Long-life impact-resistant flat cable harness

Abstract

The utility model relates to a long-life impact-resistant flat cable harness, which comprises an upper-layer flame-retardant PET insulator, a lower-layer flame-retardant PET insulator and a flat oxygen-free bare copper conductor with the thickness of 35 microns, and the flat oxygen-free bare copper conductor is arranged between the upper-layer flame-retardant PET insulator and the lower-layer flame-retardant PET insulator. The upper layer flame-retardant PET insulator and the lower layer flame-retardant PET insulator are pressed together to form a flame-retardant PET insulator, so that the upper layer flame-retardant PET insulator and the lower layer flame-retardant PET insulator wrap the flat oxygen-free bare copper conductor together. In conclusion, the design can provide a long-service-life and impact-resistant cable harness solution for an automobile electrical system, the requirements of the modern automobile industry for high-performance electrical assemblies are met, and meanwhile, the safety and the reliability are improved.

Description

Technical Field

[0001] The utility model relates to a flat cable harness with long service life and impact resistance. Background Art

[0002] In recent years, with the continuous development of the economy and the improvement of people's living standards, the automotive industry has ushered in unprecedented development opportunities. With technological advancements and changing market demands, the prospects for the automotive industry have become even brighter. As a key component for transmitting energy and information, flexible flat cables play an irreplaceable role in the automotive manufacturing industry. With the rapid development of informatization and electrification in society, flexible flat cables have become a vital foundational product in economic development.

[0003] Compared with traditional wiring harnesses, flexible flat cables have the following advantages:

[0004] The insulation distance between wires is small;

[0005] Thin thickness and small size;

[0006] Low assembly space requirements;

[0007] Lower production costs;

[0008] High production efficiency;

[0009] In today's pursuit of lightweight automobiles, flexible flat cables have become the first choice to replace complex and redundant wiring harnesses.

[0010] Existing automobile manufacturers have put forward higher requirements on the performance of flexible flat cables, especially in terms of their bending life and related technical performance. Therefore, it is very important to invent a long-life and impact-resistant flat cable harness. Utility Model Content

[0011] The utility model aims to provide a long-life impact-resistant flat cable harness that meets the bending life requirement of 20 million times under a bending radius R=8mm.

[0012] The purpose of this utility model is achieved in this way:

[0013] A long-life, impact-resistant flat cable harness includes an upper flame-retardant PET insulator, a lower flame-retardant PET insulator, and a flat oxygen-free bare copper conductor with a thickness of 35 μm. The flat oxygen-free bare copper conductor is placed between the upper flame-retardant PET insulator and the lower flame-retardant PET insulator. The upper flame-retardant PET insulator and the lower flame-retardant PET insulator are pressed together to form the flame-retardant PET insulator, so that the upper flame-retardant PET insulator and the lower flame-retardant PET insulator jointly wrap the flat oxygen-free bare copper conductor.

[0014] Fire resistance: The upper and lower flame-retardant PET insulation can effectively resist the spread of flames, improving the safety of the wiring harness in the event of a fire.

[0015] Mechanical strength: The press-fit design in the above structure can enhance the mechanical strength of the wiring harness, enabling it to withstand mechanical stresses such as extrusion and bending, thereby improving the durability and life of the wiring harness.

[0016] Conductive performance: The 35μm thick flat oxygen-free bare copper conductor has excellent conductivity and can stably transmit current and signals.

[0017] Impact resistance: Combining the properties of flame-retardant PET insulation and flat oxygen-free bare copper conductors, this wiring harness can effectively resist external impacts, improving its stability and reliability in complex working environments.

[0018] Compact design: The flat cable harness is designed to fit into tight assembly spaces, increasing flexibility and efficiency in wiring within the vehicle.

[0019] High flex life: By achieving a flex life of 20 million times in continuous life testing, the wiring harness demonstrates high durability and reliability, and can meet the application requirements of long-term use and high bending frequency.

[0020] Bending radius optimization: Taking into account the basic requirement of a bending radius of 8mm, the design structure of the wiring harness can effectively support long-term use under this bending radius, ensuring that the wiring harness is not easily damaged during bending movement.

[0021] Enhanced durability: By combining flame-retardant PET insulation with 35µm thick flat oxygen-free bare copper conductors, and by laminating the upper and lower insulation layers, the overall durability of the cable harness is improved. This helps the harness remain stable under bending stress, thus meeting flex life requirements.

[0022] In summary, this design can provide a long-life, impact-resistant cable harness solution for automotive electrical systems, meeting the modern automotive industry's demand for high-performance electrical components while improving safety and reliability.

[0023] The purpose of the utility model can also be solved by the following technical measures:

[0024] Furthermore, the upper flame-retardant PET insulation layer and the lower flame-retardant PET insulation layer are bonded tightly together by means of heat pressing.

[0025] Excellent bond strength: Thermal compression bonding, under high temperature and pressure, tightly bonds the upper and lower layers of flame-retardant PET insulation, forming a strong bond. This bond can withstand bending and stretching forces, ensuring the harness resists delamination or peeling over long periods of use, enhancing its structural stability and durability.

[0026] Improved flame retardancy: The flame retardancy is further enhanced by the tight bonding of the upper and lower flame-retardant PET insulation layers through heat pressing. In the event of a fire, the adhesive layer effectively blocks the spread of flames and heat, minimizing damage to the wiring harness and improving safety.

[0027] Prevent loosening and vibration: The hot pressing adhesive layer can effectively reduce the loosening and falling of the wiring harness in a vibrating working environment, ensuring the stability and reliability of the wiring harness under high-speed driving or harsh road conditions.

[0028] Improved Manufacturing Efficiency: Thermal compression bonding is a relatively simple and effective method that can significantly improve the manufacturing efficiency of wire harnesses. Compared to other complex bonding processes, thermal compression bonding can complete the bonding process in a shorter time while ensuring bonding quality, reducing manufacturing costs.

[0029] In summary, the use of hot pressing to tightly bond the upper flame-retardant PET insulation layer and the lower flame-retardant PET insulation layer together helps to improve the bonding strength, flame retardant properties and mechanical stability of the wiring harness, while also improving manufacturing efficiency, and is an effective production process.

[0030] Furthermore, the flame-retardant PET insulator is located between two adjacent flat oxygen-free bare copper conductors to form a separation strip, and the width of the separation strip is smaller than the width of the flat oxygen-free bare copper conductors.

[0031] The beneficial effects of the utility model are as follows:

[0032] The utility model adopts flame-retardant PET insulation, flat oxygen-free bare copper conductor with a thickness of 35um and bonding by heat pressing, so the overall durability of the wiring harness is improved and the stability of the wiring harness under bending stress is ensured.

[0033] The utility model adopts flame-retardant PET insulation, flat oxygen-free bare copper conductor and optimized fixing and separation design, so that the wiring harness has good impact resistance and maintains stable operation in complex environments such as vibration and impact.

[0034] The utility model adopts flame-retardant PET insulation material and heat pressing bonding, thereby improving the fireproof performance of the wiring harness, effectively reducing the risk of fire spreading, and improving the safety of the wiring harness in extreme environments.

[0035] The utility model improves the production efficiency of the wiring harness and reduces the manufacturing cost by simplifying the manufacturing process and optimizing the design structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 Schematic diagram of a long-life, impact-resistant flat cable harness.

[0037] Figure 2 Cross-sectional view of a flat cable harness designed for long-life impact resistance. DETAILED DESCRIPTION

[0038] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0039] Example, combined with Figures 1 to 2 As shown, a long-life, impact-resistant flat cable harness includes an upper flame-retardant PET insulator 1, a lower flame-retardant PET insulator 2, and a flat oxygen-free bare copper conductor 3 with a thickness of 35 μm. The flat oxygen-free bare copper conductor 3 is placed between the upper flame-retardant PET insulator 1 and the lower flame-retardant PET insulator 2. The upper flame-retardant PET insulator 1 and the lower flame-retardant PET insulator 2 are pressed together to form a flame-retardant PET insulator, so that the upper flame-retardant PET insulator 1 and the lower flame-retardant PET insulator 2 jointly wrap the flat oxygen-free bare copper conductor 3.

[0040] Furthermore, the upper flame-retardant PET insulator 1 and the lower flame-retardant PET insulator 2 are bonded tightly together by means of heat pressing.

[0041] Furthermore, the flame-retardant PET insulator is located between two adjacent flat oxygen-free bare copper conductors 3 to form a separation bar 4 , and the width of the separation bar 4 is smaller than the width of the flat oxygen-free bare copper conductor 3 .

[0042] Flame retardant PET insulation:

[0043] Flame-retardant PET insulation is a flame-retardant insulation material based on polyethylene terephthalate (PET). PET is a common thermoplastic polymer with excellent mechanical properties, electrical insulation, and heat resistance. By adding flame retardants or employing specialized production processes, PET insulation can be made flame-retardant, meaning it resists combustion or spreads when exposed to flames or high temperatures.

[0044] Flame-retardant PET insulators are commonly used in electrical and electronic equipment, as well as in automobiles, particularly where flame safety is a high priority. For example, in automotive electrical systems, the use of flame-retardant PET insulators can effectively reduce fire risks and improve vehicle safety. In electronic products, flame-retardant PET insulators are also commonly used to protect components such as wires and wiring harnesses, ensuring circuit stability and safety.

[0045] In general, flame retardant PET insulation combines the advantages of PET materials and flame retardant properties, has good insulation performance and flame safety, and is one of the commonly used insulation materials in many fields.

[0046] The flat oxygen-free bare copper conductor 3 with a thickness of 35 μm has the following characteristics:

[0047] Excellent electrical conductivity: Since it is made of pure copper material, the flat oxygen-free bare copper conductor 3 has excellent electrical conductivity and can effectively transmit current and signals.

[0048] Strong flexibility: Due to its flat design, the conductor has good flexibility and can be easily bent and laid, making it suitable for situations where tortuous wiring is required.

[0049] Space saving: Flat conductors have a smaller thickness than round conductors and can be flexibly arranged in a limited space, saving installation space.

[0050] Suitable for high-density wiring: Due to its flat design, it can be arranged more closely, which is suitable for occasions with high wiring density requirements.

[0051] No oxide layer: Flat oxygen-free bare copper conductor 3 is usually specially treated and has no oxide layer on the surface, which can improve its corrosion resistance and stability and extend its service life.

[0052] This flat oxygen-free bare copper conductor 3 with a thickness of 35 μm is often used in wires, wiring harnesses and other components in the fields of electronic products, electrical equipment and automobiles. It is a common conductor material with excellent performance.

[0053] The close bonding between the upper flame-retardant PET insulator 1 and the lower flame-retardant PET insulator 2 achieved by thermal compression has the following advantages and effects:

[0054] Strong Bond: During the heat-pressing process, high temperature and pressure are applied to melt the flame-retardant PET insulation layers at their contact surfaces, forming a strong bond. This bond can withstand significant tensile and shear forces, ensuring a tight connection between the upper and lower insulation layers.

[0055] Smooth Surface: During the thermal pressing process, high temperatures soften and flow the microscopic bumps on the insulator surface, filling the gaps and forming a smooth surface. This smooth surface helps increase the contact area between the insulators and enhances the bonding effect.

[0056] Reduce bubbles and voids: During the thermal compression process, high temperature helps release gas from the insulator and eliminate voids and bubbles, reducing defects and undesirable phenomena in the bonding layer and improving bonding quality and reliability.

[0057] Improved heat resistance: Because the upper and lower insulation materials melt and flow at high temperatures during the thermal bonding process, the bonding layer has higher heat resistance. This helps the wiring harness maintain stability and performance in high-temperature environments.

[0058] Simplified Manufacturing Process: Thermal compression is a simple and effective bonding process that can be completed in a short time, and the process parameters are easy to control. Therefore, using thermal compression to achieve a tight bond between insulators helps simplify the wiring harness manufacturing process and improve production efficiency.

[0059] In summary, the tight bonding between the upper flame-retardant PET insulator 1 and the lower flame-retardant PET insulator 2 is achieved by thermal compression bonding, which can ensure that the insulation layer of the wiring harness has good bonding strength and stability, thereby improving the performance and reliability of the wiring harness.

Claims

1. A long-life, impact-resistant flat cable harness, characterized by: The invention comprises an upper flame-retardant PET insulator, a lower flame-retardant PET insulator, and a flat oxygen-free bare copper conductor with a thickness of 35 μm. The flat oxygen-free bare copper conductor is placed between the upper flame-retardant PET insulator and the lower flame-retardant PET insulator. The upper flame-retardant PET insulator and the lower flame-retardant PET insulator are pressed together to form a flame-retardant PET insulator, so that the upper flame-retardant PET insulator and the lower flame-retardant PET insulator jointly wrap the flat oxygen-free bare copper conductor. The upper flame-retardant PET insulation layer and the lower flame-retardant PET insulation layer are bonded tightly together by heat pressing. The flame-retardant PET insulator is located between two adjacent flat oxygen-free bare copper conductors to form a separation strip, and the width of the separation strip is smaller than the width of the flat oxygen-free bare copper conductors.

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