One-to-multiple wire harness

Abstract

The utility model relates to the technical field of data lines, and particularly discloses a one-to-many wire harness, which comprises a plurality of strands of independent core wires, the starting ends of the core wires are uniformly connected to an input joint, the middle sections of the core wires are converged to form a bus harness, the tail ends of the core wires are branched to form a plurality of sub-wire groups, and each sub-wire group is respectively connected with an output joint; the bus thermal shrinkable sleeve is arranged on the bus bundle in a sleeving manner; a plurality of sub-line thermal shrinkable sleeves, wherein each sub-line group is sleeved with one sub-line thermal shrinkable sleeve; and the standard reinforcing blocks are fixed at the forks of the plurality of strands of independent core wires in an injection molding manner and are connected with the bus thermal shrinkable sleeve and the sub-wire thermal shrinkable sleeves. The one-to-multiple wire harness provided by the utility model can effectively reduce the mold opening cost caused by changing the length specification.

Description

Technical Field

[0001] This utility model relates to the field of data cable technology, and in particular to a one-to-many cable harness. Background Technology

[0002] The diversification of interfaces in current consumer electronics devices has led to the widespread use of multi-port cables. These cables significantly improve user device compatibility by integrating multiple interfaces. Traditional multi-port cables typically employ a multi-layer composite structure design, the core of which includes:

[0003] Multiple independent core wires are connected to a standard USB connector at their starting ends. After being combined in the middle section to form a bus bundle, they branch at the end to form several sub-wire groups. Each sub-wire group is connected to a Type-C, Lightning, or other output connector.

[0004] The insulating protective sheath includes a thick-diameter outer sheath that wraps around the busbar bundle, several thin-diameter outer sheaths that wrap around each group of sub-busbars, and reinforcing blocks that connect the thick-diameter outer sheath and each of the thin-diameter outer sheaths.

[0005] The current production process of insulating protective skin generally adopts integrated injection molding technology, that is, after multiple independent core wires are put into the injection mold cavity of the insulating protective skin, the coarse diameter outer skin, the fine diameter outer skin, and the reinforcing block are formed simultaneously in a single mold.

[0006] While this process ensures structural integrity and mechanical strength, it significantly restricts product specification adjustments.

[0007] When the length of the busbar harness and / or sub-busbars needs to be changed, a complete set of injection molds adapted to the new dimensions must be redeveloped. Because mold development involves precision machining and repeated adjustments, its cost typically accounts for 40%-60% of the total production investment, and the development cycle can take 2-4 weeks. This situation severely limits the speed of product iteration, forcing manufacturers to bear high mold replacement costs when responding to diverse market demands, especially when supplying multiple length specifications to different market segments, where cost pressures increase exponentially.

[0008] Therefore, it is necessary to improve the structure of the existing one-to-many data cable to reduce the mold opening cost caused by changing the length specification.

[0009] The information disclosed in this background section is included only to enhance the understanding of the context of this disclosure, and therefore may contain information that does not constitute prior art known to those skilled in the art. Utility Model Content

[0010] One objective of this invention is to provide a multi-wire harness that can effectively reduce the mold opening cost caused by changing the length specifications.

[0011] To achieve the above objectives, this utility model provides a multi-wire harness, comprising:

[0012] Multiple independent core wires are connected to the input connector at their starting ends. The middle sections of the core wires are combined to form a busbar bundle, and the ends are branched to form several sub-wire groups. Each sub-wire group is connected to an output connector.

[0013] Busbar heat shrink sleeve, wherein the busbar heat shrink sleeve is fitted onto the busbar bundle;

[0014] Several sub-wire heat shrink sleeves, with one sub-wire heat shrink sleeve fitted on each sub-wire group;

[0015] A standard reinforcing block is injection molded and fixed at the bifurcation of multiple independent core wires, and connects the busbar heat shrink sleeve and each of the sub-wire heat shrink sleeves.

[0016] Optionally, the input connector and each of the output connectors include a connector conductive element electrically connected to each of the core wires, and a connector insulating portion injection molded on the outside of the connector conductive element;

[0017] The ends of the busbar heat shrink sleeve and each of the sub-busbar heat shrink sleeves away from the standard reinforcing block are fixedly connected to the corresponding joint insulation part by in-mold injection molding.

[0018] Optionally, the input connector is a standard USB connector.

[0019] Optionally, the number of output connectors is two.

[0020] Optionally, both output connectors are Type-C connectors.

[0021] Optionally, one of the output connectors is a Type-C connector and the other is a Lightning connector.

[0022] Optionally, the number of output connectors is three.

[0023] Optionally, the three output connectors are a Type-C connector, a Lightning connector, and a Micro USB connector.

[0024] Optionally, the standard reinforcing block has a spherical structure.

[0025] The beneficial effects of this utility model are as follows: It provides a multi-wire harness that breaks down the traditional integral injection-molded insulating protective sheath into three independent components: a busbar heat shrink sleeve, a daughter wire heat shrink sleeve, and a standard reinforcing block. By using heat shrink sleeves to replace the traditional injection-molded coarse-diameter and fine-diameter outer sheaths, production flexibility is greatly improved—the heat shrink sleeve, as a universal tubing material, only needs to be heated and shrunk to fit the wire harness, and adjusting the length only requires cutting tubing of different sizes, without the need for re-molding;

[0026] The lengths of the busbar harness and the sub-busbars can be independently adjusted by cutting the corresponding heat-shrink sleeves, without interfering with each other. Meanwhile, the standard reinforcing block is fixed to the bifurcation point by injection molding. Its mold design only needs to be developed uniformly for the bifurcation structure. No matter how the lengths of the busbar harness and the sub-busbars change, the same mold can be reused, which avoids the cost of repeated mold opening and ensures the mechanical strength of the bifurcation point.

[0027] This design allows manufacturers to quickly launch products of various lengths simply by cutting and combining heat shrink tubing to meet market demands. This eliminates the need to bear the mold reset costs that account for 40%-60% of production costs in traditional processes. Furthermore, the production cycle is shortened from 2-4 weeks to instant adjustment, significantly reducing the cost and time pressure of product iteration while maintaining the structural reliability of key nodes.

[0028] Therefore, the multi-wire harness provided by this utility model can effectively reduce the mold opening cost caused by changing the length specifications. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of a multi-wire harness provided for an embodiment.

[0031] In the picture:

[0032] 1. Core wire; 101. Busbar bundle; 102. Sub-busbar group;

[0033] 2a. Input connector; 2b. Output connector; 201. Connector conductive part; 202. Connector insulating part;

[0034] 3. Busbar heat shrink sleeve;

[0035] 4. Heat shrink sleeve for the sub-line;

[0036] 5. Standard reinforcing block. Detailed Implementation

[0037] In this utility model, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment can be included in at least one embodiment of this utility model. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this utility model, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0038] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit the invention.

[0039] In the description of this utility model, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " generally indicates that the preceding and following objects have an "or" logical relationship.

[0040] In this invention, terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy, or order between these entities or operations.

[0041] Without further limitations, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this invention is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a series of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0042] Similar to the understanding in the Examination Guidelines, in this utility model, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments of this utility model, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.

[0043] In the description of the embodiments of this utility model, the space-related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the convenience of describing the specific embodiments of this utility model or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this utility model.

[0044] Unless otherwise expressly specified or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this utility model, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral setting; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. For those skilled in the art to which this utility model pertains, the specific meaning of the above terms in the embodiments of this utility model can be understood according to the specific circumstances.

[0045] See Figure 1 This utility model provides a one-to-many wire harness, comprising:

[0046] Multiple independent core wires 1 are connected to the input connector 2a at their starting ends. After the middle sections of the core wires 1 are combined to form a bus bundle 101, they branch at the ends to form several sub-wire groups 102. Each sub-wire group 102 is connected to an output connector 2b.

[0047] Busbar heat shrink sleeve 3, the busbar heat shrink sleeve 3 is sleeved on the busbar bundle 101;

[0048] Several sub-wire heat shrink sleeves 4, one sub-wire heat shrink sleeve 4 is fitted on each sub-wire group 102;

[0049] Standard reinforcing block 5, which is injection molded and fixed at the bifurcation of the multi-strand independent core wire 1, and connects the busbar heat shrink sleeve 3 and each of the sub-wire heat shrink sleeves 4.

[0050] The multi-wire harness provided in this embodiment separates the traditional integral injection-molded insulation protective sheath into three independent components: busbar heat shrink sleeve 3, daughter wire heat shrink sleeve 4, and standard reinforcing block 5. By using heat shrink sleeves to replace the traditional injection-molded coarse-diameter and fine-diameter outer sheaths, production flexibility is greatly improved—the heat shrink sleeve, as a universal tubing material, only needs to be heated and shrunk to fit the wire harness, and when adjusting the length, only tubing of different sizes needs to be cut, without the need to re-mold.

[0051] The lengths of the busbar harness 101 and the sub-busbar group 102 can be independently adjusted by cutting the corresponding heat shrink sleeves, without interfering with each other. At the same time, the standard reinforcing block 5 is fixed to the bifurcation point by injection molding. Its mold design only needs to be developed uniformly for the bifurcation structure. No matter how the lengths of the busbar harness 101 and the sub-busbar group 102 change, the same mold can be reused, which avoids the cost of repeated mold opening and ensures the mechanical strength of the bifurcation point.

[0052] This design allows manufacturers to quickly launch products of various lengths simply by cutting and combining heat shrink tubing to meet market demands. This eliminates the need to bear the mold reset costs that account for 40%-60% of production costs in traditional processes. Furthermore, the production cycle is shortened from 2-4 weeks to instant adjustment, significantly reducing the cost and time pressure of product iteration while maintaining the structural reliability of key nodes.

[0053] Therefore, the multi-wire harness provided by this utility model can effectively reduce the mold opening cost caused by changing the length specifications.

[0054] In this embodiment, the input connector 2a and each of the output connectors 2b each include a connector conductive element 201 electrically connected to each of the core wires 1, and a connector insulating part 202 injection molded on the outside of the connector conductive element 201;

[0055] The ends of the busbar heat shrink sleeve 3 and each of the sub-busbar heat shrink sleeves 4 away from the standard reinforcing block 5 are fixedly connected to the corresponding joint insulation part 202 by in-mold injection molding.

[0056] In the actual production process, the detailed steps are as follows:

[0057] ①The busbar heat shrink sleeve 3 is obtained by cutting according to the length of the busbar bundle 101, and the sub-branch heat shrink sleeve 4 is obtained by cutting according to the length of the sub-branch group 102;

[0058] ② Place the heat shrink sleeve 3 on the busbar bundle 101 and place the heat shrink sleeve 4 on each sub-line group 102;

[0059] ③Heat the busbar heat shrink sleeve 3 and the sub-line heat shrink sleeve 4, so that the busbar heat shrink sleeve 3 is heated and tightened on the busbar bundle 101, and each sub-line heat shrink sleeve 4 is heated and tightened on the corresponding sub-line group 102.

[0060] ④ Place the bifurcation of each core wire 1 into the mold cavity of the standard reinforcing block 5, and manufacture the standard reinforcing block 5 by in-mold injection molding process;

[0061] ⑤ Connect the starting ends of each core wire 1 to the connector conductive part 201 of the input connector 2a, and then manufacture the connector insulating part 202 of the input connector 2a by in-mold injection molding process;

[0062] ⑥ Connect each of the sub-wire groups 102 sequentially to the connector conductive part 201 of the corresponding output connector 2b, and then manufacture the connector insulating part 202 of each of the output connectors 2b by in-mold injection molding process.

[0063] In this embodiment, the input connector 2a is a standard USB connector.

[0064] In this embodiment, the number of output connectors 2b is two. Optionally:

[0065] Both output connectors 2b are Type-C connectors; the latest Apple phones have adopted Type-C interfaces, and both output connectors 2b are Type-C connectors, which can enable simultaneous charging of two devices;

[0066] Alternatively, one of the output connectors 2b may be a Type-C connector, and the other may be a Lightning connector. The Lightning connector is compatible with older Apple phones, while the Type-C connector is compatible with Android phones or the latest Apple phones.

[0067] In some other embodiments, the number of output connectors 2b is three. The three output connectors 2b are a Type-C connector, a Lightning connector, and a Micro USB connector.

[0068] In this embodiment, the standard reinforcing block 5 is a spherical structure. From a mechanical perspective, the uniform symmetry of the sphere allows the standard reinforcing block 5 to evenly distribute the complex stresses (such as tension, torsion, and bending) at the wire bifurcation point along the curved surface, avoiding the local stress concentration phenomenon common in traditional right-angle bifurcation and significantly improving fracture resistance. This characteristic is particularly suitable for the high-frequency bending scenarios of modern data cables. For example, when connecting a mobile device and a power bank simultaneously with dual Type-C interfaces, the spherical structure at the bifurcation point can withstand the multi-directional forces generated by changes in the device's placement angle. Experimental data shows that its bending life is more than 3 times higher than that of traditional designs. At the same time, the geometric versatility of the spherical mold perfectly matches the core requirement of the patent "no need for repeated mold opening"—a single spherical mold can adapt to product lines with different wire diameter specifications. The material filling uniformity during injection molding is 20% higher than that of the angular structure, which not only reduces the scrap rate but also forms a cost control combination of "fixed mold + flexible sleeve" with the heat shrink sleeve cutting process.

[0069] From a user experience perspective, the streamlined curved surface of the spherical structure eliminates sharp edges, avoiding the awkwardness of snagging on items inside the bag, and improving the feel of operation through its ergonomic grip. For example, when a user is charging two phones simultaneously using both Lightning and Type-C interfaces, their fingers naturally pinch the bifurcation of the sphere to adjust the cable routing, and its surface curvature reduces discomfort from prolonged gripping. Furthermore, the compact spherical space utilization saves approximately 20% of volume compared to a cubic design, which is crucial for storing multi-interface data cables.

[0070] In summary, the multi-wire harness provided in this embodiment has the following advantages:

[0071] (1) Flexible and adjustable line length specifications

[0072] By cutting and combining the busbar heat shrink sleeve 3 and the sub-bus heat shrink sleeve 4, the lengths of the busbar bundle 101 and the sub-bus group 102 can be quickly adjusted without re-molding, adapting to different application scenarios (such as 1-meter / 2-meter wire lengths). Traditional injection molding processes require separate molds for each length, while this design reduces mold costs by more than 60% and shortens the production cycle from several weeks to instant adjustment.

[0073] (2) Strengthening the mechanical strength at the bifurcation point

[0074] The standard reinforcing block 5 (especially the spherical structure) fixes the bifurcation point through injection molding, evenly distributing the tensile stress of the multi-strand core wire 1. Experiments show that its bending life is 3 times higher than that of the traditional unreinforced design, and the spherical mold can be adapted to products with different wire diameters, avoiding repeated mold opening.

[0075] (3) Multi-device compatibility

[0076] It supports free combination of multiple output connectors such as Type-C, Lightning, and Micro USB (e.g., dual Type-C, Type-C + Lightning), solving the need for mixing new and old devices with a single cable. For example, it can charge an iPhone 15 (Type-C) and older AirPods (Lightning) at the same time.

[0077] (4) Cost control and rapid iteration

[0078] Heat shrink tubing, as a general-purpose material, replaces customized injection-molded outer sheaths, allowing manufacturers to respond to market demand by simply stocking a few specifications of heat shrink tubing and cutting them accordingly. For example, a product line that originally required developing five sets of molds (corresponding to different lengths) can be simplified to one set of molds + heat shrink tubing cutting, significantly reducing inventory pressure.

[0079] Finally, it should be noted that although the above embodiments have been described in the text and drawings of this application, this should not limit the scope of patent protection of this application. Any technical solutions that are based on the essential concept of this application and utilize the content described in the text and drawings of this application, resulting in equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this application.

Claims

1. A one-to-many beam, characterized in that, The utility model relates to a kind of standard USB cable, including: Multiple independent core wires (1), the starting end of each of the core wire (1) is uniformly connected to input connector (2a), the middle section of each of the core wire (1) is converged to form bus bar bundle (101), and then bifurcate to form several sub-line groups (102) at the end, each of the sub-line group (102) is connected with an output connector (2b) respectively; Bus hot shrink sleeve (3), the bus hot shrink sleeve (3) is sleeved on the bus bar bundle (101); Several sub-line hot shrink sleeves (4), each of the sub-line group (102) is sleeved with one of the sub-line hot shrink sleeves (4); Standard reinforcing block (5), the standard reinforcing block (5) is injection molded in the bifurcation of multiple independent core wires (1), and is connected with the bus hot shrink sleeve (3) and each of the sub-line hot shrink sleeve (4).

2. The one-to-many beam of claim 1, wherein, The input connector (2a) and each of the output connector (2b) includes connector conductive part (201) electrically connected with each of the core wire (1), and connector insulating part (202) injection molded outside the connector conductive part (201); Wherein, the bus hot shrink sleeve (3) and each of the sub-line hot shrink sleeve (4) are connected with corresponding connector insulating part (202) in-mold injection fixedly at the end away from the standard reinforcing block (5).

3. The one-to-many beam of claim 1, wherein, The input connector (2a) is standard USB connector.

4. The one-to-many beam of claim 1, wherein, The number of the output connector (2b) is two.

5. The one-to-many beam of claim 4, wherein, Two output connectors (2b) are TypeC connector.

6. The one-to-many beam of claim 4, wherein, One of the output connector (2b) is TypeC connector, and the other output connector (2b) is Lightning connector.

7. The one-to-many beam of claim 1, wherein, The number of the output connector (2b) is three.

8. The one-to-many beam of claim 7, wherein, Three output connectors (2b) are TypeC connector, Lightning connector and Micro USB connector respectively.

9. The one-to-many beam of claim 1, wherein, The standard reinforcing block (5) is spherical structure.

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