interference to ensure the normal operation of the high-voltage system. Due to long-term thermal cycling stress caused by wire heating and mechanical vibration during installation and use, the insulation layer is prone to developing hidden micro-cracks that are difficult to repair manually. Self-healing insulation layers can repair damage on their own, avoiding leakage and short circuits, reducing maintenance costs, and ensuring driving safety.

[0003] Chinese patent CN216597051U discloses a self-healing, tensile-resistant field communication cable. From the inside out, it comprises a central filler rope, conductor units, a wrapping layer, a braided layer, a tensile layer, a sheath layer, and a coating layer. Multiple conductor units are twisted around the central aramid rope. The wrapping layer is made of polyester tape, the braided layer is made of tin-plated copper wire, the tensile layer is made of cord braid, and the sheath layer is made of cold-resistant polyvinyl chloride extrusion, capable of withstanding temperatures as low as -40℃. The coating layer is a light-shielding coating. The coating layer is prepared by using cyclodextrin-modified TIO nanoparticles as a light-shielding agent, which are then mixed and encapsulated with the guest molecule HEMA-ad, and further mixed and polymerized with butyl acrylate and HEMA-ad. The coating thickness is ±μm. This coating is environmentally friendly, non-toxic, and exhibits strong self-healing capabilities.

[0004] In the aforementioned patent, because it relies solely on the coating layer for self-healing without designing targeted repair methods for potential damage to the inner and outer walls of the insulation layer, and because the self-healing effect of the coating layer is difficult to penetrate into the insulation layer to repair deep cracks, the self-healing effect is poor, thus reducing the effectiveness of self-healing.

[0005] To this end, we propose a self-healing insulation layer for high-voltage wiring harnesses in new energy vehicles and its preparation method. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to overcome the defects of the prior art. The present invention proposes a self-healing insulation layer for high-voltage wiring harnesses of new energy vehicles and its preparation method, which solves the problem that in the prior art, the self-healing effect of the coating layer is difficult to penetrate into the interior of the insulation layer to repair deep cracks, thus reducing the self-healing effect.

[0007] To solve the above technical problems, the present invention adopts the following technical solution: a high-voltage wiring harness for new energy vehicles with a self-healing insulation layer, including a conductor, an insulation component for isolating electrical conduction fixedly installed on the outer surface of the conductor, a self-healing component for repairing the insulation component fixedly installed on the outer surface of the insulation component, and a sheath fixedly installed on the outer surface of the self-healing component. The insulation component includes an inner insulation layer fixedly installed on the outer surface of the conductor, an outer insulation layer fixedly installed on the outer surface of the inner insulation layer, and microcapsules mixed inside the inner insulation layer. The self-healing component includes a shielding layer fixedly installed on the outer surface of the insulation component, a thin film kit inside the shielding layer, and self-healing silicone rubber inside the thin film kit. The outer surface of the self-healing silicone rubber is in contact with the outer surface of the outer insulation layer.

[0008] Furthermore, the film kit is provided in multiple sets, and the multiple sets of film kits wrap the outer insulating layer. The multiple sets of film kits are connected to each other by adhesive bonding.

[0009] Furthermore, the film kit is a PE composite film. When a sharp object damages the outer insulation layer, the sharp object will puncture the PE composite film first, allowing the self-healing silicone rubber inside the PE composite film to flow out, thereby repairing the punctured outer insulation layer.

[0010] Furthermore, self-healing silicone rubber is a component made of a siloxane polymer chain as the basic skeleton, combined with hydrogen bond groups or dynamic covalent bond groups and reinforcing fillers.

[0011] Furthermore, microcapsules are components made by using epoxy resin to form the capsule wall and encapsulating a liquid repair agent inside.

[0012] Furthermore, a protective layer is fixedly installed on the inner wall of the shielding layer, and the inner wall of the protective layer is attached to the thin film kit, forming a channel between the shielding layer and the protective layer. An air vent is opened on the outer surface of the shielding layer, and the air vent is connected to the channel.

[0013] Furthermore, a filter screen is fixedly installed on the inner wall of the vent.

[0014] Furthermore, the protective layer is a component made of aluminum alloy.

[0015] Furthermore, the sheath is a component made of thermoplastic polyurethane elastomer, modified polyvinyl chloride, and engineering plastics.

[0016] The present invention proposes a technical solution: a method for preparing a high-voltage wiring harness for new energy vehicles with a self-healing insulation layer, comprising the following steps: S1: The outer insulation substrate is heated and melted by an extruder and then extruded, and then tightly wrapped on the outer surface of the conductor. After cooling and solidification, an inner insulation layer is formed. Then, the inner insulation substrate is heated and melted by an extruder again, tightly wrapped on the outer surface of the inner insulation layer and cooled and solidified to form an outer insulation layer. Then, multiple sets of film kits are independently and omnidirectionally wrapped on the surface of the outer insulation layer by a film coating equipment, so that the film kits adhere to the outer surface of the outer insulation layer. S2: The raw materials are processed into a tubular protective layer using pipe processing equipment. Then, the shielding layer is woven using a braiding machine. Next, multiple sets of air vents are drilled on the outer surface of the shielding layer using a drilling machine. Then, the filter screen is installed inside the air vents. Finally, the protective layer is fixed to the inner wall of the shielding layer by welding, so that a gas channel connected to the air vent is formed between the two. S3: Using a wire harness threading device, thread the wires, outer insulation layer and inner insulation layer made in S1 into the shielding layer and protective layer structure made in S2 as a whole, and then use an adhesive bonding device to fix the inner wall of the shielding layer to the outer surface of the outer insulation layer. S4: The sheath substrate is heated and melted by an extruder and extruded to tightly cover the outer surface of the shielding layer of the self-healing component to form a sheath. Then, the entire wire harness is cured at a constant temperature using a drying device. The integrity of the outer insulation layer, film kit, and vent, as well as the adhesion of each layer, are checked by a wire harness testing device. After confirming that all structures meet the requirements, the preparation of the self-healing insulation layer high-voltage wire harness for new energy vehicles is completed.

[0017] Compared with the prior art, the beneficial effects of the present invention are: This invention proposes a self-healing insulation layer for high-voltage wiring harnesses in new energy vehicles and its preparation method. When the inner wall of the inner insulation layer is damaged, the walls of the microcapsules mixed inside are broken, and the internal liquid repair agent flows out. It fills the cracks through capillary action and self-cures, tightly bonding with the inner insulation layer to repair the inner wall damage. When the outer insulation layer is damaged by external factors, the thin film kit adhered to its outer surface is punctured by the external factors causing the cracks, and the self-healing silicone rubber with a siloxane polymer chain as its backbone flows out. The siloxane chains are repaired by mechanical stress at the cracks. Force and environmental heat trigger hydrogen bond bonding or dynamic covalent bond recombination, driving molecular chains to aggregate and fill gaps, forming a continuous insulating structure to repair cracks in the outer wall. At the same time, the channel between the shielding layer and the protective layer introduces external gas through the vent. Combined with the high thermal conductivity of the aluminum alloy protective layer, it can cool the self-healing silicone rubber to accelerate the curing speed. The filter screen on the inner wall of the vent can prevent particulate dust from clogging the channel, ensuring that the auxiliary self-healing structure plays a stable role. This achieves targeted self-healing of the inner and outer walls of the insulating component. Through the dual-layer self-healing function, the self-healing effect of the insulation layer is improved. Attached Figure Description

[0018] The disclosure of this invention is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings, the same reference numerals are used to refer to the same parts. Wherein: Figure 1 An overall schematic diagram according to one embodiment of the present invention is shown for illustrative purposes. Figure 2 An overall internal schematic diagram according to one embodiment of the present invention is shown for illustrative purposes. Figure 3 A schematic diagram of the internal structure of a self-healing component according to an embodiment of the present invention is shown for illustrative purposes. Figure 4 A schematic diagram illustrating a thin film kit and self-healing silicone rubber according to an embodiment of the present invention is shown. Figure 5 A partial schematic diagram of an insulating component according to an embodiment of the present invention is shown for illustrative purposes.

[0019] The diagram is labeled as follows: 1. Wire; 2. Insulation component; 21. Outer insulation layer; 22. Inner insulation layer; 3. Self-healing component; 31. Shielding layer; 32. Vent; 33. Protective layer; 34. Channel; 35. Filter screen; 36. Membrane kit; 37. Self-healing silicone rubber; 4. Sheath. Detailed Implementation

[0020] It is readily understood that, based on the technical solution of this invention, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of this invention.

[0021] To address the technical challenge of improving the self-healing effect of wire harnesses, such as... Figure 1 - Figure 5 As shown, the following preferred technical solution is provided: a new energy vehicle high-voltage wiring harness with a self-healing insulation layer, including a conductor 1, an insulation component 2 for isolating electrical conduction is fixedly installed on the outer surface of the conductor 1, a self-healing component 3 for repairing the insulation component 2 is fixedly installed on the outer surface of the insulation component 2, and a sheath 4 is fixedly installed on the outer surface of the self-healing component 3. Insulation component 2 includes an inner insulation layer 22 fixedly installed on the outer surface of the conductor 1, and an outer insulation layer 21 fixedly installed on the outer surface of the inner insulation layer 22. Microcapsules are mixed and disposed inside the inner insulation layer 22. The self-healing component 3 includes a shielding layer 31 fixedly installed on the outer surface of the insulation component 2. A thin film kit 36 ​​is disposed inside the shielding layer 31. A self-healing silicone rubber 37 is disposed inside the thin film kit 36. The outer surface of the self-healing silicone rubber 37 is in contact with the outer surface of the outer insulation layer 21. Through the microcapsules inside the outer insulation layer 21, when the inner wall of the outer insulation layer 21 is damaged, This will break the capsule wall of the microcapsule, at which point the repair fluid inside the microcapsule will flow out, thereby repairing the damaged area. When the inner insulating layer 22 is damaged by external factors such as cracks, the thin film kit 36 ​​on the surface of the inner insulating layer 22 will be punctured when the crack occurs, allowing the self-healing silicone rubber 37 inside the thin film kit 36 ​​to flow out. Then, the self-healing silicone rubber 37 repairs the crack itself. At this time, by fusing the outer insulating layer 21 of the microcapsule and the self-healing silicone rubber 37, the self-healing effect can be achieved on the inner and outer walls of the insulating component 2, respectively.

[0022] Multiple sets of film kits 36 are provided, and the multiple sets of film kits 36 wrap the outer insulation layer 21. The multiple sets of film kits 36 are connected by adhesive. The multiple sets of film kits 36 can cover the surface of the outer insulation layer 21 in all directions. Since each set of film kits 36 is independent, when different areas of the inner insulation layer 22 are damaged, the film kit 36 ​​in that area will release self-healing silicone rubber 37 for repair, while the film kits 36 in other undamaged areas will remain attached to the inner insulation layer 22 and wait for repair.

[0023] The film kit 36 ​​is a PE composite film. When a sharp object damages the outer insulation layer 21, the sharp object will puncture the PE composite film first, allowing the self-healing silicone rubber 37 inside the PE composite film to flow out, thereby repairing the punctured outer insulation layer 21.

[0024] Self-healing silicone rubber 37 is a component made of siloxane polymer chains as the basic skeleton, combined with hydrogen bond groups or dynamic covalent bond groups and reinforcing fillers. When the siloxane chains of the self-healing functional groups come into contact with the crack, the mechanical stress at the crack and the ambient heat will trigger the hydrogen bonds to re-bond or the dynamic covalent bonds to break and recombine. This will drive the molecular chains to gather at the crack and fill the gaps, forming a continuous insulating structure, thereby repairing the cracks on the outer wall of the inner insulation layer 22.

[0025] Microcapsules are components made by using epoxy resin to form the capsule wall and encapsulating a liquid repair agent inside. When the capsule wall is damaged, the low-viscosity repair agent inside is released. The repair agent will flow and fill the cracks and gaps by capillary action, and then form a complete insulation structure by self-curing and tightly bonding with the original insulation layer, thereby repairing the cracks in the inner wall of the outer insulation layer 21.

[0026] A protective layer 33 is fixedly installed on the inner wall of the shielding layer 31. The inner wall of the protective layer 33 is attached to the thin film kit 36, and a channel 34 is formed between the shielding layer 31 and the protective layer 33. A vent 32 is opened on the outer surface of the shielding layer 31. The vent 32 is connected to the channel 34. External gas can be introduced into the surface of the protective layer 33 through the vent 32 and the channel 34, so that the temperature of the protective layer 33 itself is reduced, thereby accelerating the curing speed of the self-healing silicone rubber 37.

[0027] A filter screen 35 is fixedly installed on the inner wall of the vent 32. The filter screen 35 can prevent external particulate dust from entering the interior of the channel 34 and thus blocking the channel 34.

[0028] The protective layer 33 is a component made of aluminum alloy. Due to the high thermal conductivity of aluminum alloy, when the self-healing silicone rubber 37 moves to the crack, it can be cooled down by the external wind speed, which can accelerate the solidification of the self-healing silicone rubber 37.

[0029] The sheath 4 is a component made of thermoplastic polyurethane elastomer, modified polyvinyl chloride, and engineering plastics. Through the shielding layer 31, it can resist friction, impact, and squeezing during vehicle operation, prevent damage to the internal wires 1, resist environmental corrosion, and also provide auxiliary insulation, thereby ensuring the long-term stable operation of the high-voltage harness.

[0030] The present invention proposes a technical solution: a method for preparing a high-voltage wiring harness for new energy vehicles with a self-healing insulation layer, comprising the following steps: S1: The outer insulation substrate is heated and melted by an extruder and then extruded, and then tightly wrapped on the outer surface of the conductor 1. After cooling and solidification, an inner insulation layer 22 is formed. Then, the inner insulation layer 22 substrate is heated and melted by an extruder again and extruded, tightly wrapped on the outer surface of the inner insulation layer 22 and cooled and solidified to form an outer insulation layer 21. Then, multiple sets of film kits 36 are independently and omnidirectionally wrapped on the surface of the outer insulation layer 21 by a film coating equipment, so that the film kits 36 are attached to the outer surface of the outer insulation layer 21. S2: The raw materials are processed into a tubular protective layer 33 by the pipe processing equipment. Then, the shielding layer 31 is woven by the braiding machine. Next, multiple sets of air vents 32 are opened on the outer surface of the shielding layer 31 by the drilling machine. Then, the filter screen 35 is installed inside the air vent 32. Then, the protective layer 33 is fixed to the inner wall of the shielding layer 31 by welding, so that a gas channel 34 communicating with the air vent 32 is formed between the two. S3: Using a wire harness threading device, thread the wire 1, outer insulation layer 21 and inner insulation layer 22 made in S1 into the shielding layer 31 and protective layer 33 structure made in S2 as a whole, and then use an adhesive device to fix the inner wall of the shielding layer 31 to the outer surface of the outer insulation layer 21. S4: The sheath substrate is heated and melted by an extruder and extruded to tightly cover the outer surface of the shielding layer 31 of the self-healing component to form the sheath 4. Then, the entire wire harness is cured at a constant temperature using a drying device. The integrity of the outer insulation layer 21, the thin film kit 36, and the vent 32, as well as the adhesion of each layer, are checked by a wire harness testing device. After confirming that all structures meet the requirements, the preparation of the self-healing insulation layer high-voltage wire harness for new energy vehicles is completed.

[0031] Specifically, when the inner insulation layer 22 is damaged, the pre-mixed microcapsules inside will break due to the damage. At this time, the low-viscosity repair agent inside the microcapsules will immediately flow out, rapidly flowing and filling the cracks and gaps in the inner insulation layer 22 through capillary action. Subsequently, the repair agent will tightly bond with the original inner insulation layer 22 through its self-curing properties, forming a complete and continuous insulation structure, thereby completing the self-healing of the damage to the inner insulation layer 22. When cracks or other damage occur on the surface of the outer insulation layer 21, the multiple sets of PE composite film material film kits 36 attached to the outer surface of the outer insulation layer 21 will be triggered by the damage and rupture. At this time, the self-healing silicone rubber 37 inside the film kits 36 will flow out. After the siloxane chains in the self-healing silicone rubber 37 come into contact with the cracks, the mechanical stress and environmental heat at the cracks will trigger the hydrogen bonds to re-bond or the dynamic covalent bonds to break and recombine, thereby driving the molecular chains to gather at the cracks and fill the gaps, forming a continuous insulation structure, and realizing the self-healing of the outer insulation layer 22. The self-healing of surface damage to the insulation layer 21 is achieved simultaneously. During the repair of the outer insulation layer 21 by the self-healing silicone rubber 37, the channel 34 formed between the shielding layer 31 and the protective layer 33 introduces external gas through the vent 32 on the outer surface of the shielding layer 31. The protective layer 33 is made of aluminum alloy and has high thermal conductivity, which can work with the introduced external gas to quickly remove the heat from the self-healing silicone rubber 37, accelerate the curing speed of the self-healing silicone rubber 37, and ensure rapid damage repair. In addition, the filter screen 35 fixedly installed on the inner wall of the vent 32 can prevent external particles and dust from entering the channel 34 and causing blockage, ensuring that the channel 34 is always unobstructed and continuously providing airflow support for the curing of the self-healing silicone rubber 37. Finally, through the microcapsule repair of the inner insulation layer 22, the repair of the outer insulation layer 21 by the self-healing silicone rubber 37, and the auxiliary acceleration effect of the protective layer 33 and the channel 34, the self-healing effect of the wire harness insulation layer is improved through the dual-layer self-healing function.

[0032] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-voltage wiring harness for new energy vehicles with a self-healing insulation layer, characterized in that, The device includes a conductor (1), an insulating component (2) for isolating electrical conduction fixedly installed on the outer surface of the conductor (1), a self-healing component (3) for repairing the insulating component (2) fixedly installed on the outer surface of the insulating component (2), and a sheath (4) fixedly installed on the outer surface of the self-healing component (3); the insulating component (2) includes an inner insulating layer (22) fixedly installed on the outer surface of the conductor (1), an outer insulating layer (21) fixedly installed on the outer surface of the inner insulating layer (22), microcapsules mixed inside the inner insulating layer (22), and a shielding layer (31) fixedly installed on the outer surface of the insulating component (2), a thin film kit (36) disposed inside the shielding layer (31), and a self-healing silicone rubber (37) disposed inside the thin film kit (36), the outer surface of the self-healing silicone rubber (37) being in contact with the outer surface of the outer insulating layer (21). The film kit (36) is a PE composite film. When a sharp object damages the outer insulation layer (21), the sharp object will puncture the PE composite film first, allowing the self-healing silicone rubber (37) inside the PE composite film to flow out, thereby repairing the punctured outer insulation layer (21). The self-healing silicone rubber (37) is a component made of a siloxane polymer chain as the basic skeleton, combined with hydrogen bond groups or dynamic covalent bond groups and reinforcing fillers. The microcapsule is a component made of epoxy resin as the capsule wall and encapsulated with liquid repair agent. The inner wall of the shielding layer (31) is fixedly installed with a protective layer (33). The inner wall of the protective layer (33) is attached to the film kit (36). A channel (34) is formed between the shielding layer (31) and the protective layer (33). A vent (32) is opened on the outer surface of the shielding layer (31). The vent (32) is connected to the channel (34).

2. The high-voltage wiring harness for new energy vehicles with a self-healing insulation layer as described in claim 1, characterized in that: The film kit (36) is provided in multiple sets, and the multiple sets of film kits (36) wrap the outer insulating layer (21). The multiple sets of film kits (36) are connected to each other by adhesive bonding.

3. The high-voltage wiring harness for new energy vehicles with a self-healing insulation layer as described in claim 1, characterized in that: A filter screen (35) is fixedly installed on the inner wall of the vent (32).

4. The high-voltage wiring harness for new energy vehicles with a self-healing insulation layer as described in claim 1, characterized in that: The protective layer (33) is a component made of aluminum alloy.

5. The high-voltage wiring harness for new energy vehicles with a self-healing insulation layer as described in claim 1, characterized in that: The sheath (4) is a component made of thermoplastic polyurethane elastomer, modified polyvinyl chloride, and engineering plastics.

6. A method for preparing a high-voltage wiring harness for new energy vehicles with a self-healing insulation layer, applicable to a high-voltage wiring harness for new energy vehicles with a self-healing insulation layer as described in any one of claims 1-5, characterized in that, The method for preparing the self-healing insulation layer of the high-voltage wiring harness for new energy vehicles includes the following steps: S1: The outer insulation substrate is heated and melted by an extruder and then extruded, and then tightly wrapped on the outer surface of the conductor (1). After cooling and solidification, an inner insulation layer (22) is formed. Then, the inner insulation layer (22) substrate is heated and melted by an extruder again, and tightly wrapped on the outer surface of the inner insulation layer (22) and cooled and solidified to form an outer insulation layer (21). Then, multiple sets of film kits (36) are independently and omnidirectionally wrapped on the surface of the outer insulation layer (21) by a film coating equipment, so that the film kits (36) adhere to the outer surface of the outer insulation layer (21). S2: The raw materials are processed into a tubular protective layer (33) by pipe processing equipment. Then, a shielding layer (31) is made by braiding machine. Next, multiple sets of air vents (32) are opened on the outer surface of the shielding layer (31) by drilling machine. Then, the filter screen (35) is installed inside the air vent (32). Then, the protective layer (33) is fixed to the inner wall of the shielding layer (31) by welding, so that a gas channel (34) communicating with the air vent (32) is formed between the two. S3: The wire (1), outer insulation layer (21) and inner insulation layer (22) prepared in S1 are inserted into the shielding layer (31) and protective layer (33) structure prepared in S2 by the wire harness threading equipment, and then the inner wall of the shielding layer (31) and the outer surface of the outer insulation layer (21) are fixed by the bonding equipment. S4: The sheath (4) substrate is heated and melted by an extruder and tightly wrapped on the outer surface of the shielding layer (31) of the self-healing component (3) to form the sheath (4). Then, the entire wire harness is cured at a constant temperature using a drying device. The integrity of the outer insulation layer (21), the film kit (36) and the vent (32) and the adhesion of each layer are checked by a wire harness testing device. After confirming that all structures meet the requirements, the preparation of the self-healing insulation layer high voltage wire harness for new energy vehicles is completed.

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