A new energy automobile wire harness rubber sheath assembly

Abstract

The present application relates to the technical field of new energy vehicle wire harness protection, in particular to a new energy vehicle wire harness rubber sheath assembly, the sheath includes successively from inside to outside along the radial direction adaptive shape memory layer, electromagnetic shielding layer, integrated thermal management layer and composite protective layer, each layer is integrally arranged through composite forming process.Adaptive shape memory layer adopts polyurethane-based shape memory rubber material, can be softened and formed at 60 DEG C ~ 80 DEG C and cooled and shaped, realizes the adaptive fit of sheath in complex wiring environment;The electromagnetic shielding layer is composed of nano-silver or carbon nanotube film, which is used for efficient suppression of electromagnetic interference;The integrated thermal management layer includes heat-conducting sheet, heat-conducting column and heat-dissipating ring, which constitute a continuous heat-conducting channel, and realize real-time temperature monitoring and overheating early warning in combination with flexible temperature sensor.The sheath has multiple functions of adaptive forming, active heat conduction, electromagnetic shielding and mechanical protection, significantly improves the adaptability, safety and service life of new energy vehicle wire harness.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of new energy vehicle wire harness protection, in particular to a new energy vehicle wire harness rubber sheath assembly. BACKGROUND

[0002] At present, the high-voltage wire harness of new energy vehicles undertakes the key task of energy and signal transmission between the vehicle power system, energy storage system and control system. With the increase of vehicle voltage level and system power density, the wire harness is long-term operated under high temperature, high frequency vibration and complex wiring environment, and the traditional sheath structure has been difficult to balance flexibility, thermal safety and durability.

[0003] In the prior art, the commonly used wire harness sheath is usually made of ordinary rubber or thermoplastic elastomer material, and its structure is mainly single or double layer coating. Although such sheath has certain mechanical flexibility, it lacks shape memory function and needs to be adjusted in shape by manual stretching or mechanical pressing during installation, which is difficult to accurately adapt to the complex body wiring path, resulting in stress concentration at the bending part, rubber cracking and shortening of service life, etc.

[0004] In addition, for the heat generated during the operation of the high-voltage wire harness of new energy vehicles, the traditional sheath mainly relies on passive high-temperature resistance design, that is, by adding heat-resistant fillers or using high-temperature rubber materials to improve the heat resistance limit. However, this kind of scheme cannot actively conduct or diffuse heat, and when the wire harness is continuously operated under high load, the local temperature rise is still obvious, which is easy to cause insulation aging, wire core deformation and even short circuit risk, and lacks effective thermal management function.

[0005] In terms of electromagnetic protection, the prior art mainly reduces the strength of interference signals by winding metal braid or adding metal shielding layer on the outer layer of the cable. However, the metal layer has poor flexibility, large mass and is easy to fatigue and break, which is not suitable for the wiring environment of new energy vehicles with limited space and frequent bending. At the same time, such shielding structure cannot be integrated with heat conduction or mechanical protection layer, resulting in heavy overall sheath, complex process and high cost.

[0006] In terms of vibration and wear protection, the traditional sheath mainly uses single rubber layer to absorb vibration or polyethylene coating to prevent wear, but due to the low bonding strength between materials, interlayer separation or coating peeling off phenomenon easily occurs. After a long time of operation, the surface of the sheath and the contact part with the vehicle body are easy to wear and age, affecting the overall sealing and safety performance of the wire harness.

[0007] In summary, the existing new energy vehicle wire harness sheath has obvious defects in terms of insufficient self-adaptive fitting, low thermal management efficiency, unstable electromagnetic shielding effect and limited vibration and wear prevention performance. The existing structure cannot meet the requirements of long-term reliable operation under high voltage, high frequency and high temperature environment.

[0008] The present application integrates a shape memory layer, an active heat conduction channel, an electromagnetic shielding layer and a composite protective layer inside the sheath, and proposes a novel wire harness rubber sheath assembly with adaptive fitting, active heat dissipation, electromagnetic anti-interference and anti-fatigue wear, so as to overcome the problems of single structure and dispersed performance in the prior art. SUMMARY

[0009] The present application aims to realize the adaptive shaping, active heat management, electromagnetic shielding and vibration and wear prevention integration of the sheath through the integrated design of the multi-layer composite structure, so as to improve the adaptability, safety and service life of the wire harness system under complex working conditions.

[0010] The existing new energy vehicle wire harness sheath generally has the problems of insufficient flexibility, poor heat conduction performance, unstable electromagnetic protection and low fatigue resistance, which leads to aging, damage and even failure of the wire harness under high temperature, high pressure and vibration conditions. The present application innovatively introduces a shape memory polymer-based rubber, an adaptive heat conduction channel, an electromagnetic shielding structure and a composite protective layer, realizes multi-physical field collaborative protection, and fundamentally improves the thermal stability, mechanical flexibility and environmental tolerance of the sheath.

[0011] The present application provides a new energy vehicle wire harness rubber sheath assembly, which comprises an adaptive shape memory layer, an electromagnetic shielding layer, an integrated heat management layer and a composite protective layer in sequence from the inside to the outside along the radial direction. Each layer is integrally formed by co-extrusion and thermal compounding process to form a multi-layer composite sheath with stable structure.

[0012] The sheath has temperature-triggered flexible fitting function, active heat conduction and dissipation function, electromagnetic interference shielding function and vibration absorption and noise reduction and wear prevention function, and can maintain high adaptability and long-term stability in complex wiring environment.

[0013] In a preferred example, the adaptive shape memory layer is composed of a polyurethane-based shape memory polymer rubber, and shape memory particles are mixed inside, with a mass ratio of particles to rubber matrix of 1:4 to 1:6. When the temperature rises to 60℃ to 80℃, the layer material deforms and automatically adjusts the shape along the bending path of the wire harness; after cooling, it restores and fixes the shape formed, realizing "shape memory shaping".

[0014] The layer is made into a tubular structure by extrusion molding, and is installed on the surface of the wire harness in a heated state. After external force assisted deformation, it is naturally cooled and shaped. Specifically, through this structure design, the sheath can realize automatic fitting without mechanical stretching during installation, effectively prevent stress concentration and cracking at the bending part, and improve the wire harness layout efficiency by 20% to 30%.

[0015] In a preferred example, the electromagnetic shielding layer covers the outer wall of the adaptive shape memory layer, is composed of nano-silver or carbon nanotube film, and has a thickness of 0.05mm-0.2mm. The layer forms a ring-shaped conductive film through a spraying or dipping process, and is used to realize high-efficiency electromagnetic interference shielding.

[0016] An insulating buffer layer (thickness of about 0.1mm) is arranged between the electromagnetic shielding layer and the integrated thermal management layer, is made of silicone rubber material, and is used to isolate the heat conduction and electric conduction structures and prevent current coupling interference. Specifically, the structure can realize electromagnetic shielding efficiency of more than 99%, effectively reduces the crosstalk between motor high-frequency noise and control signals, and improves the electromagnetic compatibility of the system.

[0017] In a preferred example, the integrated thermal management layer is an active heat conduction and temperature control structure, and includes a heat conduction sheet, a heat conduction column and a heat dissipation ring, which form a complete heat conduction path.

[0018] The heat conduction sheet is made of copper sheet or graphene material, is uniformly distributed along the length direction of the wire harness, and is attached to the inner wall arc surface of the sheath, and is used to diffuse the heat inside the wire harness along the axial direction; the heat conduction column is arranged through the thickness direction of the sheath, and the two ends are respectively connected to the heat conduction sheet and the heat dissipation ring, and is used to realize radial heat conduction; and the heat dissipation ring is made of aluminum alloy material, is arranged on the outer arc surface of the sheath, and covers the outer side region of the heat conduction sheet, so as to increase the heat dissipation area.

[0019] In a preferred example, a graphene-based flexible temperature sensor is attached to the outer surface of the heat dissipation ring, the output end of the temperature sensor is in communication connection with a vehicle ECU temperature control module, real-time temperature monitoring and overheating early warning are realized. Specifically, the structure forms a continuous heat conduction channel of “heat conduction sheet-heat conduction column-heat dissipation ring”, and can reduce the wire harness operating temperature by more than 15℃, and significantly prolongs the service life of the wire harness by more than 50%.

[0020] In a preferred example, the composite protective layer is located at the outermost layer of the sheath, and includes a high-damping layer and a self-lubricating layer.

[0021] The high-damping layer is formed by mixing nitrile rubber and damping particles at a ratio of 3:1, the particle size is 0.1mm-0.5mm, the thickness is about 2mm, and the high-damping layer is used to absorb high-frequency vibration generated during the operation of the wire harness; the self-lubricating layer is a polytetrafluoroethylene (PTFE) coating layer, has a thickness of about 0.2mm, and has a surface friction coefficient of ≤0.1, and is used to reduce the wear at the contact position of the wire harness and the vehicle body.

[0022] The two layers are integrally formed through an extrusion co-extrusion process, and are fixedly connected through a hot melt bonding technology (temperature of 180℃, pressure of 5MPa). Specifically, the structure realizes the anti-wear and anti-aging function of the outer surface of the sheath, reduces the wear rate by 40%, and effectively improves the operation stability and weather resistance of the wire harness.

[0023] The beneficial effects achieved by the application are:

[0024] 1. In the present application, by setting an adaptive shape memory layer inside the sheath, the functions of softening and shaping under temperature triggering and cooling and curing are realized, so that the sheath can automatically deform and fit according to the wire harness path, significantly improving the installation efficiency and shape retention of the wire harness in complex wiring environment, and avoiding the problem that the traditional rubber sheath is easy to crack at the bending part.

[0025] 2. In the present application, the integrated thermal management layer builds a complete heat conduction channel through the cooperative heat conduction structure of the heat conduction sheet, the heat conduction column and the heat dissipation ring, realizes the rapid external transmission and uniform heat dissipation of the heat inside the wire harness, and realizes real-time temperature monitoring and overheating warning in combination with the flexible temperature sensor, effectively reduces the working temperature of the high-voltage wire harness, and prolongs the service life.

[0026] 3. In the present application, the composite protective layer adopts a double-layer composite structure of high-damping layer and self-lubricating layer, has the functions of vibration absorption and noise reduction, and anti-wear and anti-aging performance, can reduce the fatigue damage caused by body vibration and relative friction, and improve the safety and durability of the vehicle electrical system. BRIEF DESCRIPTION OF DRAWINGS

[0027] Fig. 1 is a schematic diagram of the overall cross-sectional structure of an embodiment of the present application;

[0028] Fig. 2 is a schematic diagram of the heat conduction sheet and the surface heat dissipation ring connection structure of an embodiment of the present application.

[0029] REFERENCE NUMERALS:

[0030] 1, adaptive shape memory layer; 2, electromagnetic shielding layer; 3, integrated thermal management layer; 4, composite protective layer; 5, heat conduction sheet; 51, heat dissipation ring; 52, heat conduction column. DETAILED DESCRIPTION

[0031] To make the purpose, technical scheme and advantages of the present application clearer and more intelligible, the present application will be further described in detail below with reference to specific embodiments and the accompanying drawings. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0032] It is understood that these descriptions are only exemplary and are not intended to limit the scope of the present application.

[0033] Some embodiments of the present application provide a new energy automobile wire harness rubber sheath assembly.

[0034] In combination with Figs. 1-2As shown, the present invention provides a rubber sheath assembly for new energy vehicle wiring harnesses, comprising, from the inside out, a self-adaptive shape memory layer 1, an electromagnetic shielding layer 2, an integrated thermal management layer 3, and a composite protective layer 4. Each layer is tightly bonded together through multi-layer co-extrusion and thermal bonding processes to form an integral sheath structure for covering the outer surface of the high-voltage wiring harness in new energy vehicles. This design balances the wiring harness's flexible bending adaptability, heat dissipation safety, electromagnetic protection, and mechanical abrasion resistance.

[0035] The adaptive shape memory layer 1 in this invention uses polyurethane-based SMP shape memory polymer rubber as the matrix material, incorporating shape memory particles with a particle-to-rubber matrix mass ratio of 1:4 to 1:6. This layer can soften and deform when heated to 60°C to 80°C to adapt to the bending path of the wire harness. After cooling, it recovers and fixes the formed shape, achieving the function of "heat-triggered memory shaping".

[0036] In this embodiment, the adaptive shape memory layer 1 is extruded into a tubular preform and then fitted onto the surface of the wiring harness under heating. Its orientation is adjusted manually or mechanically to conform to complex wiring paths, and it maintains a stable state over a long period after cooling. This layer possesses a certain degree of self-healing property, capable of repairing minor deformation damage.

[0037] Specifically, the adaptive shape memory layer 1 can significantly improve the wiring efficiency by 20% to 30% during assembly and reduce fatigue cracking at bends during operation, thereby effectively improving the mechanical stability and service life of the system.

[0038] In this embodiment, the electromagnetic shielding layer 2 is disposed on the outer surface of the adaptive shape memory layer 1, and is made of a thin film of silver nanoparticles or carbon nanotubes with a thickness of 0.05 mm to 0.2 mm, forming a uniform ring structure.

[0039] In this embodiment, the electromagnetic shielding layer 2 is uniformly covered on the inner wall surface of the sheath by spraying or impregnation processes to ensure a consistent conductive layer thickness and achieve efficient electromagnetic shielding performance. To avoid electrical interference between the electromagnetic shielding layer 2 and the outer thermally conductive structure, an insulating buffer layer with a thickness of approximately 0.1 mm, made of silicone rubber, is added between them.

[0040] The electromagnetic shielding layer 2 can achieve an electromagnetic interference shielding effect of over 99%, effectively isolating high-frequency electromagnetic noise generated by the motor and control module, and ensuring the stability and safety of the signal transmitted by the wiring harness.

[0041] like Fig. 2 As shown, the integrated thermal management layer 3 includes a heat-conducting sheet 5, heat-conducting pillars 52, and a heat dissipation ring 51. This layer is an important functional part of the present invention, used to realize the heat conduction and heat transfer of the sheath and the active temperature monitoring function.

[0042] In this embodiment: the heat-conducting sheet 5 is a copper sheet or a graphene sheet material, with a thickness of about 0.5 mm, uniformly distributed along the length of the wire harness and attached to the inner wall of the sheath, for conducting heat along the axial direction;

[0043] The heat-conducting column 52 is made of copper or high-thermal-conductivity metal, with a diameter of about 2 mm, arranged through the sheath in the thickness direction, and evenly distributed according to the heat dissipation requirements, for establishing a heat connection path between the heat-conducting sheet 5 and the heat-dissipating ring 51;

[0044] The heat-dissipating ring 51 is made of aluminum alloy material, with a thickness of about 3 mm, arranged on the outer arc surface of the sheath, covering the outer arc area of the heat-conducting sheet 5, forming an arc-shaped heat-dissipating structure to increase the air convection heat dissipation area.

[0045] In the manufacturing process of this layer, the heat-conducting sheet 5 is embedded in the inner wall of the sheath by hot pressing or bonding, and the heat-conducting column 52 is fixed between the heat-conducting sheet and the heat-dissipating ring by welding, and finally a graphene-based flexible temperature sensor is pasted on the surface of the heat-dissipating ring 51, with a thickness of about 0.01 mm, electrically connected to the vehicle ECU temperature control unit through a wire, for real-time temperature detection and overheating alarm.

[0046] Through the above structure combination, the integrated thermal management layer 3 establishes a continuous heat conduction channel of "heat-conducting sheet 5 - heat-conducting column 52 - heat-dissipating ring 51", realizing the rapid external transmission of wire harness working heat. This structure can reduce the wire harness operating temperature by about 15℃, and prolong the wire harness life by more than 50% through ECU active temperature control.

[0047] In this embodiment, the composite protective layer 4 is arranged on the outermost side of the sheath, including a high-damping layer and a self-lubricating layer.

[0048] The high-damping layer is formed by mixing nitrile rubber and damping particles, with a ratio of 3:1, a particle size of 0.1mm-0.5mm, and a thickness of about 2mm, for absorbing mechanical vibration energy;

[0049] The self-lubricating layer is a polytetrafluoroethylene PTFE coating, with a thickness of about 0.2mm and a friction coefficient ≤0.1, for reducing the relative friction between the wire harness and the vehicle body metal parts.

[0050] The two layers are integrally formed by a double-layer extrusion co-extrusion process, with a molding temperature of about 180℃ and a hot melt pressure of about 5MPa, and are firmly combined after heat bonding and solidification without delamination or falling off.

[0051] The composite protective layer 4 can effectively absorb high-frequency vibration and reduce the sheath surface wear rate by 40%, while enhancing the anti-aging performance to ensure the long-term stable operation of the sheath in the environment of -40℃-100℃.

[0052] Assembly and application:

[0053] In the assembly process, first, the self-adapting shape memory layer 1 pipe body is prepared, and the electromagnetic shielding layer 2 is sprayed on the surface thereof; then the heat conduction sheet 5 and the heat conduction column 52 of the integrated heat management layer 3 are embedded, the external heat dissipation ring 51 is installed, and the temperature sensor is adhered; finally, the composite protective layer 4 is formed through a co-extrusion composite process.

[0054] During installation, the sheath is softened in a heated state, and is manually or mechanically attached to the wiring harness bending path. After cooling, it is fixed into a solid sheath structure, which can maintain stable shape and good flexibility.

[0055] The sheath is suitable for high-voltage wiring harness of new energy vehicles, and is particularly suitable for high-voltage power transmission path from the battery pack to the motor. The structure shows good reliability in vibration, temperature fluctuation and strong electromagnetic environment.

[0056] In the description of the present specification, the description of the terms "one embodiment", "some embodiments", "a specific embodiment" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the described specific features, structures, materials or characteristics can be combined in any one or more embodiments or examples in a suitable manner.

[0057] Although the embodiments of the present application have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, replacements and variations can be made to the embodiments without departing from the principles and purposes of the present application, and the scope of the present application is defined by the claims and their equivalents.

Claims

1. A rubber sheath assembly for wiring harnesses in new energy vehicles, characterized in that, The sheath includes an adaptive shape memory layer (1), an electromagnetic shielding layer (2), an integrated thermal management layer (3), and a composite protective layer (4), with each layer sequentially arranged along the radial direction of the sheath. The adaptive shape memory layer (1) is composed of shape memory polymer-based rubber and incorporates shape memory particles. When the temperature rises to 60℃~80℃, it undergoes softening deformation to adapt to the bending path of the wire harness. After cooling, it recovers and fixes the formed shape. The integrated thermal management layer (3) has a heat-conducting sheet (5) embedded in it, and a heat dissipation ring (51) that is thermally connected to the heat-conducting sheet (5) is provided on the outside of the sheath. A flexible temperature sensor is attached to the surface of the heat dissipation ring (51). The sensor is electrically connected to the vehicle ECU and is used to monitor and transmit temperature data in real time. The composite protective layer (4) includes a high-damping layer on the inner side and a self-lubricating layer on the outer side; the shape memory polymer-based rubber is polyurethane-based SMP rubber, and the shape memory particles and the rubber matrix are mixed in a mass ratio of 1:4 to 1:6; the heat-conducting sheet (5) is a copper sheet or a graphene heat-conducting sheet, which is evenly distributed along the length of the wire harness; the heat dissipation ring (51) is made of aluminum alloy material; the heat-conducting sheet (5) is arranged along the arc surface of the inner wall of the sheath and is used to conduct internal heat along the length of the wire harness; the heat dissipation ring (51) is fixedly connected to the outer side of the sheath and covers the outer arc area of ​​the heat-conducting sheet (5); the heat dissipation ring (51) and the heat-conducting sheet (5) are thermally connected by several heat-conducting columns (52); the heat-conducting columns (52) are arranged through the thickness of the sheath to form a continuous heat-conducting channel from the heat-conducting sheet (5) to the heat dissipation ring (51).

2. The new energy vehicle wiring harness rubber sheath assembly according to claim 1, characterized in that, The flexible temperature sensor is a graphene-based thin film sensor, and its signal output terminal is communicatively connected to the temperature control unit of the vehicle's main control module.

3. The new energy vehicle wiring harness rubber sheath assembly according to claim 1, characterized in that, The electromagnetic shielding layer (2) is composed of a ring of nano-silver or carbon nanotube film; the thickness of the electromagnetic shielding layer (2) is 0.05mm to 0.2mm, and it is formed by spraying or impregnation.

4. The new energy vehicle wiring harness rubber sheath assembly according to claim 1, characterized in that, The high-damping layer is formed by mixing nitrile rubber and damping particles, and the self-lubricating layer is a polytetrafluoroethylene coating. The high-damping layer and the self-lubricating layer are integrally formed by extrusion co-extrusion process.

5. The new energy vehicle wiring harness rubber sheath assembly according to claim 1, characterized in that, An insulating buffer layer is provided between the electromagnetic shielding layer (2) and the integrated thermal management layer (3).

6. The new energy vehicle wiring harness rubber sheath assembly according to claim 1, characterized in that, The coefficient of friction of the self-lubricating layer is ≤0.

1.

7. The new energy vehicle wiring harness rubber sheath assembly according to claim 1, characterized in that, The sheath achieves shape memory function through temperature triggering.

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