Production process of high-air-tightness waterproof wire harness for automobile

Abstract

The invention discloses a production process of a high-air-tightness waterproof wire harness for an automobile, relates to the field of wire harness sealing, and aims to solve the problems that a gap is easily generated at a joint part of a plastic shell of a joint and the wire harness due to bending or vibration and the like in the installation and use process, the air tightness is poor, and the sealing performance is poor. According to the key points of the technical scheme, a male end ring and an embedded column are provided with plaster holes in a penetrating mode, the plaster holes are provided with locking bolts in a threaded connection mode, and the centers of the locking bolts are provided with discharging holes communicated with the plaster holes; the secondary sealing structure is matched with the rubber sleeve to prevent cement joint filling, multiple protection is achieved, and external water vapor invasion is effectively avoided.

Description

Technical Field

[0001] This invention relates to the technical field of wire harness sealing, specifically to a manufacturing process for high airtightness and waterproof wire harnesses for automobiles. Background Technology

[0002] For automotive electronic and electrical systems, power transmission and signal transmission are inseparable from automotive wiring harnesses, and the sealing performance, an important indicator for evaluating the quality of wiring harnesses, is directly related to the quality and performance of the vehicle.

[0003] The safety of electric vehicles has always been a major concern. Most automotive engine wiring harness interfaces are now waterproofed. When installation space is limited and sealed connectors cannot be used, the usual method is to extrude a plastic shell at the connector. The waterproof effect is achieved by the tight bond between the plastic shell and the wiring harness. However, during installation and use, bending or vibration can easily cause gaps to form between the plastic shell and the wiring harness, resulting in poor airtightness and affecting the waterproof effect of the wiring harness connector and the safety of the electric vehicle. Summary of the Invention

[0004] The purpose of this invention is to provide a manufacturing process for high airtightness and waterproof wiring harnesses for automobiles.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] The device includes male and female wire harnesses that are interlocked. The female wire harness includes a first plastic shell with a mating post fixedly mounted on one side. The mating post has a mating groove, and a plug-in post is provided within the mating groove. The plug-in post has several plug-in slots, which are electrically connected to several female wire harnesses. The male wire harness includes a second plastic shell with a male end ring that surrounds the plug-in post. The male end ring has a female end groove for the mating post to fit into. The female end groove has a secondary sealing ring that surrounds the plug-in post. The secondary sealing ring has a plug-in terminal that matches the plug-in slot. The plug-in terminal is electrically connected to several male wire harnesses. A guide strip is provided along the extension direction of the inner wall of the mating groove. The secondary sealing ring has a guide groove that matches the guide strip. A putty hole is provided through the male end ring and the mating post. A locking bolt is threaded into the putty hole, and a discharge hole communicating with the putty hole is provided at the center of the locking bolt.

[0007] By adopting the above technical solution, during insertion, the male end ring, including the fitting post, forms a first seal, and the secondary sealing ring wraps around the male end ring to form a second seal. The insertion terminal is inserted into the insertion slot to complete the electrical connection between the male and female wire harnesses. The guide strip cooperates with the guide groove to limit and guide, ensuring the smooth insertion process. In addition to the original secondary sealing structure, sufficient rubber sleeves are filled between the male and female ends during insertion to prevent cement from filling the gap and avoid external moisture intrusion. The setting of the sealant hole facilitates the smooth discharge of excess sealant to avoid obstructing the terminal insertion. The setting of the locking bolt effectively blocks the sealant hole after insertion and locks the male and female ends of the wire harness simultaneously to prevent them from separating under external force and affecting the sealing effect. At the same time, the locking bolt has a discharge hole to facilitate the smooth discharge of excess sealant to avoid obstructing the installation of the locking bolt. The setting of the sealing cap effectively seals the discharge hole to prevent moisture from entering from here, further improving the airtightness and protection effect.

[0008] Furthermore, a manufacturing process for a high-airtightness waterproof wiring harness for automobiles includes the following production and assembly steps:

[0009] S1. Trim the male and female wire harnesses in sequence so that the shielding layer, insulation layer and copper wires in the wire harness are exposed.

[0010] S2. After the ends of the shielding layer and insulation layer are trimmed neatly, the female wire harness is soldered to the plug slot of the plug post, and the male wire harness is soldered to the plug terminal.

[0011] S3. Wrap the shielding layer and welding points with high-pressure waterproof tape;

[0012] S4. Extruding plastic shells are used to form male and female wire harnesses after the above steps;

[0013] S5. Squeeze in enough rubber sleeve anti-cement into the fitting groove, then connect the male and female ends of the wire harness until the rubber sleeve anti-cement seeps out from the putty hole.

[0014] S6. Tighten the locking bolt to allow the rubber sleeve to drain cement from the discharge hole until it is fully embedded in the male and female wire harnesses.

[0015] S7. Tighten the sealing cap to seal the discharge hole.

[0016] Furthermore, the adhesive sleeve anti-cement composition by weight includes the following materials

[0017] 16 parts butyl rubber;

[0018] 200 parts of calcium carbonate;

[0019] 21 parts of high-molecular-weight polyisocyanate;

[0020] 0.15 parts carbon black;

[0021] Stearic acid 1.1 parts;

[0022] 28 parts silicone rubber oil;

[0023] 32 parts white oil.

[0024] By adopting the above technical solution, since the gaps between terminals cannot be completely eliminated by laying, they can only be minimized. Therefore, to prevent water from seeping in through the gaps between the wires, sealing measures are necessary. The rubber sleeve anti-cement formulated as described above not only has excellent adhesion, acid and alkali resistance, and aging resistance, but also outstanding waterproof, sealing, electrical insulation, and low-temperature tracking properties. Therefore, the anti-cement can adapt well to interface deformation and cracking. At the same time, the first and second plastic shells, which are integrally formed with the wire harness, are inherently seamless and have excellent airtightness. In addition, by using hydrophobic high-pressure waterproof tape such as PVC tape, it can be effectively ensured that the male and female ends of the wire harness have good original waterproof and airtightness.

[0025] In summary, the beneficial technical effects of the present invention are as follows:

[0026] 1. It adopts a male end ring, a secondary sealing ring and a rubber sleeve to prevent cement, thus creating a secondary sealing structure combined with the rubber sleeve to prevent cement from filling the gap, providing multiple protections to effectively prevent the intrusion of external moisture.

[0027] 2. The use of putty holes, locking bolts, and drain holes creates a high-airtightness waterproof wiring harness manufacturing process for automotive applications.

[0028] 3. The design incorporates a locking bolt, which effectively blocks the putty hole after insertion and locks both the male and female ends of the wire harness simultaneously, preventing them from separating under external force and affecting the sealing effect. Combined with a sealing cap, it can further seal the discharge hole. Attached Figure Description

[0029] The accompanying drawings are provided to further illustrate the invention and form part of the specification, but do not constitute a limitation thereof. In the drawings:

[0030] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0031] Figure 2 This is an exploded view of the overall structure of the present invention;

[0032] Figure 3 This is an exploded view of the overall structure of the present invention.

[0033] In the diagram, 1. Female end of wire harness; 11. First plastic shell; 12. Fitting post; 13. Fitting groove; 14. Plug-in post; 15. Plug-in groove; 16. Female wire harness; 2. Male end of wire harness; 21. Second plastic shell; 22. Male end ring; 23. Female end groove; 24. Secondary sealing ring; 25. Plug-in terminal; 26. Male wire harness; 3. Guide strip; 31. Guide groove; 4. Locking bolt; 41. Putty hole; 42. Drain hole; 43. Sealing ring; 44. Sealing cap. Detailed Implementation

[0034] The present invention will be further described in detail below with reference to the accompanying drawings.

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] Please see Figure 1-3 The present invention provides the following technical solution:

[0037] The wire harness includes a male terminal 2 and a female terminal 1 that are mutually plugged in. The female terminal 1 includes a first plastic shell 11, on one side of which a fitting post 12 is fixedly provided. The fitting post 12 has a fitting groove 13, and a plug-in post 14 is provided in the fitting groove 13. The fitting post 12 has several plug-in slots 15, which are electrically connected to several female terminal wire harnesses 16. The male terminal 2 includes a second plastic shell 21, and the second plastic shell 21 has a male end ring 22 that wraps around the plug-in post 14. The male end ring 22 has a female end groove 2 for the fitting post 12 to fit into. 3. A secondary sealing ring 24 is fixedly provided in the female end groove 23 to wrap the plug-in post 14. The secondary sealing ring 24 is provided with a plug-in terminal 25 that matches the plug-in groove 15. The plug-in terminal 25 is electrically connected to several male end wire harnesses 26. A guide strip 3 is provided in the extension direction of the inner wall of the fitting groove 13. The secondary sealing ring 24 is provided with a guide groove 31 that matches the guide strip 3. The male end ring 22 and the fitting post 12 are provided with a putty hole 41. The putty hole 41 is threadedly connected with a locking bolt 4. A discharge hole 42 that connects to the putty hole 41 is provided in the center of the locking bolt 4.

[0038] During insertion, the male end ring 22, including the fitting post 12, forms a first seal. The secondary sealing ring 24 wraps around the male end ring 22 to form a second seal. The insertion terminal 25 is inserted into the insertion slot 15 to complete the electrical connection between the male end wire harness 26 and the female end wire harness 16. The guide strip 3 cooperates with the guide groove 31 to limit and guide, ensuring the smooth insertion process. In addition to the original secondary sealing structure, sufficient rubber sleeves are filled between the male and female ends during insertion to prevent cement filling gaps and avoid external moisture intrusion. The setting of the putty hole 41 facilitates the use of extra... The rubber sleeve prevents cement from being discharged smoothly, avoiding obstruction of terminal insertion. The locking bolt 4 effectively blocks the cement hole 41 after insertion and locks the male end 2 and female end 1 of the wire harness simultaneously, preventing them from separating under external force and affecting the sealing effect. At the same time, the locking bolt 4 has a discharge hole 42 to facilitate the smooth discharge of excess cement from the rubber sleeve, avoiding obstruction of the installation of the locking bolt 4. The sealing cap 44 effectively seals the discharge hole 42 to prevent moisture from entering, further improving airtightness and protection.

[0039] A manufacturing process for a high-airtightness waterproof wiring harness for automobiles includes the following production and assembly steps:

[0040] S1. Trim the male end wire harness 26 and the female end wire harness 16 in sequence so that the shielding layer, insulation layer and copper wire in the wire harness are exposed.

[0041] S2. After the ends of the shielding layer and insulation layer are trimmed neatly, the female wire harness 16 is soldered to the plug slot 15 of the plug post 14, and the male wire harness 26 is soldered to the plug terminal 25.

[0042] S3. Wrap the shielding layer and welding points with high-pressure waterproof tape;

[0043] S4. Extruding plastic shells are used to form male end 2 and female end 1 of the wire harness 26 and female end 1, respectively, after completing the above steps.

[0044] S5. Squeeze in enough rubber sleeve anti-cement into the fitting groove 13, and then connect the male end 2 and the female end 1 of the wire harness until the rubber sleeve anti-cement seeps out from the putty hole 41.

[0045] S6. Tighten the locking bolt 4 to allow the rubber sleeve to discharge cement from the discharge hole 42 until it is fully embedded in the male wire harness 26 and the female wire harness 16.

[0046] S7. Tighten the sealing cap 44 to seal the discharge hole 42.

[0047] Furthermore, the rubber sleeve anti-cement composition by weight includes the following materials

[0048] 16 parts butyl rubber;

[0049] 200 parts of calcium carbonate;

[0050] 21 parts of high-molecular-weight polyisocyanate;

[0051] 0.15 parts carbon black;

[0052] Stearic acid 1.1 parts;

[0053] 28 parts silicone rubber oil;

[0054] 32 parts white oil.

[0055] Since the gaps between terminals cannot be completely eliminated through laying, they can only be minimized. Therefore, to prevent water from seeping in through the gaps between the wires, sealing measures are necessary. The rubber sleeve anti-cement material with the above-mentioned formula not only has excellent adhesion, acid and alkali resistance, and aging resistance, but also has outstanding waterproof, sealing, electrical insulation, and low-temperature tracking properties. Therefore, the anti-cement material can adapt well to interface deformation and cracking. At the same time, the first plastic shell 11 and the second plastic shell 21, which are integrally formed with the wire harness, are inherently seamless and have excellent airtightness. In addition, the use of hydrophobic high-pressure waterproof tape such as PVC tape can effectively ensure that the male terminal 2 and the female terminal 1 of the wire harness have good waterproof and airtightness.

[0056] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0057] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-airtightness waterproof wiring harness for automobiles, comprising a male and female terminal of the harness that are interlocked, characterized in that: The female end of the wire harness includes a first plastic shell, on one side of which a fitting post is fixedly provided. The fitting post has a fitting groove, and a plug-in post is provided in the fitting groove. The fitting post has several plug-in slots, which are electrically connected to several female end wire harnesses. The male end of the wire harness includes a second plastic shell, on which a male end ring is provided to wrap around the plug-in post. The male end ring has a female end groove for the fitting post to fit into. A secondary sealing ring is fixedly provided in the female end groove to wrap around the plug-in post. A plug-in terminal that matches the plug-in slot is provided in the secondary sealing ring. The plug-in terminal is electrically connected to several male end wire harnesses. A guide strip is provided in the extension direction of the inner wall of the fitting groove. The secondary sealing ring has a guide groove that matches the guide strip. A putty hole is provided through the male end ring and the fitting post. A locking bolt is threadedly connected to the putty hole. A discharge hole communicating with the putty hole is provided in the center of the locking bolt.

2. The manufacturing process for a high-airtightness waterproof wiring harness for automobiles according to claim 1, characterized in that: A sealing ring is fixedly provided on the outer wall of the locking bolt away from the putty hole, surrounding the discharge hole, and the sealing ring is threadedly connected and covered with a sealing cap.

3. The manufacturing process for a high-airtightness waterproof wiring harness for automobiles according to claims 1-2, characterized in that, The following production and assembly steps are included: S1. Trim the male and female wire harnesses in sequence so that the shielding layer, insulation layer and copper wires in the wire harness are exposed. S2. After the ends of the shielding layer and insulation layer are trimmed neatly, the female wire harness is soldered to the plug slot of the plug post, and the male wire harness is soldered to the plug terminal. S3. Wrap the shielding layer and welding points with high-pressure waterproof tape; S4. Extruding plastic shells are used to form male and female wire harnesses after the above steps; S5. Squeeze in enough rubber sleeve anti-cement into the fitting groove, then connect the male and female ends of the wire harness until the rubber sleeve anti-cement seeps out from the putty hole. S6. Tighten the locking bolt to allow the rubber sleeve to drain cement from the discharge hole until it is fully embedded in the male and female wire harnesses. S7. Tighten the sealing cap to seal the discharge hole.

4. The manufacturing process for a high-airtightness waterproof wiring harness for automobiles according to claim 3, characterized in that: The protective cement sleeve comprises the following materials by weight. 16 parts butyl rubber; 200 parts of calcium carbonate; 21 parts of high-molecular-weight polyisocyanate; 0.15 parts carbon black; Stearic acid 1.1 parts; 28 parts silicone rubber oil; 32 parts white oil.

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