Lightweight wire harness assembly

Abstract

The utility model discloses a lightweight wire harness assembly, which relates to the technical field of leads and comprises a lead and a connector lug, the lead is fixedly mounted on the connector lug, a movably connected wire harness sleeve is arranged on the outer side of the lead, the wire harness sleeve comprises a plurality of elastic sleeves and connecting wires, the connecting wires are fixedly mounted on the side end surfaces of the elastic sleeves, and the elastic sleeves are fixedly connected with the connecting wires. Adjacent elastic sleeves are fixed through connecting wires, adhesive stickers are arranged at the bottoms of the elastic sleeves, release paper is arranged on the outer sides of the adhesive stickers, branching protrusions are evenly arranged on the inner end faces of the elastic sleeves, and the wires comprise conductive copper wires and insulating skins. The wire harness has the advantages of being easy to wire, enhancing protection, optimizing heat dissipation and prolonging the service life, and solves the problems that a traditional wire harness is easy to damage in a complex or severe environment, long-distance wiring is inconvenient, and heat is accumulated between wires.

Description

Technical Field

[0001] This utility model relates to the field of wire technology, specifically to a lightweight wire harness assembly. Background Technology

[0002] In modern electronic devices and electrical systems, wire harnesses serve as a bridge connecting different electrical components, and their importance is self-evident. However, with technological advancements, the requirements for wire harnesses are constantly increasing, including but not limited to demands for lightweight design, flexibility, durability, and safety. Traditional wire harness assemblies typically consist of conductors and an outer insulating material.

[0003] While these designs can meet basic electrical connection requirements, they still face some challenges in practical applications. Traditional wire harnesses lack effective protection measures, especially in complex or harsh working environments, and are easily damaged by factors such as friction and impact. When wiring over long distances, due to the lack of reasonable constraint mechanisms, the wires are prone to scattering, which not only affects aesthetics but may also cause signal interference or physical damage due to misalignment or twisting. Densely arranged wires can lead to heat accumulation, thereby affecting wire performance and even causing safety hazards. Therefore, a lightweight wire harness assembly is needed to solve the above problems. Summary of the Invention

[0004] The purpose of this utility model is to provide a lightweight wire harness assembly that has the advantages of easy wiring, enhanced protection, optimized heat dissipation and extended service life, and solves the problems of traditional wire harnesses being easily damaged in complex or harsh environments, inconvenient for long-distance wiring, and heat accumulation between wires.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a lightweight wire harness assembly, including a wire and a connector, wherein the wire is fixedly mounted on the connector, and a movably connected wire harness sleeve is provided on the outside of the wire;

[0006] The wire harness includes several elastic sleeves and connecting wires. The connecting wires are fixedly installed on the side end face of the elastic sleeves. Adjacent elastic sleeves are fixed together by the connecting wires. The bottom of the elastic sleeve is provided with self-adhesive, and the outside of the self-adhesive is provided with release paper. The inner end face of the elastic sleeve is uniformly provided with branching protrusions. The wires include conductive copper wires and insulating sheaths.

[0007] Furthermore, the top and bottom of the elastic sleeve are provided with cavities, and the upper end face of the cavity is provided with a vent hole.

[0008] Furthermore, the elastic sleeve is provided with fixing heads on both the left and right sides, and the connecting wire is fixedly installed on the fixing heads.

[0009] Furthermore, the elastic sleeve is made of silicone, and the connecting wire is made of nylon.

[0010] Furthermore, the insulating layer includes an insulating layer, a tensile layer, and an abrasion-resistant layer. The insulating layer is made of PVC material, the tensile layer is made of PE material, and the abrasion-resistant layer is made of TPU material.

[0011] Furthermore, the conductor has an elliptical structure.

[0012] Furthermore, the release paper has an outwardly curled edge.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0014] Through the combination of elastic sleeves and connecting wires, adjacent elastic sleeves can move synchronously with the connecting wires, solving the problem of inconvenient operation for long-distance wiring. At the same time, it avoids localized stress concentration caused by dragging. The branching protrusions on the inner wall of the elastic sleeves create a fixed spacing between the wires, which not only prevents misalignment and twisting, but also promotes heat dissipation through the gaps, reducing the performance degradation of the wires caused by heat accumulation or mutual friction. The bottom adhesive combined with the release paper design allows the wire harness to be quickly pasted and fixed to the equipment surface, avoiding the risk of wear and breakage caused by suspended swinging, and significantly improving the stability and safety of wiring.

[0015] The cavities at the top and bottom of the elastic sleeve form a damping buffer mechanism through vent holes. When subjected to external impact, the energy is absorbed by the slow release of gas, effectively reducing vibration damage to the wires inside the harness. The elastic sleeve made of silicone material has both flexibility and anti-aging properties. Combined with the umbrella-shaped fixing head for a stable connection of the nylon connecting wire, it not only prevents the connecting wire from cutting the elastic sleeve, but also improves the tensile strength of the overall structure. This combination design ensures lightweight while effectively dispersing mechanical stress under complex working conditions, thus extending the service life of the harness.

[0016] By using elliptical conductors to increase the contact area and optimize conductivity, their longitudinal bending and lateral torsion resistance characteristics better meet the spatial deformation requirements of actual wiring scenarios. The three-layer composite insulation layer, through the synergistic effect of materials, reduces the insulation thickness while taking into account flexibility, tensile strength and wear resistance. This solves the problem of bulkiness caused by excessively thick insulation layers in traditional wire harnesses, as well as the defect of a single material being unable to balance mechanical and electrical properties. The curled edge structure of the release paper further simplifies the installation operation and improves wiring efficiency. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0018] Figure 2 This is a top view of the present invention;

[0019] Figure 3 For the present utility model Figure 2 Sectional view of AA in the middle;

[0020] Figure 4 For the present utility model Figure 3 Enlarged view at point B in the middle;

[0021] Figure 5 For the present utility model Figure 4 Cross-sectional view of the cable bundle CC.

[0022] In the diagram: 1. Wire; 101. Conductive copper wire; 102. Insulating sheath; 1021. Insulating layer; 1022. Tensile layer; 1023. Wear-resistant layer; 2. Connector; 3. Cable bundle sleeve; 301. Elastic sleeve; 3011. Cavity; 3012. Vent hole; 3013. Branching protrusion; 3014. Adhesive; 302. Connecting wire; 3021. Fixing head; 303. Release paper; 3031. Curved edge. Detailed Implementation

[0023] Please see Figures 1-5 A lightweight wire harness assembly includes a wire 1 and a connector 2. The wire 1 is fixedly mounted on the connector 2, and a movably connected wire harness sleeve 3 is provided on the outside of the wire 1.

[0024] The cable tie 3 includes several elastic sleeves 301 and connecting wires 302. The connecting wires 302 are fixedly installed on the side end face of the elastic sleeves 301. Adjacent elastic sleeves 301 are fixed together by the connecting wires 302. The bottom of the elastic sleeve 301 is provided with self-adhesive tape 3014. Release paper 303 is provided on the outside of the self-adhesive tape 3014. The inner end face of the elastic sleeve 301 is uniformly provided with branching protrusions 3013. The wire 1 includes conductive copper wire 101 and insulating sheath 102.

[0025] A wire harness sleeve 3 is fitted over the outer end of the wire 1. The wire 1 is constrained by the elastic sleeve 301 to prevent it from spreading out. The inner end face of the elastic sleeve 301 is provided with a wire separation protrusion 3013 to isolate each wire 1 from each other, while leaving a certain distance for heat dissipation, reducing mutual influence between the wires 1, and preventing the wires 1 from being misaligned or twisted. A connecting line 302 is provided between adjacent elastic sleeves 301. When the wire 1 is too long, dragging the head elastic sleeve 301 will move the rear elastic sleeve 301 together through the connecting line 302. Adhesive 3014 and release paper 303 are provided at the bottom of the elastic sleeve 301 so that the wire harness can be pasted on the inner end face of the equipment, preventing the wire harness from being suspended and frequently rubbing against other equipment during use, which could cause damage or breakage to the wire 1.

[0026] Furthermore, the top and bottom of the elastic sleeve 301 are provided with cavities 3011, and the upper end face of the cavity 3011 is provided with a vent hole 3012.

[0027] The cavity 3011 enhances the elasticity of the elastic sleeve 301. When the elastic sleeve 301 is impacted, it can slowly release air through the vent hole 3012, thereby forming a damping buffer, improving the impact resistance of the wire harness, and reducing the weight of the elastic sleeve 301.

[0028] Furthermore, the elastic sleeve 301 is provided with fixing heads 3021 on both the left and right sides, and the connecting wire 302 is fixedly installed on the fixing heads 3021.

[0029] The fixing head 3021 has an umbrella-shaped structure. The fixing head 3021 fixes the connecting wire 302, preventing the fixing wire from slipping out of the elastic sleeve 301. At the same time, it increases the force-bearing area of ​​the elastic sleeve 301, preventing the connecting wire 302 from cutting the elastic sleeve 301 during the pulling process.

[0030] Furthermore, the elastic sleeve 301 is made of silicone, and the connecting wire 302 is made of nylon.

[0031] The silicone elastic sleeve 301 has sufficient elasticity to provide excellent cushioning and impact resistance. Its soft material prevents scratches on the insulation 102 during installation. It also has good anti-aging properties, extending the service life of the wire harness assembly. The nylon connecting wire 302 has high structural strength, preventing breakage during pulling. Its soft material also allows the elastic sleeve 301 to be adjusted within a certain range.

[0032] Furthermore, the insulating layer 102 includes an insulating layer 1021, a tensile layer 1022, and an abrasion-resistant layer 1023. The insulating layer 1021 is made of PVC material, the tensile layer 1022 is made of PE material, and the abrasion-resistant layer 1023 is made of TPU material.

[0033] The insulation layer 1021 is soft and has excellent insulation performance. PE has higher tensile strength than PVC, which improves the tensile strength of the conductor 1. PU is not only wear-resistant, but also has good elastic recovery ability, which can maintain its performance even in harsh environments. The three-layer composite insulation 102 not only improves the service life compared with the traditional insulation 102, but also reduces the thickness of the insulation 102 and reduces the weight of the wire harness.

[0034] Furthermore, conductor 1 has an elliptical structure.

[0035] After multiple sets of conductors 1 are arranged in parallel, the elliptical structure of conductors 1 makes the wire harness easy to bend longitudinally but not laterally, and increases the conductive area, making it more suitable for the application scenarios of the wire harness.

[0036] Furthermore, the release paper 303 has an outwardly curled edge 3031 on its edge.

[0037] The outward-curling edge 3031 structure allows for quick and easy release of the release paper 303, making it easier to attach the elastic sleeve 301 to the surface of the equipment and improving the convenience of wiring.

[0038] Before installing the lightweight wire harness assembly, carefully check that all components, including wires 1, connectors 2, and harness sleeves 3, are complete and undamaged. Estimate the harness length based on the actual usage scenario, plan the wiring path, and determine the pasting location. Prepare auxiliary tools such as scissors and a cleaning cloth. Place the elastic sleeves 301 sequentially over the outside of the wires 1, using their branching protrusions 3013 to isolate the wires 1 and maintain spacing. Adjacent elastic sleeves 301 are secured by connecting wires 302 to ensure the continuity of the harness sleeves 3. When wiring, hold the wire harness by hand. The head elastic sleeve 301 moves along the planned path. When the wire 1 is too long, drag the head elastic sleeve 301 through the connecting wire 302 to drive the rear elastic sleeve 301. Note that because the wire 1 has an elliptical structure, it is advisable to bend it longitudinally and avoid bending it laterally when wiring to avoid excessive friction and collision between the wire harness and other equipment. After the wire harness is in place, wipe the adhesive surface of the equipment with a cleaning cloth. Pinch the curled edge 3031 of the release paper 303 from one corner of the bottom of the elastic sleeve 301 and peel it off. Adhere the bottom surface of the elastic sleeve 301 to the inner end face of the equipment and press it firmly to complete the overall fixation.

[0039] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A lightened wiring harness assembly comprising a wire (1) and a terminal (2), the wire (1) being fixedly mounted on the terminal (2), characterized in that: The outer side of the wire (1) is provided with a movable connection wire sleeve (3); The wire sleeve (3) comprises a plurality of elastic sleeves (301) and connecting lines (302), the connecting lines (302) are fixedly installed on the side end face of the elastic sleeve (301), adjacent elastic sleeves (301) are fixed through the connecting lines (302), the bottom of the elastic sleeve (301) is provided with a non-dry adhesive (3014), the outer side of the non-dry adhesive (3014) is provided with release paper (303), the inner end face of the elastic sleeve (301) is uniformly provided with a wire distribution protrusion (3013), and the wire (1) comprises a conductive copper wire (101) and an insulating skin (102).

2. A light weight wiring harness assembly as claimed in claim 1, wherein: The top and bottom of the elastic sleeve (301) are provided with cavities (3011), and the upper end face of the cavity (3011) is provided with a gas vent (3012).

3. A light weight wiring harness assembly as claimed in claim 1, wherein: The left and right sides of the elastic sleeve (301) are provided with fixed heads (3021), and the connecting lines (302) are fixedly installed on the fixed heads (3021).

4. A lightweight wiring harness assembly as defined in claim 1, wherein: The elastic sleeve (301) is made of silica gel material, and the connecting line (302) is made of nylon material.

5. A lightweight wiring harness assembly as defined in claim 1, wherein: The insulating skin (102) comprises an insulating layer (1021), a tensile-resistant layer (1022) and a wear-resistant layer (1023), the insulating layer (1021) is made of PVC material, the tensile-resistant layer (1022) is made of PE material, and the wear-resistant layer (1023) is made of TPU material.

6. A light weight wiring harness assembly as claimed in claim 1, wherein: The wire (1) is of an oval structure.

7. A light weight wiring harness assembly as claimed in claim 1, wherein: The edge of the release paper (303) is provided with an outwardly rolled up edge (3031).

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