Extension spring wire harness

Abstract

The utility model discloses an extension spring wire harness, and relates to the technical field of wire harnesses, the extension spring wire harness comprises a spring wire main body which is formed by winding a vortex ring along a straight line, and the two ends of the spring wire main body are respectively provided with a terminal stud; the spring wire main body comprises a plurality of inner cores and a protective sleeve wrapping the outer parts of the plurality of inner cores, and a tensile filling layer is filled between the protective sleeve and the plurality of inner cores along the length direction of the spring wire main body; each of the plurality of inner cores comprises a plurality of wires arranged in a stranded manner, an insulating layer wrapping the plurality of wires, a waterproof inner layer wrapping the insulating layer, and a shielding inner layer wrapping the waterproof inner layer; the protective sleeve is sequentially provided with a shielding outer layer, a waterproof outer layer wrapping the shielding outer layer, and an outer wrapping layer wrapping the waterproof outer layer from inside to outside. A plurality of performance indexes such as electromagnetic shielding, water resistance, tensile strength and flexibility are remarkably improved, and the increasing requirements for diversification and high performance can be met.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of wiring harness, concretely is a stretch spring wiring harness. BACKGROUND

[0002] In today's electronic devices and electrical systems, wiring harness as a kind of key connecting component, is widely used in various fields, such as automotive electronics, industrial automation, communication equipment and consumer electronics products, etc. With the continuous development of these fields, the performance requirements of wiring harness are also increasing.

[0003] Traditional wiring harness usually adopts simple wire twisting or wrapping structure, which gradually exposes many problems in some complex working environments. For example, in the environment with electromagnetic interference sources, due to the lack of effective electromagnetic shielding measures, the electrical signals transmitted inside the wiring harness are easily disturbed, leading to signal distortion, transmission error and even equipment failure. Especially in some electronic devices with strict electromagnetic compatibility requirements, such as precision instruments, communication base stations, etc., this electromagnetic interference problem seriously affects the normal operation and performance stability of the equipment.

[0004] At the same time, in the humid or liquid contact environment, the waterproof performance of traditional wiring harness is not good, and moisture can easily penetrate into the wire inside, causing short circuit, corrosion and other problems, reducing the reliability and service life of the wiring harness. This is particularly prominent in the engine compartment of the car, outdoor electronic equipment and underwater operation equipment, etc. Because the wiring harness in these environments often faces the threat of rain, moisture or liquid splashing.

[0005] In addition, in some occasions where the wiring harness needs to have certain elasticity and tensile resistance, such as the connection of movable parts of the equipment, the parts that are frequently bent and stretched, the traditional inelastic wiring harness cannot meet the demand. When the wiring harness is subjected to tensile force, the wire is easy to break and the internal structure is easy to damage, thereby affecting the connection and signal transmission of the entire electrical system.

[0006] Moreover, with the development of electronic devices towards miniaturization, light weight and high performance, higher challenges are put forward to the space occupation and overall performance of the wiring harness. Due to the single structure of traditional wiring harness, it cannot meet the multiple performance requirements in limited space, which limits its application in some high-end devices and compact structures.

[0007] In summary, in order to overcome the shortcomings of traditional wiring harness in electromagnetic shielding, waterproof, tensile resistance and adapt to complex environment and equipment structure, etc., a new type of wiring harness structure is urgently needed to meet the increasing diversification and high performance requirements of modern electronic devices and electrical systems. UTILITY MODEL CONTENT

[0008] The utility model overcomes the above-mentioned shortcomings, and aims to provide a technical scheme that can solve the above-mentioned problems.

[0009] A stretch spring wire harness, comprising a spring wire body wound in a spiral along a straight line, and wire terminals arranged at two ends of the spring wire body respectively;

[0010] The spring wire body comprises a plurality of inner cores and a protective sleeve wrapped outside the plurality of inner cores, and a tensile filling layer is filled between the protective sleeve and the plurality of inner cores along the length direction of the spring wire body;

[0011] The plurality of inner cores each comprise a plurality of twisted wires, an insulating layer wrapped outside the plurality of twisted wires, a waterproof inner layer wrapped outside the insulating layer, and a shielding inner layer wrapped outside the waterproof inner layer;

[0012] The protective sleeve comprises, from inside to outside, a shielding outer layer, a waterproof outer layer wrapped outside the shielding outer layer, and an outer cladding layer wrapped outside the waterproof outer layer.

[0013] As a further scheme of the utility model, the waterproof inner layer is made of rubber material, and a plurality of annular protrusions are arranged on the inner surface of the waterproof inner layer and uniformly distributed along the axial direction of the waterproof inner layer to be tightly connected with the insulating layer.

[0014] As a further scheme of the utility model, the shielding inner layer is a composite structure of metal foil and braided mesh.

[0015] As a further scheme of the utility model, the shielding outer layer is a metalized plastic film.

[0016] As a further scheme of the utility model, the outer cladding layer is internally provided with a reinforcing rib structure, the reinforcing rib is a silk-like or sheet-like structure made of fiber-reinforced plastic and is distributed along the length direction of the outer cladding layer.

[0017] As a further scheme of the utility model, the waterproof outer layer is a sealing layer made of TPU material, and a plurality of longitudinal grooves are arranged on the side of the waterproof outer layer adhered to the shielding outer layer.

[0018] As a further scheme of the utility model, the tensile filling layer is made of a mixed filling material of aramid fiber and rubber particles.

[0019] Compared with the prior art, the utility model has the beneficial effects as follows:

[0020] 1) The shielding inner layer of the inner core and the shielding outer layer of the protective sleeve jointly form an efficient electromagnetic shielding system, which can significantly reduce the influence of external electromagnetic interference on the transmission signal of the internal wires, reduce the probability of signal distortion and transmission error, improve the reliability and stability of the wire harness in the electronic equipment with a complex electromagnetic environment, and ensure the normal operation and performance of the equipment are not affected by electromagnetic interference.

[0021] 2) The double waterproof structure formed by the waterproof inner layer of the inner core and the waterproof outer layer of the protective sleeve greatly improves the waterproof capability of the wire harness. Compared with the traditional wire harness, in a humid or liquid-contacting environment, the wire harness can effectively prevent water from penetrating into the internal wires, reduce the occurrence of problems such as short circuit and corrosion, prolong the service life of the wire harness, and improve the safety and reliability of the equipment.

[0022] 3) The vortex winding structure of the spring wire body and the tensile filling layer between the protective sleeve and the inner core make the wire harness have good elasticity and tensile performance. In the connection of movable parts of the equipment or the parts that are frequently bent and stretched, the wire harness can withstand a certain tensile force without being easily damaged, avoiding the breakage of the wires and the damage of the internal structure, ensuring the connection stability of the entire electrical system and the continuity of signal transmission, which is superior to the traditional inelastic wire harness.

[0023] The additional aspects and advantages of the present application will be partially given in the following description, and some will become apparent from the following description, or be understood through the practice of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or prior art description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0025] Figure 1 is a structural schematic diagram of the present application;

[0026] Figure 2 is a cross-sectional structure schematic diagram of the spring wire body in the present application;

[0027] Figure 3 is a hierarchical distribution structure schematic diagram of the waterproof inner layer and the insulating layer in the present application;

[0028] Figure 4 is a hierarchical distribution structure schematic diagram of the protective sleeve in the present application.

[0029] The reference signs and names in the drawings are as follows:

[0030] 1, spring wire body; 2, wire end; 3, inner core; 4, protective sleeve; 5, tensile filling layer; 6, wire; 7, insulating layer; 8, waterproof inner layer; 9, shielding inner layer; 10, shielding outer layer; 11, waterproof outer layer; 12, outer cladding layer; 13, annular protrusion; 14, reinforcing rib structure; 15, groove. DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the utility model will be clearly and completely described below with reference to the drawings in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments in the utility model, all the other embodiments obtained by the ordinary skilled in the art without creative labor fall within the scope of the utility model.

[0032] Please refer to Figures 1-4 In the embodiments of the utility model, a stretch spring wire harness comprises a spring wire main body 1 which is wound in a spiral along a straight line, and the spring wire main body 1 is provided with a wire terminal 2 at each end.

[0033] The spring wire main body 1 comprises a plurality of inner cores 3 and a protective sleeve 4 wrapped outside the plurality of inner cores 3, and a tensile filling layer 5 is filled between the protective sleeve 4 and the plurality of inner cores 3 along the length direction of the spring wire main body 1.

[0034] The plurality of inner cores 3 each comprise a plurality of conductive wires 6 arranged in a twisted manner, an insulating layer 7 wrapped outside the plurality of conductive wires 6, a waterproof inner layer 8 wrapped outside the insulating layer 7, and a shielding inner layer 9 wrapped outside the waterproof inner layer 8.

[0035] The protective sleeve 4 is sequentially provided with a shielding outer layer 10, a waterproof outer layer 11 wrapped outside the shielding outer layer 10, and an outer cladding layer 12 wrapped outside the waterproof outer layer 11 from inside to outside.

[0036] In the technical solutions of the utility model,

[0037] The spring wire main body 1 wound in a spiral along a straight line is used to give the wire harness the ability of stretching and elastic recovery. The spiral structure is similar to a spring, and when subjected to external force, the spacing between the coils can be increased, thereby realizing the extension of the length. When the external force disappears, the material itself can also recover to the original shape. This design principle is based on the elastic deformation characteristics of elasticity and materials, and through reasonable structural design, the wire harness can adapt to the requirements of stretching and contraction within a certain range to meet the use requirements of the movable parts of the equipment or the frequently curved and stretched parts.

[0038] The wire terminals 2 provided at both ends of the spring wire main body 1 are based on the basic functional requirements of the wire harness as an electrical connection component. The wire terminals 2 are used for stable electrical connection with external electrical equipment or lines to ensure that the current or signal can be smoothly transmitted to the conductive wires 6 inside the wire harness or transmitted from the wire harness to other equipment. This is in line with the basic principle of circuit connection, ensuring the integrity and continuity of the electrical system.

[0039] The shielding outer layer 10 in the protective sleeve 4 is located in the innermost layer, close to the shielding inner layer 9 of the inner core 3, to jointly build a more powerful electromagnetic shielding system with the shielding inner layer 9 of the inner core 3. Through the double-layer shielding structure, the electromagnetic protection capability of the wire harness is further enhanced, preventing various electromagnetic interferences in the external complex electromagnetic environment from penetrating the protective sleeve 4 into the inner core 3 and affecting the signal transmission of the wire 6. This is based on the multi-layer shielding principle of electromagnetic shielding, using the characteristics and structural combination of different shielding materials to improve the electromagnetic shielding effect.

[0040] The waterproof outer layer 11 is wrapped outside the shielding outer layer 10, forming a double waterproof structure with the waterproof inner layer 8 of the inner core 3. This design principle is to greatly improve the overall waterproof capability of the wire harness through the synergistic effect of the two layers of waterproof materials. Even if the external moisture breaks through the waterproof outer layer 11, the waterproof inner layer 8 can still provide additional waterproof protection to ensure that the inside of the inner core 3 is not eroded by water, thereby enhancing the reliability and stability of the wire harness in harsh environments such as humidity and water, which is based on the waterproof principle of multi-layer waterproof structure.

[0041] The outer covering layer 12 is set in the outermost layer and is made of materials with wear resistance, corrosion resistance, and certain mechanical strength. The design principle is to protect the internal structures of the protective sleeve 4 from external mechanical damage, wear, and chemical corrosion. In actual use, the wire harness may come into contact with other objects, rub, or be exposed to corrosive substances. The outer covering layer 12 can act as the first line of defense, extending the overall service life of the wire harness, which is based on the principles of mechanical protection and material protection.

[0042] The tensile filling layer 5 is filled between the protective sleeve 4 and the inner core 3. The design principle is to enhance the tensile performance of the spring wire main body 1. When the wire harness is subjected to tensile force, the tensile filling layer 5 can bear part of the tensile force, evenly disperse stress, and avoid excessive friction and damage between the inner core 3 and the protective sleeve 4 due to relative displacement. The material properties of the tensile filling layer 5 (such as high strength and high elastic modulus) enable it to effectively enhance the overall tensile strength and flexibility of the wire harness, which is based on the principles of stress dispersion and structural strength enhancement in material mechanics.

[0043] In summary, the shielding inner layer 9 of the inner core 3 and the shielding outer layer 10 of the protective sleeve 4 jointly form a high-efficiency electromagnetic shielding system, which can significantly reduce the influence of external electromagnetic interference on the transmission signal of the internal wire 6, reduce the probability of signal distortion and transmission error, improve the reliability and stability of the wire harness in the complex electromagnetic environment of electronic equipment, and ensure the normal operation and performance of the equipment are not affected by electromagnetic interference; The double waterproof structure composed of the waterproof inner layer 8 of the inner core 3 and the waterproof outer layer 11 of the protective sleeve 4 greatly improves the waterproof capability of the wire harness. Compared with the traditional wire harness, it can effectively prevent water from penetrating into the internal wire 6 in a humid or liquid-contacting environment, reduce the occurrence of short circuit, corrosion and other problems, prolong the service life of the wire harness, and improve the safety and reliability of the equipment; The vortex coil winding structure of the spring wire body 1 and the anti-tension filling layer 5 between the protective sleeve 4 and the inner core 3 make the wire harness have good elasticity and tensile property, which can withstand a certain tensile force without being easily damaged in the connection of movable parts of the equipment or the frequently bending and stretching parts, avoiding the breakage of the internal wire 6 and the damage of the internal structure, ensuring the connection stability of the entire electrical system and the continuity of signal transmission, which is superior to the traditional inelastic wire harness.

[0044] As a further scheme of the present application: the waterproof inner layer 8 is made of rubber material, and the inner surface of the waterproof inner layer 8 is provided with a plurality of annular protrusions 13, which are uniformly distributed along the axial direction of the waterproof inner layer 8 to be tightly connected with the insulating layer 7.

[0045] The reason for choosing rubber as the material of the waterproof inner layer 8 is that rubber has excellent elasticity and flexibility, which can maintain its integrity without breaking when the spring wire body 1 is bent, stretched or subjected to external pressure, thereby continuously and effectively preventing water from penetrating into the insulating layer 7 and the internal wire 6. The flexible structure of the rubber molecular chain enables it to adapt to various deformations, and its relatively dense molecular arrangement can prevent water molecules from entering the inner layer by diffusion or penetration. At the same time, the rubber material has good chemical stability and is not prone to chemical reaction with water, so it can maintain its waterproof performance in a long-term humid environment.

[0046] The plurality of annular protrusions 13 provided on the inner surface of the waterproof inner layer 8 are based on the physical concept of increasing the contact area and friction. When the waterproof inner layer 8 wraps the insulating layer 7, these annular protrusions 13 can tightly fit the outer surface of the insulating layer 7, increasing the contact area between the two. This tight connection can prevent relative displacement between the waterproof inner layer 8 and the insulating layer 7 due to vibration, stretching or other external forces during use, further ensuring the integrity of the waterproof barrier and preventing water from penetrating between the two.

[0047] The shielding inner layer 9 is a composite structure of metal foil and woven mesh; and the shielding outer layer 10 is a metallized plastic film.

[0048] The design principle of the composite of the metal foil and the woven mesh is to combine the advantages of both, the metal foil is mainly used for electromagnetic reflection of a large area, and the woven mesh can supplement shielding of possible small gaps or weak parts of the metal foil while ensuring flexibility, and can better adapt to the electromagnetic shielding requirements of the wire harness in the deformation process such as bending and stretching;

[0049] The metallized plastic film is a material in which a metal layer is deposited on a plastic film substrate, and the design principle is to utilize the flexibility and easy molding characteristics of the plastic film, while combining the electromagnetic shielding performance of the metal layer; the plastic film as the substrate can provide good mechanical properties such as flexibility and tear resistance, so that the shielding outer layer 10 can bend and fold with the shape change of the wire harness and will not easily break, and the plastic film can serve as a support structure for the metal layer to ensure the stability of the metal layer during use; the metal layer is attached to the plastic film by physical or chemical deposition, which can reflect and absorb external electromagnetic interference, when the external electromagnetic signal reaches the metallized plastic film, the free electrons in the metal layer will generate an induced current, thereby reflecting and attenuating the electromagnetic signal, preventing the electromagnetic signal from penetrating the protective sleeve 4 into the inner core 3, and protecting the signals transmitted by the internal conductor 6.

[0050] In the embodiment of the utility model, the inside of the outer cladding layer 12 is equipped with the reinforcing rib structure 14, the reinforcing rib is the silk shape or sheet shape structure made of fiber reinforced plastic, and is distributed along the length direction of the outer cladding layer 12.

[0051] The fiber reinforced plastic is selected as the material of the reinforcing rib because it combines the high strength of the fiber material and the processability and flexibility of the plastic, the fiber (such as carbon fiber, glass fiber, etc.) has high strength and modulus, can withstand a large external force, provides effective mechanical reinforcement for the outer cladding layer 12, and the plastic matrix can bond the fibers together, while making the reinforcing rib have a certain flexibility, which can bend moderately with the deformation of the outer cladding layer 12, avoiding breaking due to excessive hardness during use;

[0052] The reinforcing rib is distributed along the length direction of the outer cladding layer 12, which is based on the fact that the wire harness is mainly subjected to axial tensile and bending forces during actual use, when the wire harness is subjected to tensile force, the reinforcing rib distributed along the length direction can share most of the tensile force like a skeleton, preventing the outer cladding layer 12 from excessive tensile deformation or rupture, and in the bending process, the longitudinally distributed reinforcing rib can also provide bending strength, reducing the local deformation and stress concentration of the outer cladding layer 12 at the bending part.

[0053] The waterproof outer layer 11 is a sealing layer made of TPU material, and a plurality of longitudinal grooves 15 are arranged on the side of the waterproof outer layer 11 and the shielding outer layer 10.

[0054] The TPU material has high wear resistance, so that the waterproof outer layer 11 can maintain its integrity when subjected to external friction, scratching and other mechanical effects, and prevent the waterproof performance from being reduced due to outer layer wear. Meanwhile, the TPU has high elasticity and can adapt to the deformation of the wire harness under stretching, bending and other conditions without being easily broken. The excellent waterproof performance is due to the polar groups existing in the TPU molecular structure, which can prevent the penetration of water molecules and form an effective waterproof sealing layer.

[0055] The plurality of longitudinal grooves 15 are arranged on the side of the waterproof outer layer 11 and the shielding outer layer 10, which is mainly based on the deformation and stress release principle of the material. When the waterproof outer layer 11 is subjected to external pressure or stretching, the grooves 15 can provide additional deformation space. Since the TPU is an elastic material, it will deform during the stress process. The existence of the grooves 15 allows the waterproof outer layer 11 to have a certain expansion allowance in the thickness direction, avoiding the waterproof outer layer 11 from being broken or separated from the shielding outer layer 10 due to stress concentration. In addition, the grooves 15 also help to discharge the trace amount of water that may penetrate. By using gravity or capillary action, the water flows along the grooves 15, preventing the water from accumulating between the waterproof outer layer 11 and the shielding outer layer 10, thereby better protecting the dry environment inside the wire harness.

[0056] In the embodiment of the utility model, the tensile filling layer 5 is made of aramid fiber and rubber particle mixed filling material.

[0057] The aramid fiber provides the main tensile strength, and the rubber particles impart elasticity and flexibility to the filling layer, so that the tensile filling layer 5 can better adapt to the complex deformation of the wire harness while meeting the tensile requirements, and maintain good contact between the inner core 3 and the protective sleeve 4. The tensile filling layer 5 is filled between the protective sleeve 4 and the plurality of inner cores 3, and the purpose is to uniformly disperse the stress. When the wire harness is subjected to tensile force, the aramid fiber and rubber particles in the tensile filling layer 5 will work together. The aramid fiber bears the main stress along the tensile direction, and the rubber particles provide elastic support around, ensuring that the stress will not be concentrated in a certain point or area, thereby effectively protecting the inner core 3 and the protective sleeve 4, and preventing them from being damaged due to excessive local stress.

[0058] It is apparent for a person skilled in the art that the present application is not limited to the details of the above-described exemplary embodiments, but that it can be implemented in other concrete forms without departing from the spirit or the essential characteristics of the present application. Therefore, the embodiments should be considered in all respects as illustrative and not restrictive, the scope of the present application being defined by the appended claims rather than the above description, and all changes coming within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

Claims

1. A stretch spring wire bundle characterized in that, The spring wire body is spirally wound along a straight line, and both ends of the spring wire body are respectively provided with terminal heads; The spring wire body comprises a plurality of inner cores and a protective sleeve wrapped outside the plurality of inner cores, and a tensile filling layer is filled between the protective sleeve and the plurality of inner cores along the length direction of the spring wire body; Each of the plurality of inner cores comprises a plurality of twisted conductive wires, an insulating layer wrapped outside the plurality of conductive wires, a waterproof inner layer wrapped outside the insulating layer, and a shielding inner layer wrapped outside the waterproof inner layer; The protective sleeve is sequentially provided, from inside to outside, with a shielding outer layer, a waterproof outer layer wrapped outside the shielding outer layer, and an outer cladding layer wrapped outside the waterproof outer layer.

2. A stretch spring wire bundle according to claim 1, characterized in that The waterproof inner layer is made of rubber material, and an inner surface of the waterproof inner layer is provided with a plurality of annular protrusions uniformly distributed along the axial direction of the waterproof inner layer to be tightly connected with the insulating layer.

3. A stretch spring cord according to claim 1, wherein, The shielding inner layer is a composite structure of a metal foil and a woven mesh.

4. A stretch spring cord according to claim 1, wherein, The shielding outer layer is a metalized plastic film.

5. A stretch spring cord according to claim 1, wherein, The outer cladding layer is internally provided with a reinforcing rib structure, the reinforcing rib is a filamentous or sheet-like structure made of fiber-reinforced plastic, and is distributed along the length direction of the outer cladding layer.

6. A stretch spring cord according to claim 1, wherein, The waterproof outer layer is a sealing layer made of TPU material, and a side of the waterproof outer layer adhered to the shielding outer layer is provided with a plurality of longitudinal grooves.

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