High-airtightness automobile high-voltage wire harness

Abstract

The utility model relates to the technical field of power transmission, in particular to a high-airtightness automobile high-voltage wire harness, which comprises two main wire harnesses arranged adjacently, a front-end wire harness connector used for fixing the front ends of the two main wire harnesses, and a rear-end wire harness connector used for fixing the rear ends of the two main wire harnesses, the head end and the tail end of the main wire harness are connected with crimping terminals. By optimizing the materials and the structures of the conductors, the insulating layer, the shielding layer and the sheath, the electrical performance and the durability of the wire harness are remarkably improved. And particularly, the double-arm heat shrink tube design is adopted, so that the insulation performance and the sealing performance of the wire harness at the key connection part are enhanced, and the invasion of moisture, dust and corrosive substances is effectively prevented, thereby ensuring the high air tightness and the long-term reliability of the high-voltage wire harness. The design breaks through the limitation of a traditional high-voltage wire harness in the aspect of electrical performance, and provides a safer and more efficient electric energy transmission solution for an electric vehicle and a hybrid electric vehicle.

Description

Technical Field

[0001] This utility model relates to the field of power transmission technology, specifically to a high-airtightness automotive high-voltage wiring harness. Background Technology

[0002] In the automotive industry, particularly in the fields of electric and hybrid vehicles, high-voltage wiring harnesses are a crucial component of electrical power transmission, and their performance directly impacts vehicle safety, reliability, and energy efficiency. Traditional high-voltage wiring harness designs have certain limitations in terms of electrical performance, mechanical strength, and airtightness, especially under high voltage, high current, and complex environmental conditions, where these limitations become particularly pronounced.

[0003] The conductor materials, insulation materials, and shielding layer designs of traditional high-voltage harnesses may not fully meet the requirements of high voltage and high current transmission, leading to increased power loss and even electrical faults.

[0004] High-voltage wiring harnesses inside vehicles must withstand various mechanical stresses, such as vibration, impact, and torsion. Traditional designs may be inadequate in these aspects, leading to harness damage or performance degradation.

[0005] In high humidity, high dust, or corrosive environments, the airtightness of traditional high-voltage harnesses may not be effectively guaranteed, leading to problems such as electrical short circuits and corrosion. Utility Model Content

[0006] This utility model addresses the technical problems existing in the prior art by providing a high airtightness automotive high-voltage wiring harness to solve the aforementioned problem of poor reliability in automotive high-voltage wiring harnesses.

[0007] The technical solution of this utility model to solve the above-mentioned technical problems is as follows: a high airtight automotive high-voltage wiring harness, including two adjacent main wiring harnesses, a front wiring harness connector for fixing the front ends of the two main wiring harnesses, and a rear wiring harness connector for fixing the rear ends of the two main wiring harnesses; both ends of the main wiring harnesses are connected to crimp terminals.

[0008] The main wire harness includes a conductor, and an insulation layer, a shielding layer, and a sheath that are sequentially wrapped around the conductor from the inside out.

[0009] Both ends of the main harness have their wires stripped to expose the conductors, which then pass through the front or rear harness connectors and are crimped to the crimp terminals.

[0010] Based on the above technical solution, the present invention can be further improved as follows.

[0011] Furthermore, the front-end wire harness connector includes a connector housing, and two adjacent wire harness press-fit fixing grooves adapted to the main wire harness are formed in the connector housing.

[0012] Furthermore, a fixing hole is also provided on the connector housing.

[0013] Furthermore, the rear-end wire harness connector includes a connector housing two, and two adjacent wire harness press-fit fixing grooves adapted to the main wire harness are formed in the connector housing two.

[0014] Furthermore, a sealing plug is also formed at one end of the connector housing near the crimp terminal.

[0015] Furthermore, a second fixing hole is also provided on the connector housing.

[0016] Furthermore, the exposed conductor of the main wire harness is provided with a double-arm heat shrink tubing covering the conductor, insulation layer, shielding layer, and sheath; a hot melt adhesive tube is also provided between the shielding layer and the sheath.

[0017] Furthermore, the two main wire harnesses are also covered with self-winding tubes, and the self-winding tubes are provided with clips for fixing the position of the main wire harnesses.

[0018] Furthermore, adhesive tape is wrapped around both ends of the self-winding tube.

[0019] Furthermore, the high airtightness automotive high-voltage wiring harness provided by this utility model has at least the following advantages compared with the prior art:

[0020] 1. By optimizing the materials and structure of the conductor, insulation layer, shielding layer, and sheath, the electrical performance and durability of the wiring harness are significantly improved. In particular, the double-arm heat-shrink tubing design not only enhances the insulation and sealing performance of the wiring harness at critical connection points but also effectively prevents the intrusion of moisture, dust, and corrosive substances, thereby ensuring the high airtightness and long-term reliability of the high-voltage wiring harness. This design overcomes the limitations of traditional high-voltage wiring harnesses in terms of electrical performance, providing a safer and more efficient power transmission solution for electric and hybrid vehicles.

[0021] 2. Both the front and rear wiring harness connectors utilize meticulously designed wire harness press-fit grooves to ensure secure installation and connection of the main wiring harness. Simultaneously, the combined use of self-winding tubing and clips not only provides additional mechanical protection for the wiring harness but also facilitates its fixation and installation on the vehicle. These design features collectively enhance the high-voltage wiring harness's resistance to vibration, impact, and torsion, enabling it to maintain excellent performance and stability even under complex environmental conditions. This innovative design not only extends the service life of the high-voltage wiring harness but also reduces maintenance costs and safety risks caused by harness damage. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0023] Figure 2 This is a partial structural diagram of the main wire harness of this utility model;

[0024] Figure 3 This is a cross-sectional view of the main wire harness of this utility model.

[0025] The attached diagram lists the components represented by each number as follows:

[0026] 1. Main harness; 1.1 Conductor; 1.2 Insulation layer; 1.3 Shielding layer; 1.4 Sheath; 1.5 Double-arm heat shrink tubing; 1.6 Hot melt adhesive tubing; 2. Front-end harness connector; 2.1 Connector housing one; 2.2 Harness crimping and fixing groove one; 2.3 Fixing hole one; 3. Rear-end harness connector; 3.1 Connector housing two; 3.2 Harness crimping and fixing groove two; 3.3 Sealing plug; 3.4 Fixing hole two; 4. Crimping terminal; 5. Self-winding tube; 5.1 Clip. Detailed Implementation

[0027] The principles and features of this utility model are described below with reference to the accompanying drawings. The examples given are only for explaining this utility model and are not intended to limit the scope of this utility model.

[0028] It should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integrally formed structures. Those skilled in the art can understand the specific meaning of these terms in this patent based on the specific circumstances.

[0029] like Figures 1-3 As shown, the high airtight automotive high-voltage wiring harness of this practical design includes two adjacent main wiring harnesses 1, a front wiring harness connector 2 for fixing the front ends of the two main wiring harnesses 1, and a rear wiring harness connector 3 for fixing the rear ends of the two main wiring harnesses 1; both ends of the main wiring harness 1 are connected to crimp terminals 4.

[0030] The main wire harness 1 includes a conductor 1.1, and an insulating layer 1.2, a shielding layer 1.3, and a sheath 1.4 that are sequentially wrapped around the conductor 1.1 from the inside out.

[0031] Both ends of the main harness 1 are stripped to expose conductor 1.1, which passes through the front harness connector 2 or the rear harness connector 3 and is crimped to the crimp terminal 4.

[0032] These two main wire harnesses are fixed at their front and rear ends respectively via front harness connector 2 and rear harness connector 3. The core component of main harness 1 is conductor 1.1, which is responsible for transmitting current. To ensure the safety and efficiency of current transmission, conductor 1.1 is covered from the inside out with an insulation layer 1.2, a shielding layer 1.3, and a sheath 1.4. Insulation layer 1.2 is used to prevent current leakage, shielding layer 1.3 is used to reduce electromagnetic interference, and sheath 1.4 provides additional mechanical protection and abrasion resistance. At both ends of main harness 1, conductor 1.1 is exposed by stripping the wire and passing it through the front or rear harness connector to be crimped to the crimp terminal 4, thereby achieving electrical connection. This design not only ensures the high airtightness of the high-voltage wire harness but also improves its electrical performance and durability.

[0033] As a supplement, shielding layer 1.3 plays a crucial role in high-airtightness automotive high-voltage wiring harnesses. Its main function is to reduce electromagnetic interference (EMI) and radio frequency interference (RFI) to protect the signals inside the wiring harness from external interference.

[0034] The shielding layer often takes the form of a metal woven mesh, which can be made of copper, aluminum or other highly conductive metal materials.

[0035] Besides metal braided mesh, shielding layers sometimes use metal foil, such as aluminum foil or copper foil. Metal foil also has good conductivity and can provide a more uniform shielding effect, which will not be elaborated on here.

[0036] In one embodiment, the front-end wire harness connector 2 includes a connector housing 2.1, and two adjacent wire harness press-fit fixing grooves 2.2 adapted to the main wire harness 1 are formed in the connector housing 2.1.

[0037] Specifically, a fixing hole 2.3 is also reserved on the connector housing 2.1.

[0038] The front-end wiring harness connector 2 is a key component designed specifically for high-airtightness automotive high-voltage wiring harnesses. Its core component is the connector housing 2.1, which has two carefully designed adjacent wiring harness press-fitting grooves 2.2 inside. These two grooves are perfectly matched with the shape and size of the main wiring harness 1, aiming to achieve a secure installation and connection of the main wiring harness.

[0039] In one embodiment, the rear-end wire harness connector 3 includes a connector housing 3.1, and two adjacent wire harness press-fitting grooves 3.2 adapted to the main wire harness 1 are formed in the connector housing 3.1.

[0040] Specifically, a sealing plug 3.3 is also formed at one end of the connector housing 3.1 near the crimp terminal 4.

[0041] Specifically, the connector housing 3.1 also has a pre-drilled fixing hole 3.4.

[0042] The rear-end wiring harness connector 3 is an important component of the high-airtightness automotive high-voltage wiring harness, specifically designed for connecting the automotive battery. This connector consists of a connector housing 3.1, which contains two adjacent wiring harness press-fit grooves 3.2. These grooves are perfectly fitted to the main wiring harness 1, ensuring a secure installation of the main wiring harness.

[0043] To enhance the airtightness of the connector, especially when connected to critical components such as automotive batteries, a sealing plug 3.3 is specially provided at the end of the connector housing 3.1 near the crimp terminal 4. The function of the sealing plug is to provide an additional sealing layer when the connector is connected to the battery or other components, preventing the intrusion of moisture, dust, and corrosive substances, thereby ensuring the high airtightness and long-term reliability of the high-voltage wiring harness.

[0044] In one implementation, the main wire harness 1, at the position where the conductor 1.1 is exposed after stripping, is further provided with a double-arm heat shrink tubing 1.5 covering the conductor 1.1, insulation layer 1.2, shielding layer 1.3, and sheath 1.4; a hot melt adhesive tube 1.6 is also provided between the shielding layer 1.3 and the sheath 1.4. After the hot melt adhesive tube 1.6 melts, it will overflow the shielding layer 1.3, thereby filling the gaps in the shielding layer 1.3.

[0045] In the design of high-airtightness automotive high-voltage wiring harnesses, several key measures were adopted to improve the overall performance and airtightness of the harness. Firstly, a double-arm heat-shrink tubing 1.5 was specially installed at the location where the conductor 1.1 of the main wiring harness 1 is exposed. This design not only covers the conductor 1.1 but also extends to the insulation layer 1.2, the shielding layer 1.3, and the sheath 1.4, thus forming an additional protective layer at the critical connection points of the wiring harness. The double-arm heat-shrink tubing 1.5 has excellent insulation and sealing properties, effectively preventing the intrusion of moisture, dust, and other corrosive substances, further enhancing the airtightness and reliability of the wiring harness.

[0046] Specifically, the two main wire harnesses 1 are also covered with self-winding tubes 5, and the self-winding tubes 5 are provided with clips 5.1 for fixing the position of the main wire harnesses 1.

[0047] Specifically, PVC tape is wrapped around both ends of the self-winding tube 5. The PVC tape has excellent adhesion, wear resistance and corrosion resistance, which can effectively prevent moisture and dust from entering from the end of the wire harness, thereby ensuring the overall airtightness and long-term reliability of the wire harness.

[0048] The self-coiling tube 5 possesses excellent flexibility and self-adhesion, allowing it to fit tightly against the surface of the wire harness and providing additional mechanical protection. On the outer side of the self-coiling tube 5, a retainer 5.1 is also provided for securely fixing the wire harness to a designated location on the vehicle. The design of the retainer 5.1 not only enhances the stability of the wire harness but also facilitates operation during installation and maintenance.

[0049] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover a 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 a process, method, article, or apparatus. Unless otherwise expressly specified and limited, the terms "installed," "connected," or "linked" should be interpreted broadly, for example, as a fixed connection, a detachable connection, or an integral connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection via an intermediate medium; or a connection within two elements. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0050] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0051] Obviously, those skilled in the art can make various modifications and variations to this utility model without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this utility model and their equivalents, this utility model also intends to include these modifications and variations.

Claims

1. A high-airtightness automotive high-voltage wiring harness, characterized in that, It includes two adjacent main wire harnesses (1), a front wire harness connector (2) for fixing the front end of the two main wire harnesses (1), and a rear wire harness connector (3) for fixing the rear end of the two main wire harnesses (1); both ends of the main wire harnesses (1) are connected to crimp terminals (4). The main wire harness (1) includes a conductor (1.1), and an insulating layer (1.2), a shielding layer (1.3), and a sheath (1.4) that are sequentially wrapped around the conductor (1.1) from the inside out. The main harness (1) has its conductors (1.1) stripped at both ends and passed through the front harness connector (2) or the rear harness connector (3) and crimped to the crimp terminal (4).

2. The high airtightness automotive high-voltage wiring harness according to claim 1, characterized in that, The front-end wire harness connector (2) includes a connector housing (2.1), and two adjacent wire harness press-fit fixing grooves (2.2) adapted to the main wire harness (1) are formed in the connector housing (2.1).

3. The high airtightness automotive high-voltage wiring harness according to claim 2, characterized in that, The connector housing (2.1) also has a pre-drilled fixing hole (2.3).

4. The high airtightness automotive high-voltage wiring harness according to claim 1, characterized in that, The rear-end wire harness connector (3) includes a connector housing (3.1), and two adjacent wire harness press-fit fixing grooves (3.2) adapted to the main wire harness (1) are formed in the connector housing (3.1).

5. The high airtightness automotive high-voltage wiring harness according to claim 4, characterized in that, A sealing plug (3.3) is also formed at one end of the connector housing (3.1) near the crimp terminal (4).

6. The high airtightness automotive high-voltage wiring harness according to claim 4, characterized in that, The connector housing 2 (3.1) also has a pre-drilled fixing hole 2 (3.4).

7. The high airtightness automotive high-voltage wiring harness according to claim 1, characterized in that, The main wire harness (1) is provided with a double-arm heat shrink tubing (1.5) covering the conductor (1.1), insulation layer (1.2), shielding layer (1.3) and sheath (1.4) at the position where the conductor (1.1) is exposed after stripping the wire; a hot melt adhesive tube (1.6) is also provided between the shielding layer (1.3) and the sheath (1.4).

8. The high-airtightness automotive high-voltage wiring harness according to any one of claims 1-7, characterized in that, The two main wire harnesses (1) are also covered by self-winding tubes (5), and the self-winding tubes (5) are provided with clips (5.1) for fixing the position of the main wire harnesses (1).

9. The high airtightness automotive high-voltage wiring harness according to claim 8, characterized in that, The self-winding tube (5) is wrapped with PVC tape at both ends.

Images