Integrally injection-molded wire harness directly connected with automobile controller

Abstract

The utility model relates to the technical field of controller connectors, in particular to an integrally injection-molded wire harness directly connected with an automobile controller, which solves the problem that two sets of connectors are needed for connecting a wire harness and a control panel in the prior art, and comprises an injection-molded outer shell, an injection-molded inner shell embedded in the injection-molded outer shell, and a PCB (Printed Circuit Board) terminal embedded in the injection-molded inner shell, the PCB terminal comprises a plurality of pins, the pins are mutually connected in the process of connecting the PCB terminal and the injection molding inner shell, and the pins are disconnected before the injection molding inner shell and the injection molding outer shell are connected. The beneficial effects of the utility model are that the terminal and the lead are integrally embedded in the injection molding housing, so that the wire harness is directly connected with the control panel, a set of connector and terminal waterproof plug is omitted, the cost of the controller is reduced, and the reliability of the connection between the wire harness and the control panel is improved; and the external impact force on the PCB terminal is reduced by adopting a secondary injection molding mode, so that the perpendicularity and the location degree of the terminal are kept more stable, and the reject ratio is greatly reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of controller connectors, in particular to a wire harness integrally injection-molded and directly connected to an automotive controller. Background Art

[0002] In recent years, with the rapid development of the automotive industry, especially the increasing market share occupied by new energy vehicles recently, the wire harness industry is also constantly evolving to adapt to the development of this industry. The traditional automotive wire harness industry relies on a large number of personnel for repetitive and time-consuming operations. However, with the increasing application of intelligent systems in automobiles, a large number of controllers have replaced the previous cumbersome wiring work, and the use of domain controllers optimizes the functions that required many wire harnesses in the wire harness through logical algorithms.

[0003] The patent with the patent number CN221282424U discloses a board-end connector and a connector assembly, including a metal seat provided with a plurality of insertion cavities, a board-end insulator disposed in the insertion cavity, a board-end signal terminal inserted into the insulator, and an integral panel that can be fixed on the circuit board. The integral panel includes a base, an insertion portion provided on one side of the base, and a groove portion provided on the other side of the base. The metal seat can be entirely or partially inserted into the insertion portion.

[0004] In automobiles, more and more integrated circuit boards are used. The traditional processing method is to use board-end connectors at the device end and the board end, and then use wire-harness-end connectors at the wire harness end for plug-in connection. In this case, two connectors and two sets of matching terminals and connectors are required to achieve any connection. The connection reliability between the connectors cannot be guaranteed, and at the same time, the cost of automotive controllers will be increased. Summary of the Utility Model

[0005] The utility model provides a wire harness integrally injection-molded and directly connected to an automotive controller, which solves the problems in the prior art that two connectors are required for the connection between the wire harness and the control board and the connection reliability between the connectors cannot be guaranteed.

[0006] The technical solution of the utility model is realized as follows:

[0007] An integrally injection-molded wire harness directly connected to an automotive controller, comprising an injection-molded outer shell, an injection-molded inner shell is embedded in the injection-molded outer shell, a PCB terminal is embedded in the injection-molded inner shell, the PCB terminal includes a plurality of pins, during the connection process of the PCB terminal and the injection-molded inner shell, the pins are connected to each other, and before the injection-molded inner shell and the injection-molded outer shell are connected, the pins are disconnected from each other. The terminal and the wire are integrally injection-molded in the injection-molded outer shell, so that the wire harness can be directly connected to the control board, saving a set of connectors and terminal waterproof plugs, reducing the cost of the controller, and at the same time improving the reliability of the connection between the wire harness and the control board; The verticality of the PCB terminal and the relative positions of the pins are improved by means of secondary injection molding.

[0008] The PCB terminal is connected to the wire, and the end of the wire is embedded in the injection-molded inner shell. It is ensured that the injection-molded inner shell can completely wrap the connection position between the PCB terminal and the wire, avoiding the situation of wire exposure.

[0009] The pin is connected to the wire by welding. The wire and the pin are connected by ultrasonic welding or resistance welding to ensure the stable connection between the wire and the PCB terminal.

[0010] A flow guide groove is provided on the pin, and the flow guide groove is located at the connection position between the pin and the wire. The shape of the flow guide groove is circular or strip-shaped. The flow guide groove can reduce the energy generated during the welding of the wire and the pin, and thus effectively reduce the deformation of the PCB terminal caused by welding.

[0011] A bump is provided on the pin, and the bump is located at the connection position between the pin and the wire. The bump is a circular bump or a strip-shaped bump. The bump can reduce the energy generated during the welding of the wire and the pin, and thus effectively reduce the deformation of the PCB terminal caused by welding.

[0012] A connection skeleton is provided between two adjacent pins. The connection skeleton can increase the structural strength of the PCB terminal; during the connection process between the PCB terminal and the wire, the connection skeleton can effectively ensure the relative positions of the pins are stable, and thus ensure the accurate positions of the pins after injection molding.

[0013] The injection-molded inner shell includes an inner shell main body, and a hollow structure is provided on the inner shell main body, and the hollow structure corresponds to the position of the connection skeleton. Before the injection-molded outer shell is connected, the connection skeleton is cut off so that each pin has an independent connection relationship, and the setting of the hollow structure facilitates cutting off the connection skeleton.

[0014] Guide strips are provided on both sides of the injection-molded outer shell, and the guide strips on both sides of the injection-molded outer shell are arranged in a staggered manner. The guide strips facilitate the connection between the wire harness and the control board, and the staggered guide strips have an anti-misconnection function, avoiding the situation of incorrect connection between the PCB terminal and the control board.

[0015] The beneficial effects of the present utility model are as follows: The terminal and the wire are integrally embedded in the injection molded housing, enabling the wire harness to be directly connected to the control board, eliminating a set of connectors and terminal waterproof plugs, reducing the cost of the controller, and at the same time improving the reliability of the connection between the wire harness and the control board; The secondary injection molding method is adopted to reduce the impact force on the PCB terminal from the outside, making the perpendicularity and position of the terminal more stable, and greatly reducing the rejection rate.

[0016] When welding the pins of the wire harness and the PCB terminal, the energy generated by the welding can be concentrated and released near the required connection flow guide groove or bump, reducing the deformation caused by the high energy acting on the connection area for a long time, and ensuring the accurate relative position between each pin. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present utility model. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0018] Figure 1 It is a schematic structural diagram of a wire harness with integral injection molding directly connected to an automotive controller;

[0019] Figure 2 It is a schematic connection diagram of the injection molded inner housing and the PCB terminal;

[0020] Figure 3 It is a schematic connection diagram of the PCB terminal and the wire;

[0021] Figure 4 It is a schematic structural diagram of the PCB terminal;

[0022] Figure 5 It is a schematic structural diagram of the injection molded inner housing.

[0023] In the figure: 1. Injection molded housing, 2. PCB terminal, 3. Wire, 4. Injection molded inner housing, 21. Pin, 22. Flow guide groove, 23. Connection skeleton, 41. Inner housing main body, 42. Hollow structure. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0024] The following will clearly and completely describe the technical solutions in the embodiments of the present utility model with reference to the drawings in the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, rather than all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the protection scope of the present utility model.

[0025] Example 1, as Figure 1 , Figure 2 shown, an integrally injection-molded wire harness directly connected to an automotive controller, including an injection-molded outer shell 1, an injection-molded inner shell 4 is embedded in the injection-molded outer shell 1, a PCB terminal 2 is embedded in the injection-molded inner shell 4, the PCB terminal 2 includes a plurality of pins 21, during the connection process of the PCB terminal 2 and the injection-molded inner shell 4, the pins 21 are connected to each other, and before the injection-molded inner shell 4 is connected to the injection-molded outer shell 1, the pins 21 are disconnected from each other. In this embodiment, the PCB terminal 2 includes four pins 21, and the pins 21 are arranged in parallel; the PCB terminal 2 and the wire 3 are integrally embedded in the injection-molded outer shell 1, so that the wire harness can be directly connected to the control board, saving a set of connectors and terminal waterproof plugs, reducing the cost of the controller, and at the same time improving the reliability of the connection between the wire harness and the control board; in addition, the secondary injection-molding method can reduce the impact force on the PCB terminal 21 from the outside, making the perpendicularity and position of the terminal more stable, and greatly reducing the rejection rate.

[0026] Further, as Figure 3 shown, the PCB terminal 2 is connected to the wire 3, and the end of the wire 3 is embedded in the injection-molded inner shell 4. The injection-molded inner shell 4 completely wraps the connection position of the PCB terminal 2 and the wire 2, preventing the PCB terminal 2 and the wire 3 from falling off the injection-molded inner shell 4 and avoiding the situation of the wire 3 being exposed. In this embodiment, the wire 3 is a pure copper wire or a tinned copper wire or an alloy copper wire. The pin 21 is connected to the wire 3 by welding. The wire 3 and the pin 21 are connected by ultrasonic welding or resistance welding to ensure the stable connection between the wire 3 and the PCB terminal 2, meet the requirements of tensile force and peel force, and have no failure problems such as flash and impurities.

[0027] Further, as Figure 4 shown, a flow guiding groove 22 is provided on the pin 21, and the flow guiding groove 22 is located at the connection position of the pin 21 and the wire 3. The shape of the flow guiding groove 22 is circular or strip-shaped. The flow guiding groove 22 can reduce the energy generated during the welding of the wire 3 and the pin 21, and thus effectively reduce the deformation of the PCB terminal 2 caused by welding, ensuring the structural stability of the PCB terminal 2.

[0028] Example 2, different from Example 1, an integrally injection-molded wire harness directly connected to an automotive controller, a bump is provided on the pin 21, and the bump is located at the connection position of the pin 21 and the wire 3. The bump is a circular bump or a strip-shaped bump. The bump can reduce the energy generated during the welding of the wire 3 and the pin 21, and thus effectively reduce the deformation of the PCB terminal 2 caused by welding, ensuring the structural stability of the PCB terminal 2.

[0029] Example 3, on the basis of Example 1, an integrally injection-molded wire harness directly connected to an automotive controller, asFigure 4 As shown, a connecting skeleton 23 is provided between two adjacent pins 21. The connecting skeleton 23 can increase the structural strength of the PCB terminal 2; during the connection process between the PCB terminal 2 and the wire 3, the connecting skeleton 23 can effectively ensure the relative position stability between the respective pins 21, thereby ensuring the accurate position of the pins 21 after injection molding is completed.

[0030] Furthermore, as Figure 5 shown, the injection molded inner shell 4 includes an inner shell main body 41, and a hollow structure 42 is provided on the inner shell main body 41. The hollow structure 42 corresponds to the position of the connecting skeleton 23. Before connecting the injection molded outer shell 1, the connecting skeleton 23 is cut off so that each pin 21 has an independent connection relationship, and the setting of the hollow structure 41 facilitates cutting off the connecting skeleton 23.

[0031] Furthermore, guide strips are provided on both sides of the injection molded outer shell 1, and the guide strips on both sides of the injection molded outer shell 1 are arranged in a staggered manner. The setting of the guide strips facilitates the connection between the wire harness and the control board, and the staggered guide strips have an anti-misalignment function to avoid the situation of incorrect connection between the PCB terminal and the control board.

[0032] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An integrally injection-molded wire harness directly connected to an automotive controller, comprising an injection-molded housing (1), characterized in that, An injection-molded outer shell (1) is internally provided with an injection-molded inner shell (4), and the injection-molded inner shell (4) is internally provided with a PCB terminal (2). The PCB terminal (2) includes a plurality of pins (21). During the connection process between the PCB terminal (2) and the injection-molded inner shell (4), the respective pins (21) are connected to each other. Before the injection-molded inner shell (4) is connected to the injection-molded outer shell (1), the connection between the respective pins (21) is disconnected.

2. The integrally injection-molded wire harness directly connected to the vehicle controller according to claim 1, wherein The PCB terminal (2) is connected to a wire (3), and the end of the wire (3) is embedded in the injection-molded inner shell (4).

3. The integrally molded wiring harness directly connected to the vehicle controller according to claim 2, characterized in that, The pin (21) is connected to the wire (3) by soldering.

4. The integrally molded wiring harness directly connected to the vehicle controller according to any one of claims 1 to 3, characterized in that A flow guide groove (22) is provided on the pin (21), and the flow guide groove (22) is located at the connection position between the pin (21) and the wire (3).

5. The integrally molded wire harness directly connected to the vehicle controller according to claim 4, characterized in that, The shape of the flow guide groove (22) is circular or strip-shaped.

6. The integrally molded wiring harness directly connected to the vehicle controller according to any one of claims 1 to 3, characterized in that A bump is provided on the pin (21), and the bump is located at the connection position between the pin (21) and the wire (3).

7. The integrally molded wire harness directly connected to the vehicle controller according to claim 6, characterized in that, The bump is a circular bump or a strip-shaped bump.

8. The integrally molded wire harness directly connected to the vehicle controller according to any one of claims 1 to 3, 5, and 7, characterized in that A connection skeleton (23) is provided between two adjacent pins (21).

9. The integrally molded wire harness directly connected to the vehicle controller according to claim 8, characterized in that, The injection-molded inner shell (4) includes an inner shell main body (41), and a hollow structure (42) is provided on the inner shell main body (41). The hollow structure (42) corresponds to the position of the connection skeleton (23).

10. The integrally molded wiring harness directly connected to the vehicle controller according to claim 1 or 9, characterized in that, Guide strips are provided on both sides of the injection-molded outer shell (1), and the guide strips on both sides of the injection-molded outer shell (1) are arranged in a staggered manner.

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