Vehicle high-voltage wire harness with anti-fracture structure

Abstract

The utility model relates to the technical field of wire harnesses, in particular to a vehicle high-voltage wire harness with an anti-fracture structure, which comprises a high-voltage wire harness body and a wire harness connector terminal, the anti-fracture structure is arranged outside the high-voltage wire harness body, and the high-voltage wire harness body comprises a main body wire harness and anti-pulling fracture spiral wire harnesses positioned at two ends of the main body wire harness. The main body wire harness and the anti-pulling and anti-fracture spiral wire harness are integrally produced, connected and combined to form a high-voltage wire harness body, the high-voltage wire harness body comprises a copper wire, a first insulating layer, a shielding layer, an anti-interference metal foil layer and a second insulating layer, and the anti-fracture structure comprises a protection sleeve and an extension sleeve. The rhombic extension structure of the extension sleeve is filled with a shape memory polymer layer; the rhombic extension structure of the extension sleeve is filled with the shape memory polymer layer, physical protection is provided, the shape memory polymer layer and other materials restore to the original shape when being impacted or deformed, the durability and protection performance of the high-voltage wire harness body are enhanced, and breakage is prevented.

Description

Technical Field

[0001] The utility model relates to the technical field of wire harnesses, in particular to a vehicle high-voltage wire harness with an anti-fracture structure. Background Art

[0002] Automotive high-voltage wiring harnesses are important components used in new energy vehicles to transmit high voltage and high current. They are responsible for transmitting large-capacity electrical energy and ensuring the power supply of the motor control system.

[0003] There are two main types of automotive high-voltage wiring harness materials: aluminum wire and copper wire. Although aluminum wire is slightly inferior to copper in conductivity, it is lighter and has a lower cost, which is in line with the trend of lightweighting and cost control. Copper wire has excellent electrical and thermal conductivity and is suitable for high-load, high-performance application scenarios.

[0004] New energy vehicles require more high-voltage wiring harnesses due to their power supply. In order to prevent breakage, existing automotive wiring harnesses wrap the copper wire with an insulating layer and a shielding layer, and then put a protective cover on the outside of the shielding layer. The existing wiring harnesses have certain anti-breakage performance, but the automotive high-voltage wiring harnesses are shaken by the vehicle during use, and the automotive wiring harnesses are subjected to external vibration and pulling, which causes the wiring harness joints to crack easily. In addition, the existing wiring harnesses do not have an extended protective layer on the outside, and are easily cracked due to external vibration and pulling for a long time during use. Utility Model Content

[0005] The purpose of the present utility model is to provide a high-voltage wiring harness for a vehicle with an anti-fracture structure to solve the problems raised in the above-mentioned background technology.

[0006] To achieve the above objectives, the present invention provides the following technical solutions:

[0007] A high-voltage wiring harness for a vehicle with an anti-fracture structure includes a high-voltage wiring harness body and a wiring harness connector terminal. The anti-fracture structure is provided on the outside of the high-voltage wiring harness body. The high-voltage wiring harness body includes a main wiring harness and anti-pull-and-fracture spiral wiring harnesses located at both ends of the main wiring harness. The main wiring harness is arranged in an I-shaped structure, and the anti-pull-and-fracture spiral wiring harness is arranged in a spiral structure. The main wiring harness and the anti-pull-and-fracture spiral wiring harness are produced and connected as an integrated unit to form the high-voltage wiring harness body.

[0008] As a preferred solution of the present invention, the high-voltage wiring harness body includes a copper wire located inside, the outer circumferential wall of the copper wire is wrapped with a first insulating layer, the outer circumferential wall of the first insulating layer is wrapped with a shielding layer, the outer circumferential wall of the shielding layer is wrapped with an anti-interference metal paper layer, the outer circumferential wall of the anti-interference metal paper layer is wrapped with a second insulating layer, and the anti-fracture structure is located on the outer circumferential wall of the second insulating layer.

[0009] As a preferred solution of the present invention, the anti-fracture structure includes a protective cover and an extension cover arranged in sequence and cross-connected, a diamond-shaped extension structure is arranged inside the extension cover, and a shape memory polymer layer is filled inside the diamond-shaped extension structure. The protective cover and the extension cover are arranged on the outer circumferential wall of the second insulating layer.

[0010] As a preferred solution of the present invention, the wiring harness connector terminal is arranged in an L-shaped structure, and the wiring harness connector terminal is connected to both ends of the anti-pull-break spiral wiring harness.

[0011] As a preferred solution of the present invention, the second insulating layer is a thermoplastic elastomer.

[0012] As a preferred solution of the present invention, the shielding layer is a metal mesh woven from tinned copper wires.

[0013] As a preferred solution of the present invention, the first insulating layer is a high molecular polymer cross-linked polyethylene.

[0014] Compared with the prior art, the beneficial effects of the present invention are:

[0015] In response to the problems raised in the background technology, the high-voltage wiring harness of the present application includes a main wiring harness and anti-pull spiral wiring harnesses at both ends, and adopts an integrated production connection combination. The copper wire is wrapped with a first insulation layer, a shielding layer, an anti-interference metal paper layer and a second insulation layer in sequence for basic protection. The first insulation layer is a high-molecular polymer cross-linked polyethylene, which has good electrical insulation performance and high-temperature resistance. Its main function is to isolate the conductor from direct contact with the outside world, prevent leakage and short-circuit accidents, and ensure that the current is transmitted inside the conductor; the shielding layer is a metal mesh woven with tinned copper wire, which can effectively shield electromagnetic interference from external equipment or the natural environment, forming a protective "electromagnetic barrier" around the wire, so that the external electromagnetic field around the cable is zero, thereby ensuring the safe transmission of high-voltage current; the anti-interference metal paper layer reduces the interference of external electromagnetic waves on the inside of the wiring harness by reflection and absorption, thereby protecting the stability and accuracy of data transmission; the second insulation layer is a thermoplastic elastomer, which has excellent flexibility and can maintain its elasticity at different temperatures, making it an ideal insulating material;

[0016] The anti-fracture structure includes a protective cover and an extension cover. The diamond-shaped extension structure of the extension cover is filled with a shape memory polymer layer to provide physical protection. The shape memory polymer layer and other materials restore the original shape when impacted or deformed, thereby enhancing the durability and protection performance of the high-voltage wire harness.

[0017] The connector terminals are L-shaped and connected to both ends of the anti-pull spiral harness to ensure a stable connection between the harness and the battery or other equipment. During use, the terminals are pulled at the connection point between the harness and the terminal to prevent breakage. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a side view of the overall high-voltage wire harness body of the utility model;

[0019] Figure 2 This is a schematic diagram of the high-voltage wire harness body structure of the utility model;

[0020] Figure 3 This is a schematic diagram of the extension sleeve structure of the utility model.

[0021] In the figure: 1. High-voltage wire harness body; 101. Copper wire; 102. First insulation layer; 103. Shielding layer; 104. Anti-interference metal foil layer; 105. Second insulation layer; 11. Main wire harness; 12. Anti-pull and break spiral wire harness; 2. Wire harness connector terminal; 3. Protective cover; 31. Extension cover; 311. Diamond extension structure; 312. Shape memory polymer layer. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the embodiments of the present invention. Example

[0023] See also Figure 1-3 The utility model provides a technical solution: a high-voltage wiring harness for a vehicle with an anti-fracture structure, comprising a high-voltage wiring harness body 1 and a wiring harness connector terminal 2. The anti-fracture structure is arranged on the outside of the high-voltage wiring harness body 1. The high-voltage wiring harness body 1 comprises a main wiring harness 11 and an anti-pull and fracture spiral wiring harness 12 located at both ends of the main wiring harness 11. The main wiring harness 11 is arranged in an I-shaped structure, and the anti-pull and fracture spiral wiring harness 12 is arranged in a spiral structure. The main wiring harness 11 and the anti-pull and fracture spiral wiring harness 12 are integrally produced and connected to form the high-voltage wiring harness body 1. The wiring harness connector terminal 2 is arranged in an L-shaped structure, and the wiring harness connector terminal 2 is connected at both ends of the anti-pull and fracture spiral wiring harness 12.

[0024] It should be noted that, in this embodiment, the high-voltage wiring harness body 1 includes a main wiring harness 11 and anti-pull and breakage spiral wiring harnesses 12 at both ends. It adopts an integrated production connection combination, and the connector terminal is L-shaped and connected to the two ends of the anti-pull spiral wiring harness to ensure a stable connection between the wiring harness and the battery or other equipment, and reduce the pulling at the connection between the terminal and the wiring harness to prevent breakage during use.

[0025] See also Figure 2 and 3The high-voltage wire harness body 1 includes a copper wire 101 located inside, and the outer circumferential wall of the copper wire 101 is wrapped with a first insulating layer 102, the outer circumferential wall of the first insulating layer 102 is wrapped with a shielding layer 103, the outer circumferential wall of the shielding layer 103 is wrapped with an anti-interference metal paper layer 104, and the outer circumferential wall of the anti-interference metal paper layer 104 is wrapped with a second insulating layer 105, and the anti-fracture structure is located on the outer circumferential wall of the second insulating layer 105; the second insulating layer 105 is a thermoplastic elastomer; the shielding layer 103 is a metal mesh woven with tinned copper wire; the first insulating layer 102 is a high molecular polymer cross-linked polyethylene; the anti-fracture structure includes a protective cover 3 and an extension cover 31 arranged in sequence and cross-connected, a diamond extension structure 311 is provided inside the extension cover 31, and a shape memory polymer layer 312 is filled inside the diamond extension structure 311, and the protective cover 3 and the extension cover 31 are sleeved on the outer circumferential wall of the second insulating layer 105.

[0026] It should be noted that in this embodiment, the copper wire 101 is sequentially wrapped with a first insulating layer 102, a shielding layer 103, an anti-interference metal foil layer 104, and a second insulating layer 105 for basic protection. The first insulating layer 102 is a high-molecular polymer cross-linked polyethylene with excellent electrical insulation and high-temperature resistance. Its main function is to isolate the conductor from direct contact with the outside world, prevent leakage and short-circuit accidents, and ensure that current is transmitted within the conductor.

[0027] Furthermore, the shielding layer 103 is a metal mesh woven from tinned copper wires, which can effectively shield electromagnetic interference from external devices or the natural environment, forming a protective "electromagnetic barrier" around the conductors, making the external electromagnetic field around the cable zero, thereby ensuring the safe transmission of high-voltage current;

[0028] Furthermore, the anti-interference metal foil layer 104 reduces the interference of external electromagnetic waves on the inside of the wiring harness by reflection and absorption, thereby protecting the stability and accuracy of data transmission;

[0029] Furthermore, the second insulating layer 105 is a thermoplastic elastomer, which has excellent flexibility and can maintain its elasticity at different temperatures, making it an ideal insulating material;

[0030] Furthermore, the anti-fracture structure includes a protective cover 3 and an extension cover 31. The diamond extension structure 311 of the extension cover 31 is filled with a shape memory polymer layer 312. The shape memory polymer layer 312 is a special layer made using the characteristics of shape memory polymer. It can change its shape under different stimuli and remember its original shape to provide physical protection. It can restore its original shape when impacted or deformed through materials such as the shape memory polymer layer, thereby enhancing the durability and protection performance of the high-voltage wire harness body 1.

[0031] The working process of this utility model:

[0032] The high-voltage wiring harness body 1 includes a main wiring harness 11 and anti-pull and breakage spiral wiring harnesses 12 at both ends. It adopts an integrated production connection combination, and the connector terminal is L-shaped and connected to the two ends of the anti-pull spiral wiring harness. The copper wire 101 is wrapped with a first insulating layer 102, a shielding layer 103, an anti-interference metal paper layer 104 and a second insulating layer 105 in sequence for basic protection. The first insulating layer 102 is a high-molecular polymer cross-linked polyethylene with good electrical insulation performance and high temperature resistance. Its main function is to isolate the conductor from direct contact with the outside world, prevent leakage and short circuit accidents, and ensure that the current is transmitted inside the conductor; the shielding layer 103 is a metal mesh woven with tinned copper wire, which can effectively shield electromagnetic interference from external equipment or natural environment, forming a shield around the wire. The protective "electromagnetic barrier" makes the external electromagnetic field around the cable zero, thereby ensuring the safe transmission of high-voltage current; the anti-interference metal paper layer 104 reduces the interference of external electromagnetic waves on the inside of the harness by reflection and absorption, thereby protecting the stability and accuracy of data transmission; the second insulating layer 105 is a thermoplastic elastomer with excellent flexibility and the ability to maintain its elasticity at different temperatures, which makes it an ideal insulating material; the anti-fracture structure includes a protective cover 3 and an extension cover 31, and the diamond-shaped extension structure 311 of the extension cover 31 is filled with a shape memory polymer layer 312 to provide physical protection, and through materials such as the shape memory polymer layer 312, it returns to its original shape when impacted or deformed, thereby enhancing the durability and protection performance of the high-voltage harness body 1.

[0033] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high-voltage wiring harness for a vehicle with an anti-fracture structure, comprising a high-voltage wiring harness body (1) and a wiring harness connector terminal (2), characterized in that: The high-voltage wiring harness body (1) is provided with an anti-fracture structure on the outside. The high-voltage wiring harness body (1) comprises a main wiring harness (11) and anti-pull-fracture spiral wiring harnesses (12) located at both ends of the main wiring harness (11). The main wiring harness (11) is provided in an I-shaped structure, and the anti-pull-fracture spiral wiring harness (12) is provided in a spiral structure. The main wiring harness (11) and the anti-pull-fracture spiral wiring harness (12) are integrally produced and connected to form the high-voltage wiring harness body (1).

2. The vehicle high-voltage wire harness with an anti-fracture structure according to claim 1, characterized in that: The high-voltage wire harness body (1) includes a copper wire (101) located inside, the outer circumferential wall of the copper wire (101) is wrapped with a first insulating layer (102), the outer circumferential wall of the first insulating layer (102) is wrapped with a shielding layer (103), the outer circumferential wall of the shielding layer (103) is wrapped with an anti-interference metal paper layer (104), the outer circumferential wall of the anti-interference metal paper layer (104) is wrapped with a second insulating layer (105), and the anti-fracture structure is located on the outer circumferential wall of the second insulating layer (105).

3. The high-voltage wiring harness for a vehicle with an anti-fracture structure according to claim 2, characterized in that: The anti-fracture structure comprises a protective sleeve (3) and an extension sleeve (31) arranged in sequence and cross-connected, a diamond-shaped extension structure (311) being provided inside the extension sleeve (31), and a shape memory polymer layer (312) being filled inside the diamond-shaped extension structure (311), and the protective sleeve (3) and the extension sleeve (31) being sleeved on the outer circumferential wall of the second insulating layer (105).

4. The vehicle high-voltage wire harness with an anti-fracture structure according to claim 1, characterized in that: The wiring harness connector terminal (2) is arranged in an L-shaped structure, and the wiring harness connector terminal (2) is connected to both ends of the anti-pull-break spiral wiring harness (12).

5. The vehicle high-voltage wire harness with an anti-fracture structure according to claim 2, characterized in that: The second insulating layer (105) is a thermoplastic elastomer.

6. The vehicle high-voltage wire harness with an anti-fracture structure according to claim 2, characterized in that: The shielding layer (103) is a metal mesh woven from tinned copper wires.

7. The vehicle high-voltage wire harness with an anti-fracture structure according to claim 2, characterized in that: The first insulating layer (102) is a high molecular polymer cross-linked polyethylene.

Images