Waterproof production process for wiring harness of hot water kettle and wiring harness

Abstract

The invention relates to the technical field of wire harnesses, in particular to a water-proof production process for a kettle wire harness and the kettle wire harness, and the water-proof production process for the kettle wire harness comprises the following processing steps: splitting a wire; making a copper strip; installing a first heat shrink tube and a second heat shrink tube; installing a neon lamp; dipping in insulating paint; installing a third heat shrink tube; an auxiliary heat shrink tube is installed; mounting an outer rubber pipe; punching a terminal; and conducting testing. And secondly, the water-proof wiring harness of the hot water kettle is obtained through the water-proof production process of the wiring harness of the hot water kettle. The invention provides a kettle wire harness waterproof production process and a wire harness. The waterproof performance of the wire harness can be further improved.

Description

Technical Field

[0001] This application relates to the technical field of wire harnesses, and in particular to a waterproof manufacturing process and wire harness for a kettle. Background Technology

[0002] In composite cable harnesses, because the multiple insulated wires contained in the cable, such as signal wires and power wires, have different connection purposes, the insulated wires need to be branched according to each connection destination. At the branching points of the insulated wires, since the insulated wires are exposed from the sheath, there is a concern that moisture may flow along the insulated wires and penetrate into the sheath. Therefore, the exposed parts of the insulated wires need to be water-resistant to prevent moisture from penetrating into the sheath.

[0003] In the existing technology, in order to achieve the waterproof function of the kettle wiring harness during the production process, some traditional water-blocking measures are usually adopted, such as wrapping the branch parts of the wiring harness with water-blocking tape. However, the water-blocking tape may age and fall off during long-term use, resulting in a decrease in water-blocking effect. Summary of the Invention

[0004] In order to overcome the problems existing in the above-mentioned background technology, this application provides a waterproof manufacturing process and wire harness for kettles, which can further improve the waterproof performance of the wire harness.

[0005] Firstly, this application provides a waterproof manufacturing process for a kettle wiring harness, which employs the following technical solution: A waterproof manufacturing process for a kettle wiring harness includes a first conductor and a second conductor, both comprising an internally hollow insulating tube and a conductive wire placed inside the insulating tube. The first conductor has ends A and B, and the second conductor has ends C and D. The process includes the following steps: Opening the wires: Strip the insulation from the ends of the first and second conductors to expose the conductive wires at ends A, B, C, and D. Copper strip installation: At end A of the first conductor, where the first conductor protrudes from the insulation, a resistor is connected, and a first copper strip and a third copper strip are installed. The first copper strip is positioned near the end of the insulation, and the first and third copper strips are installed symmetrically with the resistor as the center. At end C of the second conductor, a second copper strip is installed where the second conductor protrudes from the insulation, and the second copper strip is positioned near the end of the insulation. Install the first heat shrink tubing and the second heat shrink tubing: Place a first heat shrink tubing over end A of the first conductor, covering the first copper strip and the third copper strip; place a second heat shrink tubing over end C of the second conductor, covering the second copper strip; perform heat shrink treatment on the first heat shrink tubing and the second heat shrink tubing. Install the neon lamp: The neon lamp is simultaneously riveted to both ends A and C to obtain the wire harness; Install a third heat shrink tubing: A third heat shrink tubing is fitted over the neon lamp of the wire harness. The end of the third heat shrink tubing away from the neon lamp simultaneously covers the ends of the first and second heat shrink tubing, and the third heat shrink tubing is heat-shrinked. Install outer tubing: Outer tubing is fitted onto the first wire and the second wire respectively; Terminal crimping: Install terminals on the B end of the first wire and the D end of the second wire respectively; Continuity test: Connect the first wire (B end) and the second wire (D end) to determine the brightness of the neon lamp.

[0006] By adopting the above technical solution, the steps of installing the first heat shrink tubing and the second heat shrink tubing utilize the properties of heat shrink material to tightly wrap the ends of the wires and the copper strip, forming the first waterproof barrier. The installation of the third heat shrink tubing further expands the waterproof range, ensuring comprehensive protection for the neon lamp and its connection points. Furthermore, by installing an outer tubing, additional mechanical protection can be provided to prevent the wire harness from being damaged by external forces during use.

[0007] Compared with the existing technology of wrapping wire harnesses with water-blocking tape, the wire harness of this application, after being heat-shrinked by the first heat-shrink tubing, the second heat-shrink tubing, and the third heat-shrink tubing, can fit the wires and connection points more tightly, further reducing the installation gap, effectively preventing moisture intrusion, and has better waterproof performance and durability. It is also easier to produce and helps to improve production efficiency.

[0008] Preferably, before the processing step of installing the third heat shrink tubing, an insulating varnish impregnation step is also included. The process includes impregnation with insulating varnish: the portion of the wire harness containing the neon lamp is immersed in insulating varnish and then dried.

[0009] By adopting the above technical solution and adding the insulating varnish impregnation step, an insulating varnish layer is formed on the wire harness at the neon lamp and its connection points. The insulating varnish layer can fill the tiny gaps between the heat shrink tubing, the wires, and the neon lamp, forming a more airtight waterproof structure. This effectively prevents moisture from penetrating the wire harness through these gaps, further enhancing the electrical insulation performance of the wire harness and improving the waterproof effect. At the same time, the insulating varnish layer also has a certain degree of corrosion resistance, which can protect the wire harness from the erosion of chemicals in the environment and extend the service life of the wire harness.

[0010] Preferably, in the process of impregnating with insulating varnish, the wire harness is perpendicular to the insulating varnish liquid until the riveting point between the neon lamp and the first wire, the riveting point between the neon lamp and the second wire, and the neon lamp are simultaneously immersed, and the immersion is continued for 5-6 seconds. After drying, an insulating varnish layer is attached to the outer wall of the neon lamp and the riveting point.

[0011] By adopting the above technical solution, the wire harness is vertically immersed in the insulating varnish liquid, and the neon lamp and its rivet points are immersed simultaneously. This ensures that the insulating varnish evenly covers the key parts of the wire harness, avoiding uneven coating or omissions caused by improper immersion. The controlled immersion time of 5-6 seconds allows the insulating varnish to fully penetrate into the tiny gaps between the heat shrink tubing, the wire, and the neon lamp, forming a tight waterproof structure. This prevents excessive accumulation of insulating varnish or difficulty in drying due to excessive immersion time. After drying, the insulating varnish layer is evenly adhered to the outer wall of the neon lamp and the rivet points, effectively preventing moisture from penetrating the wire harness through these gaps, further improving the waterproof and electrical insulation performance of the wire harness.

[0012] Preferably, in the terminal crimping process, the terminal installed on the first conductor has its outer end pressed against the outer wall of the insulation layer of the first conductor, and its inner end pressed against the conductive wire at end B. After the outer end is crimped, the cross-section presents a "B" shaped structure.

[0013] By adopting the above technical solution, the inner end of the terminal is pressed against the conductive wire to form a reliable electrical connection, ensuring that the circuit can pass stably. The outer end of the terminal is pressed against the insulating sheath, which can provide a robust mechanical connection, making it difficult for the first conductive wire to separate from the terminal, and enhancing the tensile strength and vibration resistance. After the outer end of the terminal of this application is pressed, the cross-section presents a "B" shape structure, which further enhances the connection stability between the terminal and the wire, and improves the waterproof performance of the wire harness and the reliability of the electrical connection.

[0014] Preferably, the clamping mechanism is used to clamp the first conductor during the copper strip bonding process. The clamping mechanism includes a base, a first clamp, a second clamp, and a rotating component. The first clamp and the second clamp are arranged opposite each other along the base with a distance between them. In the processing step of installing the first copper strip on the first conductor, the first clamp clamps end A and the second clamp clamps end B, so that the first conductor is in a taut state. The first clamp and the second clamp rotate in the same direction through the rotating component and drive the first conductor to rotate. The copper strip is wrapped around the first copper strip installation point at least twice, the copper strip is cut, and the tangent is welded.

[0015] By adopting the above technical solution and the clamping mechanism, the first conductor can be kept taut when installing the copper strip. This is beneficial for the copper strip to be accurately and tightly wound around the first conductor installation point. The first clamp and the second clamp rotate in the same direction through the rotating part, thereby driving the first conductor to rotate. This ensures that the copper strip can be evenly and firmly wound around the first copper strip installation point at least two times. After welding the tangent, a stable and reliable electrical connection can be formed, thereby improving the installation efficiency and quality of the copper strip and providing a good foundation for subsequent welding processes.

[0016] Preferably, the copper strip is wound into a roll and hung on an unwinding frame. The copper strip is then fed forward by a clamping mechanism. In the processing step of installing the first copper strip on the first conductor, after the copper strip is wound around the first conductor to a preset length, it is cut by a punching mechanism.

[0017] By adopting the above technical solution, the copper strip is wound into coils and hung on an unwinding rack, facilitating orderly management and continuous supply of the copper strip. The copper strip is fed forward by a clamping mechanism, allowing precise control of its conveying speed and position, ensuring accurate arrival at the installation point of the first conductor. Once the copper strip reaches the preset length on the first conductor, a punching mechanism cuts it, guaranteeing the accuracy and consistency of the copper strip length and preventing subsequent installation and welding quality issues caused by unsuitable strip length. This improves the level of automation and production efficiency.

[0018] Preferably, the copper strip is pulled out from the unwinding frame, first embossed by an embossing mechanism to create a grid-like indentation on the surface of the copper strip, and then conveyed to the first conductor by the clamping and feeding mechanism.

[0019] By adopting the above technical solution, the grid-like indentation increases the surface roughness of the copper strip. When it is subsequently wrapped and soldered with the conductor, it can increase the friction between the copper strip and the conductor, making the copper strip adhere more tightly to the conductor and less prone to loosening or slippage, thereby further improving the stability of the electrical connection.

[0020] Preferably, the bottom of the clamping mechanism is provided with a horizontal moving component and a position identification component. The horizontal moving component drives the clamping mechanism and the unwinding frame to move horizontally in the Y direction. The position identification component is set on the clamping mechanism, and the two move synchronously and in the same direction. In the copper strip processing step of the first conductor, after the first copper strip is installed on the first conductor, the horizontal moving part is driven to drive the clamping mechanism and the unwinding frame to move horizontally in the Y direction until the clamping mechanism is aligned with the third copper strip installation point. The steps of clamping the copper strip by the clamping mechanism, winding the copper strip on the first conductor, and cutting the copper strip by the punching mechanism are repeated.

[0021] By adopting the above technical solution, the horizontal moving component can drive the clamping mechanism and the unwinding frame to move horizontally in the Y direction. This allows the position of the clamping mechanism to be flexibly adjusted after the first copper strip is installed on the first conductor. The position identification component is set on the clamping mechanism and moves synchronously and in the same direction as the clamping mechanism, which can accurately identify the current position and ensure that the clamping mechanism can accurately align with the third copper strip installation point. Then, the steps of clamping the copper strip by the clamping mechanism, winding the copper strip on the first conductor, and cutting the copper strip by the punching mechanism are repeated, realizing the automation and continuity of the production process, greatly improving production efficiency, and ensuring the accuracy of the installation position of each copper strip, further improving the quality of the kettle wiring harness and the reliability of the electrical connection.

[0022] Preferably, the first copper strip, the second copper strip, and the third copper strip are pressed together by a pressing mechanism.

[0023] By adopting the above technical solution, the first copper strip, the second copper strip, and the third copper strip are pressed together by a pressing mechanism, which can further enhance the tightness of the connection between the copper strip and the wire, prevent the copper strip from loosening or falling off due to vibration or external force during use, and thus ensure the stable and reliable electrical connection of the wire harness.

[0024] Secondly, the waterproof wiring harness for a kettle provided in this application adopts the following technical solution: A waterproof wiring harness for a kettle, manufactured using a waterproof manufacturing process, includes a first conductor, a second conductor, a neon lamp, a first heat shrink tubing, a second heat shrink tubing, and a third heat shrink tubing. The first conductor has ends A and B, and the second conductor has ends C and D. The neon lamp is riveted to both ends A and C. Terminals are connected to ends B and D. Two copper strips are connected to end A, and a resistor is connected between the two copper strips. The first heat shrink tubing is fixed to end A and covers the copper strips. One copper strip is connected to end B. The second heat shrink tubing is fixed to end C and covers the second copper strip. An insulating varnish layer is applied to the riveting points between the neon lamp and the first conductor, the riveting points between the neon lamp and the second conductor, and the outer wall of the neon lamp. The third heat shrink tubing is sleeved on the neon lamp and fixed to both the first and second heat shrink tubing.

[0025] In summary, this application includes at least one of the following beneficial technical effects: 1. After the wire harness of this application is heat-shrinked by the first heat shrink tubing, the second heat shrink tubing and the third heat shrink tubing, it can fit the wires and connection points more tightly, further reduce the installation gap, effectively prevent moisture intrusion, have better waterproof performance and durability, and are easier to produce, which helps to improve production efficiency. 2. The insulating varnish fully penetrates into the tiny gaps between the heat shrink tubing, the wires, and the neon lamp, forming a tight waterproof structure. Attached Figure Description

[0026] Figure 1 This is a flowchart of the waterproof manufacturing process for the kettle wiring harness in this application embodiment.

[0027] Figure 2 This is a schematic diagram of the waterproof wiring harness for the kettle in an embodiment of this application.

[0028] Explanation of reference numerals in the attached diagram: 1. First conductor; 11. Terminal A; 12. Terminal B; 13. First copper strip; 14. Third copper strip; 2. Second conductor; 21. Terminal C; 22. Terminal D; 23. Second copper strip; 3. Neon lamp; 4. First heat shrink tubing; 5. Second heat shrink tubing; 6. Third heat shrink tubing; 7. Auxiliary heat shrink tubing; 8. Resistor; 9. Terminal; 10. Outer tubing. Detailed Implementation

[0029] The following is in conjunction with the appendix Figure 1-2 This application will be described in further detail.

[0030] In one aspect, embodiments of this application disclose a waterproof wiring harness for a kettle.

[0031] Reference Figure 1 A waterproof wiring harness for a kettle includes a first conductor 1, a second conductor 2, a neon lamp 3, a first heat shrink tubing 4, a second heat shrink tubing 5, and a third heat shrink tubing 6. The first conductor 1 includes an A end 11 and a B end 12, and the second conductor 2 includes a C end 21 and a D end 22. The neon lamp 3 is riveted to both the A end 11 and the C end 21. Terminals 9 are connected to the B end 12 and the D end, respectively. Two copper strips are connected to the A end 11, and a resistor 8 is connected between the two copper strips. The first heat shrink tubing 4 is fixed to the A end 11 and covers the copper strips. A copper strip is connected to the B end 12. The second heat shrink tubing 5 is fixed to the C end 21 and covers the second copper strip 23. An insulating varnish layer is attached to the riveting points between the neon lamp 3 and the first conductor 1, the riveting points between the neon lamp 3 and the second conductor 2, and the outer wall of the neon lamp 3. The third heat shrink tubing 6 is sleeved on the neon lamp 3 and fixed to the first heat shrink tubing 4 and the second heat shrink tubing 5.

[0032] Specifically, both the first conductor 1 and the second conductor 2 include an internally hollow insulating tube and a conductive wire placed inside the insulating tube. The insulating tube is capable of withstanding high temperatures of 200℃ and is made of fluoroplastic wire capable of withstanding 300V. Terminal A 11 and Terminal B 12 of the first conductor 1 refer to the portions of the conductor exposed outside the insulating tube at both ends; that is, the portion of the conductive wire protruding from the insulating tube at one end is Terminal A 11, and the other end is similarly designated as Terminal B 12. The same applies to Terminal C 21 and Terminal D 22 of the second conductor 2.

[0033] Two copper strips are connected to end A 11, namely, a first copper strip 13 is fixed at the mounting point of the first copper strip 13, and a third copper strip 14 is fixed at the mounting point of the third copper strip 14; end B 12 is connected to one copper strip, namely, a second copper strip 23 is fixed at the mounting point of the second copper strip 23. In this application, the copper strip has good conductivity, and its surface is relatively flat and has a certain degree of ductility. After the copper strip is wound around the conductive wire, it needs to be further welded and fixed. During the welding process, the solder can better fuse with the copper strip, so that a stable and reliable electrical connection can be formed between the copper strip, the conductive wire, and other connected components.

[0034] The first heat shrink tubing 4 is fixed to end A 11 and covered with copper tape. After heat shrinking, the first heat shrink tubing 4 tightly wraps end A 11, the first copper tape 13, and the third copper tape 14. The second heat shrink tubing 5 is fixed to end C 21 and covered with the second copper tape 23, and its function is similar to that of the first heat shrink tubing 4. Then, an insulating varnish layer is applied to the riveting point between the neon lamp 3 and the first wire 1, the riveting point between the neon lamp 3 and the second wire 2, and the outer wall of the neon lamp 3. The insulating varnish layer fills the tiny gaps between the heat shrink tubing and the wires and the various parts of the neon lamp 3. The third heat shrink tubing 6 is sleeved on the neon lamp 3 and fixed to the first heat shrink tubing 4 and the second heat shrink tubing 5. It tightly wraps the first heat shrink tubing 4, the second heat shrink tubing 5, and the connection part of the neon lamp 3 together, forming a reliable waterproof and insulating barrier, effectively preventing moisture and external impurities from penetrating into the wire harness, so that the wire harness maintains good waterproof performance and reliable electrical connection.

[0035] In this application, the waterproof wiring harness effectively prevents moisture intrusion through the use of heat-shrink tubing and an insulating varnish layer, protecting the wires and connections and extending the harness's lifespan. Compared to traditional kettle wiring harnesses, it offers superior waterproofing, safety, and reliability.

[0036] Secondly, this application discloses a waterproof manufacturing process for a kettle wiring harness, used to produce a waterproof kettle wiring harness.

[0037] A manufacturing process for waterproofing kettle wiring harnesses includes the following steps: Reference Figure 1 and Figure 2 Wire stripping: Strip the insulation from the ends of the first conductor 1 and the second conductor 2 to expose the conductive wires at ends A 11, B 12, C 21, and D 22. Specifically, during the wire stripping process, the stripping length must be strictly controlled to ensure that the length of the exposed conductive wires at each end meets the design requirements. A professional automatic wire stripper or manual wire stripper can be used as the wire stripping tool. Regardless of the tool chosen, the stripping depth and length must meet a uniform standard. After stripping, clean the exposed conductive wires to remove any oxide layer or impurities, providing a good contact surface for subsequent copper strip installation and soldering.

[0038] Copper strip installation: On end A 11 of the first conductor 1, where the first conductor 1 is exposed from the insulation, a resistor 8 is connected, and a first copper strip 13 and a third copper strip 14 are installed. The first copper strip 13 is positioned near the end of the insulation. The first copper strip 13 and the third copper strip 14 are installed symmetrically with the resistor 8 as the center, that is, the first copper strip 13 is fixed at the first copper strip 13 installation point, and the third copper strip 14 is fixed at the third copper strip 14 installation point. On end C 21 of the second conductor 2, a second copper strip 23 is installed where the second conductor 2 is exposed from the insulation. The second copper strip 23 is positioned near the end of the insulation, that is, the second copper strip 23 is fixed at the second copper strip 23 installation point.

[0039] In this application, the copper strip is generally made of pure copper, with a low resistance (8%), good conductivity, and corrosion resistance. The copper strip can be installed manually or using automated copper strip installation equipment. The copper strip is thin and flexible; it is wound into coils and hung on an unwinding rack, allowing for a more orderly unfolding of the output. The installation methods for the first copper strip 13, the second copper strip 23, and the third copper strip 14 are the same, differing only in their installation positions. The installation process of the first copper strip 13 is taken as an example.

[0040] Specifically, the continuous output direction of the copper strip is the X-direction. The copper strip installation equipment includes at least a clamping mechanism, an embossing mechanism, a punching mechanism, a horizontal moving component, a position identification component, and a welding component. The clamping mechanism includes a base, a first clamp, a second clamp, and a rotating component. The first and second clamps are arranged opposite each other along the base, with a distance between them. The first and second clamps are arranged in the Y-direction of the copper strip installation equipment. In the processing step of installing the first copper strip 13 onto the first conductor 1, the first clamp clamps end A 11 of the first conductor 1, and the second clamp clamps end B 12, keeping the first conductor 1 taut. The first and second clamps rotate in the same direction through the rotating component, driving the first conductor 1 to rotate. For example, if the first and second clamps are existing robotic arm structures, with a motor as the power source for the rotating component, the first and second clamps are driven to rotate in the same direction, requiring that the first conductor 1 does not twist when clamped and rotated.

[0041] Furthermore, in the X direction, an embossing mechanism and a blanking mechanism are sequentially arranged in the spatial position from the unwinding frame to the clamping mechanism. The unwinding frame, embossing mechanism, blanking mechanism, and position identification component are all mounted on a horizontally moving component. This horizontally moving component can be a structure where a rodless cylinder drives a slider to reciprocate. The unwinding frame, embossing mechanism, blanking mechanism, and position identification component are mounted on the top surface of the slider. The embossing mechanism can be a roller-type embossing device, which presses a grid-like indentation onto the copper strip surface using the pattern on the roller surface. The indentation must not damage the copper strip; only uneven marks are allowed. The blanking mechanism can be a hydraulic blanking machine capable of cutting the copper strip. The welding component can be a welding machine, fixed to the side near the clamping mechanism, used for tangential welding of the wound cylindrical copper strip. The position identification component can be an infrared identification sensor.

[0042] In practical applications, the copper strip is wound into a coil and placed on the unwinding frame. The horizontal moving component is activated, moving the unwinding frame, embossing mechanism, punching mechanism, and position identification component along the Y-axis to the appropriate position. At this time, the position identification component provides real-time positional feedback to ensure precise equipment positioning. After the copper strip is pulled from the unwinding frame, it first passes through the embossing mechanism. The roller-type embossing device presses a grid-like indentation on the surface of the copper strip, increasing the friction between the copper strip and the conductor. The copper strip then enters the clamping mechanism area. Simultaneously, the first clamp holds end A 11 of the first conductor 1, and the second clamp holds end B 12, keeping the first conductor 1 taut. A motor-driven rotating component causes the first and second clamps to rotate in the same direction, thereby rotating the first conductor 1 and evenly winding the copper strip around the mounting point of the first copper strip 13. When the winding length reaches a preset value, the punching mechanism is activated, and the hydraulic punching machine precisely cuts the copper strip. The first copper strip 13 at the mounting point is wound into a cylindrical shape, and the tangent line of the copper strip is welded using a welding machine.

[0043] More specifically, in this application, in order to make the first copper strip 13 fit more tightly on the first conductor 1 and prevent loosening or slippage, the copper strip is conveyed to the first conductor 1 by a clamping mechanism. The copper strip is wound around the mounting point of the first copper strip 13 on the first conductor 1 at least two turns, that is, at least the cross-section of the copper strip attached to the conductor is in the shape of a "6". Then, the copper strip is cut by a punching mechanism, and the welding machine performs the first welding treatment on the cut line of the copper strip, so that the copper strip can be installed on the first copper strip 13 in a stable wound shape.

[0044] At this point, the above steps can be repeated to adjust the position of the device by using the horizontal moving parts, and the installation of the third copper strip 14 on the first conductor 1 can be completed. Further, the first conductor 1 on the clamping mechanism can be replaced with the second conductor 2, and the above steps can be repeated to adjust the position of the device by using the horizontal moving parts, and the installation of the second copper strip 23 on the second conductor 2 can be completed.

[0045] After installation, the connection between the copper strip and the conductor is carefully inspected for any looseness, insufficient winding, or other abnormalities. The first copper strip 13, the second copper strip 23, and the third copper strip 14 are also pressed together using a pressing mechanism. The grid-like indentation increases the surface roughness of the copper strip, increasing the friction between the copper strip and the conductor, allowing the copper strip to adhere more tightly to the conductor and reducing the likelihood of loosening or slippage. A second welding process is then performed to close the gap between the copper strip and the conductor. During welding, the embossed copper strip allows the solder to embed better into the grid-like indentation, resulting in better fusion with the copper strip and enhanced bonding strength. This contributes to a stronger weld point, reduces welding defects such as incomplete soldering, and ensures welding quality and reliability.

[0046] Install the first heat shrink tubing 4 and the second heat shrink tubing 5: Place one first heat shrink tubing 4 on end A 11 of the first conductor 1, covering the first copper strip 13 and the third copper strip 14. The first heat shrink tubing 4 extends to at least one-third of the length of the insulating tube. Place one second heat shrink tubing 5 on end C 21 of the second conductor 2, covering the second copper strip 23. Perform heat shrink treatment on the first heat shrink tubing 4 and the second heat shrink tubing 5. Specifically, the heat shrink tubing is generally made of polyolefin material, which has the characteristic of shrinking when heated. The heat shrink treatment can be performed using a heat gun or heat shrink machine, so that the heat shrink tubing is tightly wrapped around the conductor, providing waterproofing and insulation.

[0047] Install neon lamp 3: Simultaneously rivet neon lamp 3 to end A 11 and end C 21 to obtain a wire harness.

[0048] Impregnating with insulating varnish: The wire harness is perpendicular to the insulating varnish liquid until the riveting point between the neon lamp 3 and the first conductor 1, the riveting point between the neon lamp 3 and the second conductor 2, and the neon lamp 3 are simultaneously immersed, and the immersion is continued for 5-6 seconds. The insulating varnish layer can fill the tiny gaps between the heat shrink tubing and the conductor and the neon lamp 3, forming a more tight waterproof structure.

[0049] The epoxy resin-based insulating varnish used in this product possesses excellent waterproof and corrosion-resistant properties. After drying, it forms a waterproof layer on the surface of the wire harness. After drying, an insulating varnish layer adheres to the outer walls of the neon lamp 3 and the riveting points. This insulating varnish layer provides good insulation, effectively preventing electrical faults such as short circuits caused by external environmental factors like moisture and humidity during use. Simultaneously, the insulating varnish layer also offers some protection, reducing physical damage to the wire harness during transportation, installation, and use, thus extending its service life.

[0050] Install the third heat shrink tubing 6: Slide the third heat shrink tubing 6 onto the neon lamp 3 portion of the wire harness, ensuring that the third heat shrink tubing 6 is positioned away from the end of the neon lamp 3. Simultaneously, the coverage area of ​​the third heat shrink tubing 6 should include the ends of the first heat shrink tubing 4 and the second heat shrink tubing 5 to further protect and secure the first two heat shrink tubing sections. Then, heat shrink the third heat shrink tubing 6, heating it to ensure it adheres tightly to the wire harness and the first two heat shrink tubing sections, thus forming a strong and sealed protective layer. The third heat shrink tubing 6 must be fixed to the ends of the first heat shrink tubing 4 and the second heat shrink tubing 5, extending at least one-third of the length of the first and second heat shrink tubing sections.

[0051] Install the auxiliary heat shrink tubing 7: The auxiliary heat shrink tubing 7 is connected at the junction of the third heat shrink tubing 6 and the first heat shrink tubing 4 and the second heat shrink tubing 5, completely covering the joint. The inner side of the auxiliary heat shrink tubing 7 near the joint is filled with adhesive, so that the adhesive fills the entire interior of the auxiliary heat shrink tubing 7. The auxiliary heat shrink tubing 7 is heat-shrinked using a heat gun or heat shrink machine to make it tightly adhere to the wire harness. During the heat shrinking process, the adhesive will solidify due to heat, further enhancing the connection strength between the auxiliary heat shrink tubing 7 and the wire harness. This application requires that the auxiliary heat shrink tubing 7 can still cover the joint when it is heat-shrinked, and metal pressure rings are fixed to the outer walls of both ends of the auxiliary heat shrink tubing 7. The metal pressure rings are mechanically pressed to fix the auxiliary heat shrink tubing 7 to both ends, which plays a role in stabilization and sealing, effectively preventing moisture and impurities from entering the wire harness from the joint, and improving the overall waterproof performance and reliability of the wire harness.

[0052] Install outer tubing 10: Outer tubing 10 is respectively fitted onto the first conductor 1 and the second conductor 2. The length of the outer tubing 10 needs to be reasonably cut according to the actual length of the first conductor 1 and the second conductor 2. Two outer tubing 10s are taken so that they can completely cover the other areas of the first conductor 1 and the second conductor 2 except for the connection part.

[0053] After the outer tubing 10 is installed, it can provide additional protection for the first conductor 1 and the second conductor 2, preventing the conductors from being subjected to physical damage such as wear and scratches during daily use, and further improving the overall performance and service life of the wire harness.

[0054] Terminal 9: Install terminals 9 on the B end 12 of the first wire 1 and the D end 22 of the second wire 2 respectively.

[0055] Specifically, terminal 9 can be installed using a terminal 9 crimping machine. The outer end of terminal 9 installed on the first conductor 1 is pressed against the outer wall of the insulation layer of the first conductor 1, and the inner end is pressed against the conductive wire of terminal B 12. After crimping, the cross-section of the outer end presents a "B" shape, ensuring that terminal 9 is firmly connected to the conductor. Terminal 9 on the second conductor 2 is set in the same way.

[0056] The inner end of terminal 9 of this application presses against the conductive wire to form a reliable electrical connection, ensuring that the circuit can pass stably. The outer end of terminal 9 presses against the insulating sheath, which can provide a strong mechanical connection, making it difficult for the first conductive wire to separate from terminal 9, and enhancing tensile strength and vibration resistance.

[0057] Continuity test: Connect the B end 12 of the first conductor 1 and the D end 22 of the second conductor 2 to power. By observing the brightness of the neon lamp 3, the continuity of the wire harness and whether its electrical performance is normal can be detected.

[0058] The above are all preferred embodiments of this application. These embodiments are merely explanations of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A hot kettle wire harness waterproof production process, comprising a first wire (1) and a second wire (2), both comprising an internally hollow insulating tube and an electrically conductive wire placed inside the insulating tube, the first wire (1) having an A end (11) and a B end (12) at both ends, the second wire (2) having a C end (21) and a D end (22) at both ends, characterized in that, The processing steps include: Opening line: the end of the first wire (1), the second wire (2) is respectively stripped, the A end (11), the B end (12), the C end (21) and the D end (22) are exposed to the conductive wire; Copper band: on the A end (11) of the first wire (1), the position of the first wire (1) exposed to the insulating skin is connected with the resistance (8), and the first copper band (13) and the third copper band (14) are installed, the first copper band (13) is arranged at the position close to the end of the insulating skin, and the first copper band (13) and the third copper band (14) are symmetrically installed with the resistance (8) as the center; on the C end (21) of the second wire (2), the second copper band (23) is arranged at the position of the second wire (2) exposed to the insulating skin; Install the first heat shrink tube (4) and the second heat shrink tube (5): one first heat shrink tube (4) is sleeved on the A end (11) of the first wire (1), and covers the first copper band (13) and the third copper band (14); one second heat shrink tube (5) is sleeved on the C end (21) of the second wire (2), and covers the second copper band (23); the first heat shrink tube (4) and the second heat shrink tube (5) are heat shrunk; Install the neon lamp (3): the neon lamp (3) is riveted with the A end (11) and the C end (21) at the same time, and a wire harness is obtained; Install the third heat shrink tube (6): the third heat shrink tube (6) is sleeved on the neon lamp (3) of the wire harness, the end of the third heat shrink tube (6) away from the neon lamp (3) covers the ends of the first heat shrink tube (4) and the second heat shrink tube (5) at the same time, and the third heat shrink tube (6) is heat shrunk; Install the outer rubber tube (10): the first wire (1) and the second wire (2) are respectively sleeved with the outer rubber tube (10); Terminal (9) is punched: the B end (12) of the first wire (1) and the D end (22) of the second wire (2) are respectively installed with the terminal (9); Conduction test: the B end (12) of the first wire (1) and the D end (22) of the second wire (2) are electrically connected, and the brightness of the neon lamp (3) is judged.

2. The production process of a hot kettle wire harness waterproof according to claim 1, characterized in that, Before the processing step of installing the third heat shrink tube (6), the processing step of dipping insulating paint is further included, Wherein, dip insulating paint: dip the wire harness with the neon lamp (3) part into insulating paint, and dry.

3. The production process of a hot kettle wire harness waterproof according to claim 2, characterized in that, In the processing step of dipping insulating paint, the wire harness is perpendicular to the insulating paint liquid, and the riveting points between the neon lamp (3) and the first wire (1), the riveting points between the neon lamp (3) and the second wire (2), and the neon lamp (3) are immersed at the same time, and the immersion time is 5-6 seconds. After drying, a layer of insulating paint is attached to the outer wall of the neon lamp (3) and the riveting point.

4. The production process of a hot kettle wire harness waterproof according to claim 1, characterized in that, In the processing step of punching the terminal (9), the terminal (9) installed on the first wire (1) is pressed against the insulating layer outer wall of the first wire (1) at the outer end and the conductive wire of the B end (12) at the inner end, and the cross section after the outer end pressure welding presents a "B" type structure.

5. The production process of a hot kettle wire harness waterproof according to claim 1, characterized in that, In the processing step of punching the copper band of the first wire (1) by the clamping mechanism, clamping is carried out The clamping mechanism comprises a seat body, a first clamp, a second clamp and a rotating member. The first clamp and the second clamp are arranged opposite to each other along the seat body and are spaced apart. In the processing step of installing the first copper tape (13) on the first wire (1), the first clamp clamps the A end (11) and the second clamp clamps the B end (12), so that the first wire (1) is in a straightened state. The first clamp and the second clamp are driven to rotate in the same direction by the rotating member and drive the first wire (1) to rotate. The copper tape is wound at least two turns around the installation point of the first copper tape (13), the copper tape is cut off, and the cutting line is welded.

6. The production process of a hot kettle wire harness waterproof according to claim 5, characterized in that, The copper tape is wound into a roll and hung on the unwinding frame. The copper tape is clamped and fed forward by the clamping and feeding mechanism. In the processing step of installing the first copper tape (13) on the first wire (1), the copper tape is wound on the first wire (1) to a predetermined length, and then the copper tape is cut off by the punching mechanism.

7. The process for producing a hot kettle wiring harness according to claim 6, wherein The copper tape is pulled out from the unwinding frame, first passes through the embossing mechanism to perform embossing treatment on the copper tape, so that the surface of the copper tape presents a grid-shaped indentation, and then the copper tape is transmitted to the first wire (1) by the clamping and feeding mechanism.

8. The production process of a hot kettle wire harness waterproof according to claim 7, characterized in that, The bottom of the clamping and feeding mechanism is provided with a horizontal moving member and a position recognition member. The clamping and feeding mechanism and the unwinding frame are driven to horizontally move in the Y direction by the horizontal moving member. The position recognition member is arranged on the clamping and feeding mechanism, and the two are synchronously and directionally displaced, In the processing step of installing the first copper tape (13) on the first wire (1), after the installation of the first copper tape (13) on the first wire (1) is completed, the horizontal moving member drives the clamping and feeding mechanism and the unwinding frame to horizontally move in the Y direction until the clamping and feeding mechanism is aligned with the installation point of the third copper tape (14). The steps of clamping and feeding the copper tape by the clamping mechanism, winding the copper tape on the first wire (1), and cutting off the copper tape by the punching mechanism are repeated.

9. The process for producing a hot kettle wiring harness according to claim 8, wherein The first copper tape (13), the second copper tape (23) and the third copper tape (14) are pressed by the pressing mechanism.

10. A hot water kettle cord set, characterized by The hot water kettle wire harness is obtained by the production process of any one of claims 1-9, comprising a first wire (1), a second wire (2), a neon lamp (3), a first heat shrink tube (4), a second heat shrink tube (5) and a third heat shrink tube (6). The first wire (1) comprises an A end (11) and a B end (12), and the second wire (2) comprises a C end (21) and a D end (22). The neon lamp (3) is riveted to the A end (11) and the C end (21) at the same time. The B end (12) and the D end are respectively connected with a terminal (9). The A end (11) is connected with two copper tapes. The two copper tapes are further connected with a resistor (8). The first heat shrink tube (4) is fixed on the A end (11) and covers the copper tapes. The B end (12) is connected with one copper tape. The second heat shrink tube (5) is fixed on the C end (21) and covers the second copper tape (23). The riveting points between the neon lamp (3) and the first wire (1), the riveting points between the neon lamp (3) and the second wire (2), and the outer wall of the neon lamp (3) are attached with an insulating paint layer. The third heat shrink tube (6) is sleeved on the neon lamp (3) and is fixed with the first heat shrink tube (4) and the second heat shrink tube (5).

Images