New energy automobile wire harness with high-temperature-resistant function

Abstract

The utility model discloses a new energy automobile wire harness with a high-temperature-resistant function, relates to the technical field of automobile wire harnesses, and aims to solve the technical problems of poor local high-temperature protection adaptability and material redundancy of an existing wire harness. Fastening mechanisms are arranged at the two ends of the protection mechanism, the protection mechanism comprises a corrugated pipe, a heat insulation layer A is arranged on the corrugated outer wall face of the corrugated pipe, and a heat insulation layer B is arranged on the corrugated inner wall face of the corrugated pipe. The corrugated structure of the polyethylene corrugated pipe is matched with the bending requirement, the wave trough air layer and the wave crest flow guide design disperse heat conduction, the aerogel heat insulation layer A arranged on the outer wall face blocks external heat radiation, the ceramic fiber heat insulation layer B arranged on the inner wall face blocks residual heat conduction, and a gradient heat insulation system is formed by the aerogel heat insulation layer A and the ceramic fiber heat insulation layer B; the temperature rise of the conductor in a local high-temperature area is reduced while the flexibility is ensured, and bloating and cost waste caused by redundant protection of the whole wire are avoided.

Description

Technical Field

[0001] This utility model relates to the field of automotive wiring harness technology, and more specifically, to a new energy vehicle wiring harness with high temperature resistance. Background Technology

[0002] Wiring harnesses are a core component of the vehicle's electrical system, responsible for functions such as power transmission, signal control, and device interconnection. As pure electric and hybrid new energy vehicles develop towards higher power density and longer range, wiring harnesses need to pass through heat-prone areas such as the motor compartment and engine compartment. These areas generate continuous high temperatures during motor and engine operation, placing stringent requirements on the temperature resistance of the wiring harnesses.

[0003] Currently, the protection of wiring harnesses in high-temperature areas often involves adding high-temperature resistant materials throughout the entire harness. While this improves temperature resistance, it increases the harness's outer diameter and weight, and the redundant use of high-cost materials in low-temperature areas leads to resource waste. Therefore, we propose a new type of wiring harness for new energy vehicles with high-temperature resistance. Utility Model Content

[0004] The purpose of this utility model is to overcome the shortcomings of the existing technology, adapt to the needs of reality, and provide a new energy vehicle wiring harness with high temperature resistance, so as to solve the technical problems of poor adaptability of existing wiring harnesses in local high temperature protection and material redundancy.

[0005] To solve the above technical problems, this utility model provides the following technical solution: a new energy vehicle wiring harness with high temperature resistance, including a protection mechanism, a conductor mechanism arranged inside the protection mechanism, fastening mechanisms arranged at both ends of the protection mechanism, and a conductor mechanism passing through the fastening mechanism;

[0006] The protective mechanism includes a corrugated pipe made of polyethylene material. A heat insulation layer A is arranged on the outer corrugated wall of the corrugated pipe, which is made of aerogel material. A heat insulation layer B is arranged on the inner corrugated wall of the corrugated pipe, which is made of ceramic fiber material.

[0007] Preferably, the conductor mechanism includes a conductive core, an insulating layer is arranged around the outer periphery of the conductive core, a shielding layer is arranged around the outer periphery of the insulating layer, a heat insulation layer C is arranged around the outer periphery of the shielding layer, and a weather-resistant sheath is arranged around the outer periphery of the heat insulation layer C.

[0008] Preferably, the fastening mechanism includes a fixing sleeve fixed to both ends of the bellows, and a fastening head is arranged at one end inside the fixing sleeve. The fastening head is connected to the thread on the inner wall of the fixing sleeve by a thread on its surface.

[0009] Preferably, a fixing ring is arranged at the other end of the fixing sleeve, and a plurality of fastening pieces are spaced apart on the side of the fixing ring along its circumference, with one end of the plurality of fastening pieces being tangent to one end of the fastening head.

[0010] Preferably, the heat insulation layer A is formed by spraying aerogel onto the corrugated outer wall of the corrugated pipe, and the heat insulation layer B is formed by weaving ceramic fibers into a woven sleeve and fixed onto the corrugated inner wall of the corrugated pipe.

[0011] Compared with the prior art, the beneficial effects of this utility model are:

[0012] 1. This utility model utilizes a corrugated pipe structure. The corrugated pipe, made of polyethylene material, possesses excellent flexibility and high-temperature resistance, providing initial protection against the heat generated by the motor or engine in new energy vehicles. Its corrugated structure facilitates bending according to the installation position of the conductor mechanism, while continuing to protect the internal conductor mechanism after bending. Furthermore, an air layer is formed at the troughs of the corrugated structure, preventing heat from easily entering the corrugated pipe through these troughs. The pointed peaks guide heat into the troughs, where the air layer directs it to the outer wall of the corrugated structure. The heat insulation layers A and B installed here effectively block this heat. Through the design of the structures of heat insulation layers A and B, they respectively employ… Made of aerogel and ceramic fiber materials, the aerogel insulation layer A is installed on the outer corrugated wall of the bellows, avoiding the crests and troughs of the bellows, thus not affecting the bending of the bellows. The aerogel insulation layer A has the advantage of low thermal conductivity and is lightweight, effectively blocking external heat radiation and temperature conduction. The ceramic fiber insulation layer B is installed on the inner corrugated wall of the bellows, avoiding the crests and troughs of the bellows, thus not affecting the bending of the bellows. The ceramic fiber insulation layer B is resistant to high temperature and can further isolate residual heat, preventing heat from being transferred inward through the bellows. The two layers form a gradient insulation, significantly reducing the internal temperature rise of the conductor structure.

[0013] 2. This utility model designs a fixed sleeve and a fastening head structure. Because both the inner and outer surfaces are threaded, when the fastening head rotates inside the fixed sleeve, its threads will engage, allowing the fastening head to move within the fixed sleeve. The moving fastening head will push a fastening plate that is in contact with one end, allowing adjustment of the fastening plate's state. By designing the fastening plate, the fastening plate is installed at an angle on the side of the fixed ring, and one end of the fastening plate adopts an inclined bevel structure design. This inclined bevel is tangent to the bevel set at one end of the fastening head. When the fastening head moves within the fixed sleeve due to rotation and engagement, the bevel set at one end of the fastening head will squeeze the bevel at one end of the fastening plate, thereby adjusting the tilt angle of the fastening plate. This allows multiple fastening plates to tilt and constrict to clamp and fix the conductor mechanism placed between them, indirectly fixing the position of the bellows.

[0014] 3. The purpose of using a spraying process to install the insulation layer A of this utility model is to control the thickness of the aerogel to less than 2 mm. This thickness has little impact on the bending performance of the corrugated pipe. If it is greater than 3 mm, the insulation layer A is easy to break or fall off when the corrugated pipe is bent. The purpose of using a weaving process for the insulation layer B is that its flexible weaving structure is easier to bend. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the main appearance structure of this utility model;

[0016] Figure 2 This is a front view sectional view of the present invention.

[0017] Figure 3 This is a cross-sectional view of the fastening mechanism of this utility model;

[0018] Figure 4 This is a schematic diagram of the separation structure of the fastening mechanism of this utility model;

[0019] Figure 5 This is a cross-sectional view of the protective mechanism of this utility model;

[0020] Figure 6 This is a schematic diagram of the internal structure of the conductor mechanism of this utility model.

[0021] Explanation of the labels in the diagram:

[0022] 1. Protective mechanism; 101. Corrugated pipe; 102. Insulation layer A; 103. Insulation layer B; 2. Conductor mechanism; 201. Conductive core; 202. Insulation layer; 203. Shielding layer; 204. Insulation layer C; 205. Weather-resistant sheath; 3. Fastening mechanism; 301. Fixing sleeve; 302. Fastening head; 303. Fixing ring; 304. Fastening plate. Detailed Implementation

[0023] like Figures 1 to 6As shown, the present invention relates to a new energy vehicle wiring harness with high temperature resistance, including a protection mechanism 1, a conductor mechanism 2 arranged inside the protection mechanism 1, fastening mechanisms 3 arranged at both ends of the protection mechanism 1, and a conductor mechanism 2 passing through the fastening mechanism 3.

[0024] The protective mechanism 1 includes a corrugated pipe 101, which is made of polyethylene material. A heat insulation layer A102 is arranged on the corrugated outer wall surface of the corrugated pipe 101, which is made of aerogel material. A heat insulation layer B103 is arranged on the corrugated inner wall surface of the corrugated pipe 101, which is made of ceramic fiber material. This invention utilizes a corrugated pipe 101 structure. The corrugated pipe 101, made of polyethylene material, possesses advantages such as good flexibility and high-temperature resistance, providing initial protection against the heat generated by the motor or engine in new energy vehicles. Its corrugated structure facilitates bending according to the installation position of the conductor mechanism 2, and even after bending, it continues to protect the internal conductor mechanism 2. Furthermore, an air layer is formed at the troughs of the corrugated structure, preventing heat from easily entering the corrugated pipe 101 through these troughs. The pointed peaks guide heat into the troughs, where the air layer then guides it to the outer wall of the corrugation. The heat insulation layers A102 and B103 installed here effectively block this heat. The heat insulation layers A102 and B103 are designed using aerogel material and... The heat insulation layer A102, made of ceramic fiber material and aerogel material, is installed on the outer corrugated wall of the corrugated pipe 101, avoiding the crests and troughs of the outer surface of the corrugated pipe 101, so as not to affect the bending of the corrugated pipe 101. The heat insulation layer A102 made of aerogel material has the advantage of low thermal conductivity and lightweight properties, which can effectively block external heat radiation and temperature conduction. The heat insulation layer B103 made of ceramic fiber material is installed on the inner corrugated wall of the corrugated pipe 101, avoiding the crests and troughs of the inner surface of the corrugated pipe 101, so as not to affect the bending of the corrugated pipe 101. The heat insulation layer B103 made of ceramic fiber material is resistant to high temperature, which can further isolate residual heat and prevent heat from being transferred inward through the corrugated pipe 101. The two form a gradient heat insulation, which significantly reduces the internal temperature rise of the conductor structure 2.

[0025] In an embodiment of this invention, the conductor mechanism 2 includes a conductive core 201, an insulating layer 202 arranged around the outer periphery of the conductive core 201, a shielding layer 203 arranged around the outer periphery of the insulating layer 202, a heat insulation layer C204 arranged around the outer periphery of the shielding layer 203, and a weather-resistant sheath 205 arranged around the outer periphery of the heat insulation layer C204. The conductive core 201 of this invention is configured such that the devices connected at both ends can be electrically connected to each other. The heat insulation layer C204 is also made of aerogel material, achieving the same effect as the heat insulation layer A102. By designing the structure of the insulating layer 202, shielding layer 203, heat insulation layer C204, and weather-resistant sheath 205, the problems of insulation, electromagnetic shielding, high-temperature resistance, and wear resistance are solved layer by layer.

[0026] In an embodiment of this utility model, the fastening mechanism 3 includes a fixing sleeve 301 fixed to both ends of the bellows 101. A fastening head 302 is arranged at one end inside the fixing sleeve 301. The fastening head 302 is connected to the thread on the inner wall of the fixing sleeve 301 by a thread on its surface. By designing the structure of the fixing sleeve 301 and the fastening head 302, since both its inner and outer surfaces are threaded, when the fastening head 302 rotates inside the fixing sleeve 301, its threads will engage, which will allow the fastening head 302 to move inside the fixing sleeve 301. The moving fastening head 302 will push the fastening plate 304 that is in contact with one end, and the state of the fastening plate 304 can be adjusted.

[0027] In an embodiment of this utility model, a fixing ring 303 is arranged at the other end of the fixing sleeve 301. Multiple fastening pieces 304 are spaced apart along the circumference of the fixing ring 303, with one end of each fastening piece 304 tangent to one end of the fastening head 302. This utility model designs the fastening pieces 304 to be inclined and mounted on the side of the fixing ring 303. One end of the fastening piece 304 has an inclined bevel structure, which is tangent to the bevel at one end of the fastening head 302. When the fastening head 302 moves within the fixing sleeve 301 due to rotational engagement, the bevel at one end of the fastening head 302 will press against the bevel at one end of the fastening piece 304, thereby adjusting the inclination angle of the fastening piece 304. This allows the multiple fastening pieces 304 to clamp and fix the conductor mechanism 2 placed between them, indirectly fixing the position of the bellows 101.

[0028] In this embodiment of the invention, the heat insulation layer A102 is made by spraying aerogel onto the corrugated outer wall of the corrugated pipe 101, and the heat insulation layer B103 is made by weaving ceramic fibers into a woven sleeve and fixed onto the corrugated inner wall of the corrugated pipe 101. The purpose of using a spraying process to install the heat insulation layer A102 is to control the thickness of the aerogel to less than 2 mm. This thickness has little impact on the bending performance of the corrugated pipe 101. If it is greater than 3 mm, the heat insulation layer A102 is prone to breakage or detachment when the corrugated pipe 101 is bent. The purpose of using a weaving process for the heat insulation layer B103 is that its flexible woven structure is easier to bend.

[0029] Working Principle: This embodiment provides a high-temperature resistant wiring harness for new energy vehicles. During use, the operator first connects the conductor mechanism 2 to one device in the new energy vehicle, and then connects its other end to another device. After the conductor mechanism 2 is arranged, it may pass near the motor or engine. The conductor mechanism 2 located in this position will experience higher temperatures than other locations. At this point, the operator moves the corrugated tube 101 inside the protection mechanism 1 to this position. After the corrugated tube 101 is moved to this position, the operator pinches the fastening head 30 with their fingers. 2. When force is applied and rotated, the fastening head 302 will move inside the fixed sleeve 301 due to the thread engagement. One end of the moving fastening head 302 will abut against one end of the fastening plate 304, causing the fastening plate 304 to abut and tighten. The tightened fastening plate 304 will fasten the conductor mechanism 2 placed between it, thus completing the position fixation of the protection mechanism 1. When the new energy vehicle is running, the high temperature generated by its motor or engine will be isolated and blocked by the heat insulation layer A102 and heat insulation layer B103 installed on the bellows 101, protecting the internal conductor mechanism 2 from high temperature damage.

[0030] The embodiments disclosed herein are preferred embodiments, but are not limited thereto. Those skilled in the art can readily grasp the spirit of this utility model based on the above embodiments and make different extensions and variations. However, as long as they do not depart from the spirit of this utility model, they are all within the protection scope of this utility model.

Claims

1. A new energy vehicle wiring harness with high temperature resistance, comprising a protection mechanism (1), characterized in that: The protective mechanism (1) is provided with a conductor mechanism (2), and fastening mechanisms (3) are provided at both ends of the protective mechanism (1). The conductor mechanism (2) passes through the fastening mechanism (3). The protective mechanism (1) includes a corrugated pipe (101) made of polyethylene material. A heat insulation layer A (102) is arranged on the corrugated outer wall surface of the corrugated pipe (101) and is made of aerogel material. A heat insulation layer B (103) is arranged on the corrugated inner wall surface of the corrugated pipe (101) and is made of ceramic fiber material.

2. The high-temperature resistant wiring harness for new energy vehicles according to claim 1, characterized in that: The conductor mechanism (2) includes a conductive core (201), an insulating layer (202) is arranged on the outer periphery of the conductive core (201), a shielding layer (203) is arranged on the outer periphery of the insulating layer (202), a heat insulation layer C (204) is arranged on the outer periphery of the shielding layer (203), and a weather-resistant sheath (205) is arranged on the outer periphery of the heat insulation layer C (204).

3. A new energy vehicle wiring harness with high-temperature resistance according to claim 2, characterized in that: The fastening mechanism (3) includes a fixing sleeve (301) fixed at both ends of the bellows (101). A fastening head (302) is arranged at one end of the fixing sleeve (301). The fastening head (302) is connected to the thread on the inner wall of the fixing sleeve (301) by a thread on its surface.

4. A new energy vehicle wiring harness with high-temperature resistance according to claim 3, characterized in that: A fixing ring (303) is arranged at the other end of the fixing sleeve (301). A plurality of fastening pieces (304) are spaced apart on the side of the fixing ring (303) along its circumference. One end of the plurality of fastening pieces (304) is tangent to one end of the fastening head (302).

5. A new energy vehicle wiring harness with high-temperature resistance according to claim 4, characterized in that: The heat insulation layer A (102) is made by spraying aerogel onto the corrugated outer wall of the corrugated pipe (101), and the heat insulation layer B (103) is made by weaving ceramic fibers into a woven sleeve and fixed onto the corrugated inner wall of the corrugated pipe (101).

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