A high temperature resistant automobile wheel wiring harness assembly for new energy

Abstract

The utility model discloses a high-temperature resistant automobile wheel wiring harness assembly for new energy, and relates to the technical field of automobile wheel wiring harnesses. The wiring harness assembly comprises a sheathed wire, a connector, and a terminal. The moving area of ​​the sheathed wire and the connector are fixed by an injection molding process, and the static area of ​​the sheathed wire is fixed by a cable tie, a clamp, and a rubber part. The sheathed wire comprises a conductor; an insulating layer is coated on the outside of the conductor to form an electric wire; two groups of electric wires are twisted to form a twisted pair; an inner sheath portion is extruded and coated on the outside of the twisted pair; a plurality of groups of electric wires are distributed around the outer periphery of the inner sheath portion; an inner sheath portion is extruded and coated on the outside of the electric wire located on the outer periphery of the inner sheath portion; an aluminum foil layer is coated on the outer layer of the inner sheath portion to isolate external heat; a protective layer is extruded and coated on the outside of the aluminum foil layer; the wiring harness is temperature resistant at 40 to 200°C and voltage resistant at 600V, meeting market application requirements; and the wiring difficulty is low, and the wiring space of the wheel wiring harness is expanded; the wiring harness assembly meets multiple functional uses and is widely used.

Description

Technical Field

[0001] The utility model relates to the technical field of automobile wheel wiring harnesses, in particular to a high temperature resistant automobile wheel wiring harness assembly for new energy. Background Art

[0002] The system voltage used in electric vehicles is higher than that of traditional vehicles. The higher the system voltage, the lower the voltage of the wire with the same cross-section, which is beneficial to signal transmission and reduces the weight of the vehicle. The wiring environment of the car is relatively complex, and the ambient temperature near the exhaust pipe and the engine is relatively high, which is not conducive to the design of the wheel wiring harness. Existing automobile wheel wiring harnesses are often used in systems less than DC 60V or AC 25V; the structure is usually a protective tube, sheathed wire, single-core wire, injection molded parts, connectors and terminals. The common temperature resistance of existing automobile wheel wiring harnesses is -40 to 105℃ and -40 to 125℃.

[0003] Existing automobile wheel wiring harnesses still have the following defects:

[0004] 1. The applicable system voltage environment is low and not suitable for higher system voltage;

[0005] 2. The wire harness has low temperature resistance and is not suitable for use in environments with higher temperatures;

[0006] 3. There are high requirements for vehicle layout; for example, the exhaust pipe temperature is high. When the wheel harness and the exhaust pipe are too close, the harness temperature will exceed the standard and affect the risk of use. When the layout cannot be adjusted, the existing wheel harness will not meet the use environment.

[0007] Therefore, it is urgent to design a wheel wiring harness suitable for higher voltage rating systems and ambient temperatures to facilitate the wiring process. Summary of the invention

[0008] The utility model aims to provide a high temperature resistant automobile wheel harness assembly for new energy which meets the requirements of high pressure resistance and high temperature resistance, is convenient for wiring and use, and prolongs the service life of the wheel harness.

[0009] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0010] A high temperature resistant automobile wheel wiring harness assembly for new energy, the wiring harness assembly comprises a sheathed wire, a connector, and a terminal. The moving area of ​​the sheathed wire and the connector are fixed by an injection molding process, and the static area of ​​the sheathed wire is fixed by a cable tie, a staple, and a rubber part. The sheathed wire comprises:

[0011] conductor;

[0012] An insulating layer, wherein the insulating layer is coated on the outside of the conductor to form an electric wire;

[0013] The two groups of wires are twisted together to form a twisted pair;

[0014] An inner sheath portion, wherein the inner sheath portion is extruded and coated on the outside of the twisted pair;

[0015] A plurality of groups of electric wires are distributed around the outer periphery of a portion of the inner sheath;

[0016] The second inner sheath part is extruded and covered on the outside of the electric wire located on the outer periphery of the first inner sheath part;

[0017] An aluminum foil layer, the aluminum foil layer is coated on the outer layers of the two inner sheaths to isolate external heat;

[0018] The protective layer is extruded and coated on the outside of the aluminum foil layer.

[0019] Further, the conductor is formed by twisting copper wire and bulletproof wire;

[0020] The copper wire is made of oxygen-free copper or tinned copper;

[0021] The purity of the copper wire is above 99.99%;

[0022] The copper wire diameter is ≤0.18 mm.

[0023] Furthermore, the insulating layer is made of polystyrene and cross-linked polyethylene with Shore D 65±20 and is formed by an extrusion process;

[0024] The temperature resistance range of the insulation layer is -40 to 125°C;

[0025] The insulation layer has a withstand voltage of 600V;

[0026] The insulation concentricity of the insulation layer is ≥95%.

[0027] Furthermore, the twisted pitch of the twisted pair is 17±2 mm.

[0028] Furthermore, the material of the inner sheath part one and the inner sheath part two is polystyrene or cross-linked polyethylene or polyurethane;

[0029] The hardness range of the inner sheath part one and the inner sheath part two is Shore 50-90A;

[0030] The temperature resistance range of the inner sheath part one and the inner sheath part two is -40 to 125°C;

[0031] The thickness of the inner sheath part one and the inner sheath part two is 0.5±0.05mm.

[0032] Furthermore, the aluminum foil layer is an aluminum foil corrugated tube or an aluminum foil tape or a nylon corrugated tube coated with an aluminum layer.

[0033] Furthermore, the protective layer is made of silicone rubber;

[0034] The thickness of the silicone rubber is 1.0±0.05mm;

[0035] The temperature resistance range of the silicone rubber is -40 to 200°C.

[0036] Furthermore, the protective layer is a fluoroplastic heat shrinkable tube that shrinks after heating;

[0037] The thickness of the fluoroplastic heat shrink tube is 1.0±0.05mm;

[0038] The fluoroplastic heat shrink tube has a temperature resistance range of -40 to 200°C.

[0039] Furthermore, the protective layer is formed by using a glass fiber tube and drying at high temperature;

[0040] The inner layer of the glass fiber tube is woven with alkali-free glass fibers;

[0041] The outer layer of the alkali-free glass fiber is coated with silicone resin;

[0042] The thickness of the glass fiber tube is 0.3-0.5 mm;

[0043] The temperature resistance range of the glass fiber tube is -40 to 200°C.

[0044] In the above technical solution, the utility model of a new energy high temperature resistant automobile wheel wiring harness assembly has the following beneficial effects:

[0045] 1. The wiring harness assembly can provide wheel wiring harness products with a temperature resistance of -40 to 200°C and a voltage resistance of 600V, meeting the market gap for such products;

[0046] 2. The wiring difficulty of the wiring harness assembly is low, and the wiring space of the wheel harness is expanded due to the excellent temperature resistance of the wiring harness;

[0047] 3. This wiring harness assembly can be used for ABS, ESP, WSS and other functions and has a wide range of applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present utility model. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0049] Figure 1 A schematic diagram of the structure of a sheathed wire in a high temperature resistant automobile wheel wiring harness assembly for new energy provided by an embodiment of the utility model;

[0050] Figure 2The present invention is a schematic diagram of the assembly structure of a high temperature resistant automobile wheel wiring harness assembly for new energy vehicles provided in an embodiment of the present invention.

[0051] Description of reference numerals:

[0052] 1. Sheathed wire:

[0053] 11. Conductor; 12. Insulation layer; 13. Twisted pair; 14. Inner sheath part 1; 15. Inner sheath part 2; 16. Aluminum foil layer; 17. Protective layer. DETAILED DESCRIPTION

[0054] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below in conjunction with the accompanying drawings.

[0055] It should be noted that the terms "periphery", "outer layer", "interior", "exterior", etc. used in this article indicate the orientation or position relationship based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description. Similar expressions are only for the purpose of explanation, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention; in addition, the terms "one part", "two parts", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0056] See also Figure 1-Figure 2 As shown;

[0057] A high temperature resistant automobile wheel harness assembly for new energy, the harness assembly comprises a sheathed wire 1, a connector, and a terminal. The moving area of ​​the sheathed wire 1 and the connector are fixed by an injection molding process, and the static area of ​​the sheathed wire 1 is fixed by a cable tie, a staple, and a rubber part. The sheathed wire 1 comprises:

[0058] Conductor 11;

[0059] An insulating layer 12, wherein the insulating layer 12 is coated on the outside of the conductor 11 to form a wire;

[0060] Two sets of wires are twisted together to form a twisted pair 13;

[0061] An inner sheath portion 14, the inner sheath portion 14 is extruded and coated on the outside of the twisted pair 13;

[0062] A plurality of groups of electric wires are distributed around the outer periphery of the inner sheath 14;

[0063] The second inner sheath part 15 is extruded and covered on the outer part of the electric wire located on the outer periphery of the first inner sheath part 14;

[0064] An aluminum foil layer 16, the aluminum foil layer 16 is coated on the outer layer of the second inner sheath portion 15 to isolate external heat;

[0065] The protective layer 17 is extruded and coated on the outside of the aluminum foil layer 16 .

[0066] Specifically, a high-temperature resistant automobile wheel wiring harness assembly for new energy, wherein the sheathed wire 1 used in the wheel wiring harness is different from the existing traditional wiring harness structure, the center of the sheathed wire 1 is a twisted pair 13 formed by two twisted strands, the wires constituting the twisted pair 13 are composed of a copper conductor 11 and an insulating layer 12, a foamed sheath layer, i.e., an inner sheath part 14, is extruded on the outside of the twisted pair 13, a plurality of groups of wires are evenly distributed on the outer periphery of the inner sheath part 14, and then a foamed sheath layer, i.e., an inner sheath part 2 15, is extruded on the outside of the evenly distributed plurality of groups of wires, the outer layer of the inner sheath part 15 is coated with an aluminum foil layer 16 for heat insulation, and a protective layer 17 is extruded on the outside of the aluminum foil layer 16, the protective layer 17 can cope with the external high temperature environment for a long time, protect the internal wiring harness safety, and finally form a wheel wiring harness with high voltage resistance and high temperature resistance, which brings convenience to the later wiring process.

[0067] The conductor 11 is formed by twisting copper wire and bulletproof wire;

[0068] The copper wire is made of oxygen-free copper or tinned copper;

[0069] The purity of copper wire is above 99.99%;

[0070] Copper wire diameter ≤0.18mm.

[0071] Specifically, the conductor 11 is made of oxygen-free metal copper with a purity of more than 99.99%, tinned or bare copper on the surface, and has excellent conductivity; the conductor 11 is made of a single wire with a diameter of ≤0.18mm and a bulletproof wire twisted to form a fine or ultra-fine conductor 11. The conductor 11 is soft and has high tensile strength and excellent bending performance, which improves the bending life of the wiring harness.

[0072] The insulating layer 12 is made of polystyrene and cross-linked polyethylene with Shore D 65±20 and is formed by an extrusion process;

[0073] The temperature resistance range of the insulating layer 12 is -40 to 125°C;

[0074] The insulation layer 12 has a withstand voltage of 600V;

[0075] The insulation concentricity of the insulation layer 12 is ≥95%.

[0076] Specifically, the insulating layer 12 is made of polystyrene, cross-linked polyethylene copolymer, etc. with a hardness of Shore D 65±20 through an extrusion process, with a temperature resistance of -40 to 125°C, a withstand voltage of 600V, a concentricity of ≥95%, a smooth surface, a soft texture, and excellent low-temperature performance; during a -35°C wheel jump test, the insulating surface will not crack or turn white.

[0077] The twist pitch of the twisted pair 13 is 17±2 mm.

[0078] Specifically, the twisting process uses a back-twisting bundler or cage twisting or tube twisting to form a twisted pair 13. The specific operation is as follows:

[0079] The insulating layer 12 and the conductor 11 are combined into an electric wire. The two electric wires form a twisted structure according to a twisting pitch within the range of 17±2 mm. During the twisting process, the electric wires are untwisted, the twisted structure is stable, the twisting pitch is uniform, and there is no internal stress.

[0080] The material of the inner sheath part 14 and the inner sheath part 2 15 is polystyrene or cross-linked polyethylene or polyurethane;

[0081] The hardness range of the inner sheath part 14 and the inner sheath part 2 15 is Shore 50-90A;

[0082] The temperature resistance range of the inner sheath part 14 and the inner sheath part 2 15 is -40 to 125°C;

[0083] The thickness of the inner sheath part 14 and the inner sheath part 2 15 is 0.5±0.05 mm.

[0084] Specifically, the inner sheath part 14 located on the outer layer of the twisted pair cable 13 and the sheath part 2 15 located on the outside of the wire on the outer periphery of the inner sheath part 14 have a hardness of 50-90A and a temperature resistance of -40 to 125°C. The material may be polystyrene, cross-linked polyethylene, polyurethane or other elastomers with a thickness of 0.5±0.05mm. The material is used to stabilize the twisted pair cable 13 and prevent the external environment such as bending, vibration, impact, and scouring from causing changes in the twisting pitch of the twisted pair cable 13, thereby affecting the stability or interruption of signal transmission.

[0085] The aluminum foil layer 16 is an aluminum foil corrugated tube, an aluminum foil tape, or a nylon corrugated tube coated with an aluminum layer.

[0086] Specifically, the outer layer of the second inner sheath part 15 is wrapped with an aluminum foil layer 16, and the aluminum foil layer 16 is made of an aluminum foil corrugated tube or an aluminum foil tape or a nylon corrugated tube to isolate external heat. Among them, the nylon corrugated tube is extruded and formed with a high-temperature nylon material, and is electroplated with an aluminum layer through a special process. It is specially designed to provide thermal protection for the wiring harness in the high-temperature area of ​​the automobile, effectively protects the wire from heat damage, and has the characteristics of good softness, high temperature resistance, wear resistance, oil resistance, etc.;

[0087] Preferably, the aluminum layer of the aluminum foil corrugated tube, aluminum foil tape or nylon corrugated tube is metal, which has strong heat reflection ability and can effectively prevent external heat from being transmitted to the internal structure. At the same time, the wrinkled structure can well cope with the wiring harness movement caused by the bending wiring of the wiring harness and the up and down bouncing of the wheel.

[0088] The protective layer 17 is made of silicone rubber;

[0089] Silicone rubber thickness is 1.0±0.05mm;

[0090] The temperature resistance range of silicone rubber is -40~200℃.

[0091] The protective layer 17 is a fluoroplastic heat shrinkable tube that shrinks after heating;

[0092] The thickness of fluoroplastic heat shrink tube is 1.0±0.05mm;

[0093] The temperature range of fluoroplastic heat shrink tubing is -40 to 200°C.

[0094] The protective layer 17 is formed by using a glass fiber tube and drying at high temperature;

[0095] The inner layer of the fiberglass tube is woven with alkali-free glass fiber;

[0096] The outer layer of alkali-free glass fiber is coated with silicone resin;

[0097] The thickness of the fiberglass tube is 0.3-0.5mm;

[0098] The temperature resistance range of glass fiber tube is -40~200℃.

[0099] The specific embodiment of the protective layer 17 is as follows:

[0100] Embodiment 1: A layer of silicone rubber is extruded on the outside of the aluminum foil corrugated tube or aluminum foil tape or nylon corrugated tube, with a thickness of 1.0±0.05mm, and is vulcanized to form a protective layer 17, which is temperature-resistant at -40 to 200°C and can effectively cope with external high temperature environments for a long time and protect the safety of the internal wiring harness;

[0101] Embodiment 2: A layer of fluoroplastic heat shrink tube is placed outside the aluminum foil corrugated tube or aluminum foil tape or nylon corrugated tube, with a thickness of 1.0±0.05mm. After heating and shrinking, a protective layer 17 is formed, which is temperature-resistant at -40 to 200°C and can effectively cope with external high temperature environment for a long time and protect the safety of the internal wiring harness;

[0102] Embodiment 3: A layer of glass fiber tube is put on the outside of the aluminum foil corrugated tube or aluminum foil tape or nylon corrugated tube with a thickness of 0.3-0.5mm. The inner layer of the glass fiber tube is woven with alkali-free glass fiber and then coated with silicone resin. It is made by high-temperature drying and shaping. It has the advantages of heat resistance, corrosion resistance, aging resistance, and softness. It can withstand temperatures of -40 to 200°C, can effectively cope with external high temperature environments for a long time, and protect the safety of the internal wiring harness.

[0103] Among them, the above three embodiments can form ABS sheathed wires, EPB sheathed wires, etc. that are resistant to high temperature and high pressure. The sheathed wire 1 is suitable for wiring in an external environment of 200°C, and the sheathed wire 1 has a withstand voltage of 600V.

[0104] The utility model provides a high temperature resistant automobile wheel wiring harness assembly for new energy, which has flexible design and can be designed with multiple functional branches according to the configuration requirements of different customers to further meet the requirements of customers.

[0105] The above only describes some exemplary embodiments of the present invention by way of illustration. It is undoubted that those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A high temperature resistant automobile wheel wiring harness assembly for new energy, the wiring harness assembly comprising a sheathed wire (1), a connector, and a terminal, wherein the moving area of ​​the sheathed wire (1) and the connector are fixed by an injection molding process, and the static area of ​​the sheathed wire (1) is fixed by a cable tie, a staple, or a rubber part, characterized in that: The sheathed cable (1) comprises: Conductor (11); An insulating layer (12), the insulating layer (12) covering the conductor (11) to form an electric wire; The two groups of electric wires are twisted together to form a twisted pair (13); An inner sheath portion (14), wherein the inner sheath portion (14) is extruded and coated on the outside of the twisted pair (13); A plurality of groups of electric wires are distributed around the outer periphery of the inner sheath portion (14); The second inner sheath part (15) is extruded and coated on the outside of the electric wire located on the outer periphery of the first inner sheath part (14); An aluminum foil layer (16), the aluminum foil layer (16) is coated on the outer layer of the second inner sheath part (15) to isolate external heat; A protective layer (17), wherein the protective layer (17) is extruded and coated on the outside of the aluminum foil layer (16).

2. The high temperature resistant automobile wheel wiring harness assembly for new energy according to claim 1 is characterized in that: The conductor (11) is formed by twisting copper wire and bulletproof wire; The copper wire is made of oxygen-free copper or tinned copper; The purity of the copper wire is above 99.99%; The copper wire diameter is ≤0.18 mm.

3. The high temperature resistant automobile wheel wiring harness assembly for new energy according to claim 2 is characterized in that: The insulating layer (12) is made of polystyrene or cross-linked polyethylene with Shore D 65±20 and is formed by an extrusion process; The insulation layer (12) has a temperature resistance range of -40 to 125°C; The insulating layer (12) has a withstand voltage of 600V; The insulation concentricity of the insulation layer (12) is ≥95%.

4. The high temperature resistant automobile wheel wiring harness assembly for new energy according to claim 3 is characterized in that: The twisted pitch of the twisted pair (13) is 17±2 mm.

5. The high temperature resistant automobile wheel wiring harness assembly for new energy according to claim 4 is characterized in that: The material of the inner sheath part (14) and the inner sheath part (15) is polystyrene, cross-linked polyethylene or polyurethane; The hardness range of the inner sheath part (14) and the inner sheath part (15) is Shore 50-90A; The temperature resistance range of the inner sheath part (14) and the inner sheath part (15) is -40 to 125°C; The thickness of the inner sheath part one (14) and the inner sheath part two (15) is 0.5±0.05 mm.

6. The high temperature resistant automobile wheel wiring harness assembly for new energy according to claim 5 is characterized in that: The aluminum foil layer (16) is an aluminum foil corrugated tube, an aluminum foil tape, or a nylon corrugated tube coated with an aluminum layer.

7. A high temperature resistant automobile wheel wiring harness assembly for new energy according to claim 6, characterized in that: The protective layer (17) is made of silicone rubber; The thickness of the silicone rubber is 1.0±0.05mm; The temperature resistance range of the silicone rubber is -40 to 200°C.

8. The high temperature resistant automobile wheel wiring harness assembly for new energy according to claim 6 is characterized in that: The protective layer (17) is a fluoroplastic heat shrinkable tube that shrinks after heating; The thickness of the fluoroplastic heat shrink tube is 1.0±0.05mm; The fluoroplastic heat shrink tube has a temperature resistance range of -40 to 200°C.

9. The high temperature resistant automobile wheel wiring harness assembly for new energy according to claim 6 is characterized by: The protective layer (17) is formed by using a glass fiber tube and drying at high temperature; The inner layer of the glass fiber tube is woven with alkali-free glass fibers; The outer layer of the alkali-free glass fiber is coated with silicone resin; The thickness of the glass fiber tube is 0.3-0.5 mm; The temperature resistance range of the glass fiber tube is -40 to 200°C.

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