Safe sealing wire harness structure formed by winding
By employing a four-layer gradient winding structure and end composite sealing design, combined with materials such as polytetrafluoroethylene-doped carbon nanotubes, alternating winding of silicone rubber/fluororubber, and nickel-titanium shape memory alloy, the interlayer bonding force and dynamic sealing problems of traditional wound wire harnesses in extreme environments have been solved, achieving a high-performance wire harness structure.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-24
- Publication Date
- 2026-04-03
AI Technical Summary
Traditional wound safety sealing harnesses suffer from insufficient interlayer bonding and weak dynamic sealing under extreme environments, making it difficult to meet high-performance requirements.
It adopts a four-layer gradient winding structure and an end composite sealing structure, combined with in-situ polymerization winding process and ultraviolet curing, and uses materials such as polytetrafluoroethylene-doped carbon nanotubes, alternating winding of silicone rubber/fluororubber, corrugated TPU elastomer and nickel-titanium shape memory alloy to enhance interlayer bonding and sealing effect.
It improves the interlayer bonding strength and dynamic sealing performance of the wire harness, enabling it to maintain stability and sealing performance in extreme environments and adapt to the usage requirements of different environments.
Smart Images
Figure CN224082218U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of wire harness technology, specifically to a safety-sealed wire harness structure formed by winding. Background Technology
[0002] Wire harnesses have wide applications in modern industry and daily life, and are an indispensable component of many electrical devices. In products such as machinery, automobiles, and home appliances, the use of wire harnesses makes the wiring arrangement more organized and orderly, facilitating wiring layout and troubleshooting.
[0003] Traditional wound-wound safety sealed wire harnesses are manufactured using a multi-layer winding process, offering numerous advantages. They possess excellent sealing properties, effectively preventing moisture, dust, oil, and other impurities from entering the harness and protecting the wires from external environmental corrosion. They also offer good protection, resisting a certain degree of physical damage, such as friction and impact. Furthermore, they exhibit high reliability, enabling stable operation for extended periods in relatively stable environments, making them suitable for harsh environments with high wire harness performance requirements, such as high-temperature, humid, vibration, and corrosive conditions.
[0004] However, with the continuous development and progress of technology in various fields, the requirements for wire harness performance are also constantly increasing. Traditional wound sealed wire harnesses have exposed many problems in extreme environments:
[0005] (1) Insufficient interlayer bonding: In multilayer winding structures, the expansion coefficients of different materials are different. Under the action of long-term thermal cycling or mechanical vibration, the interlayers rely only on physical adhesion and lack chemical bonding, which makes the multilayer winding interface prone to delamination.
[0006] (2) Weak dynamic sealing: Existing end sealing methods, such as potting and heat shrink tubing, do not perform well in scenarios with frequent bending or dynamic displacement. Traditional potting has high brittleness after curing and is prone to micro-cracks under high-frequency vibration, thus destroying the sealing effect.
[0007] To meet ever-increasing performance requirements, developing a new type of wound-molded safety sealed wire harness structure is of significant practical importance. Utility Model Content
[0008] Purpose of the utility model: In order to overcome the above shortcomings, the purpose of this utility model is to provide a safe and sealed wire harness structure with a reasonable design. It adopts a combination of a four-layer gradient winding structure and a composite sealing structure at the end, which can meet the safety and sealing requirements of wire harnesses in different fields and environments, and has broad application prospects.
[0009] Technical solution: A safety sealed wire harness structure formed by winding includes a wire harness body and composite sealing structures disposed at both ends of the wire harness body; wherein, the wire harness body includes, from the inside to the outside, a conductor, a basic insulation layer, a gradient sealing layer, a dynamic buffer layer and a protective layer, and the composite sealing structure includes a corrugated sealing sleeve and a dual-phase sealant filled in the corrugated sealing sleeve.
[0010] The safety sealed wire harness structure described in this utility model adopts a design combining a four-layer gradient winding structure and an end composite sealing structure. The four-layer gradient winding structure includes a base insulation layer, a gradient sealing layer, a dynamic buffer layer, and a protective layer sequentially disposed outside the conductor. It is manufactured through an in-situ polymerization winding process, and ultraviolet light curing is carried out simultaneously during the winding process to achieve chemical cross-linking between the layers and improve the interlayer bonding force. The end composite sealing structure includes a corrugated sealing sleeve and a dual-phase sealant, which has a good sealing effect.
[0011] Furthermore, the sealing interface between the wire harness body and the composite sealing structure is laser-etched with micron-level grooves with a depth of 10~50μm, which can increase the anchoring effect and improve the stability of the seal.
[0012] Furthermore, in the aforementioned wound-formed safety sealed wire harness structure, the basic insulation layer is made of polytetrafluoroethylene-doped carbon nanotube material.
[0013] The basic insulation layer uses a combination of polytetrafluoroethylene (PTFE) and carbon nanotubes. PTFE itself has good insulation properties, while the addition of carbon nanotubes enhances its thermal conductivity and creep resistance. A suitable doping concentration of carbon nanotubes in the basic insulation layer is 3-5 wt%.
[0014] Furthermore, in the aforementioned wound-molded safety sealed wire harness structure, the gradient sealing layer is formed by alternating winding of silicone rubber and fluororubber.
[0015] The gradient sealing layer is made of alternating layers of silicone rubber and fluororubber. Silicone rubber has good flexibility and resistance to high and low temperatures, while fluororubber has excellent resistance to chemical corrosion. The alternating winding of the two can give full play to their respective advantages, improving the sealing performance of the wire harness and its adaptability to different environments.
[0016] Furthermore, in the aforementioned wound safety sealed wire harness structure, the gradient sealing layer adopts a 7-layer alternating winding structure, including 4 layers of silicone rubber near the base insulation layer and 3 layers of fluororubber near the dynamic buffer layer, with a single layer thickness of 0.2~0.5mm and a cross-winding angle of 45°.
[0017] The inner four layers of silicone rubber (Shore hardness around 50A) closest to the base insulation layer preferentially absorb thermal expansion stress, while the outer three layers of fluororubber (Shore hardness around 75A) closest to the dynamic buffer layer provide chemical protection. The use of a 45° cross-wrap angle can reduce interlayer shear stress.
[0018] Furthermore, in the above-mentioned wound safety sealed wire harness structure, the dynamic buffer layer (14) is made of corrugated TPU elastomer, and the geometric parameters are set as follows: the corrugated wavelength λ is 5~10mm, the corrugated amplitude h is 1~3mm, and the wall thickness t is 1~2mm.
[0019] The dynamic buffer layer uses a corrugated TPU (thermoplastic polyurethane) elastomer, which can stretch 10-30% axially and has a radial compressive strength of 40-70 MPa. This design allows the harness to absorb energy through the deformation of the dynamic buffer layer when subjected to axial tension or radial pressure, thus protecting the internal structure.
[0020] Furthermore, in the aforementioned wound-formed safety sealed wire harness structure, the protective layer is a Kevlar / graphene composite braided layer.
[0021] Kevlar is characterized by high strength and high modulus, while graphene has good electrical and thermal conductivity. The protective layer made by weaving the two together can provide reliable mechanical protection and electromagnetic shielding for the wire harness.
[0022] Furthermore, in the aforementioned wound-molded safety sealing wire harness structure, the corrugated sealing sleeve is made of nickel-titanium shape memory alloy.
[0023] The corrugated sealing sleeve is made of nickel-titanium shape memory alloy. This alloy has the characteristic of temperature-triggered contraction. When the temperature reaches a set value, the corrugated sealing sleeve will contract to compensate for the sealing gap and improve the sealing effect.
[0024] Among them, the phase transformation temperature of nickel-titanium shape memory alloy can be set to 80°C, which can cover common working conditions. That is, when the temperature reaches 80°C, the corrugated sealing sleeve will undergo a phase transformation and shrink to compensate for the sealing gap.
[0025] Furthermore, in the aforementioned wound-molded safety sealed wire harness structure, the dual-phase sealant comprises an inner layer of flexible silicone and an outer layer of epoxy-polyurethane.
[0026] The inner layer of the dual-phase sealant is made of flexible silicone, which has good vibration resistance, while the outer layer is made of epoxy-polyurethane, which has excellent chemical corrosion resistance. This dual-phase sealant design can simultaneously meet the sealing requirements of wire harness ends in vibration and corrosive environments.
[0027] The beneficial effects of this utility model are as follows: The safety sealed wire harness structure of this utility model is reasonably designed, combining a four-layer gradient winding structure with a composite sealing structure at the ends; wherein, the basic insulation layer is made of polytetrafluoroethylene doped with carbon nanotubes, which has excellent insulation performance; the gradient sealing layer is made of alternating winding of silicone rubber and fluororubber, combining the good flexibility and high and low temperature resistance of silicone rubber with the excellent chemical corrosion resistance of fluororubber, and the alternating winding of the two can adapt to different environmental conditions, improving the sealing performance of the wire harness; the dynamic buffer layer is made of corrugated TPU elastomer, which can absorb the stress through deformation when the wire harness is subjected to axial tension or radial pressure. It absorbs energy and protects the internal structure. The protective layer uses a Kevlar / graphene composite braided layer. The high strength and high modulus of Kevlar can provide reliable mechanical protection for the wire harness, preventing damage from external forces during installation and use. The good electrical and thermal conductivity of graphene can achieve electromagnetic shielding and heat dissipation functions. The composite sealing structure at the end includes a corrugated sealing sleeve and a dual-phase sealant. The corrugated sealing sleeve uses a nickel-titanium shape memory alloy, which can compensate for the sealing gap through shrinkage and improve the sealing effect. The inner flexible silicone of the dual-phase sealant has good vibration resistance, and the outer epoxy-polyurethane has excellent chemical corrosion resistance, which can simultaneously meet the sealing requirements of the wire harness end in vibration and corrosive environments. Attached Figure Description
[0028] Figure 1 This is an overall cross-sectional view of the safety sealed wire harness structure wound and molded according to the present invention;
[0029] Figure 2 This is an enlarged schematic diagram of point A of the winding-molded safety sealed wire harness structure described in this utility model;
[0030] Figure 3 This is a schematic diagram of the composite sealing structure of the safety sealing wire harness structure wound and molded according to the present invention;
[0031] In the diagram: 1. Main body of wire harness, 11. Wire, 12. Basic insulation layer, 13. Gradient sealing layer, 14. Dynamic buffer layer, 15. Protective layer, 2. Composite sealing structure, 21. Corrugated sealing sleeve, 22. Duplex sealant. Detailed Implementation
[0032] The following is in conjunction with the appendix Figure 1 , 2 Examples 1 and 2 further illustrate this utility model.
[0033] Example 1
[0034] like Figure 1 , 2As shown in Figure 3, the safety sealed wire harness structure of the present invention is formed by winding. The wire harness body 1 adopts a four-layer gradient winding structure, including a basic insulation layer 12, a gradient sealing layer 13, a dynamic buffer layer 14 and a protective layer 15 arranged sequentially outside the conductor 11. The composite sealing structure 2 at both ends of the wire harness body 1 includes a corrugated sealing sleeve 21 and a biphase sealant 22 filled in the corrugated sealing sleeve 21.
[0035] The basic insulation layer 12 is a combination of polytetrafluoroethylene (PTFE) and carbon nanotubes. PTFE has excellent insulation properties, while the addition of carbon nanotubes enhances its thermal conductivity and creep resistance. The gradient sealing layer 13 is formed by alternating winding of silicone rubber and fluororubber. Silicone rubber has good flexibility and resistance to high and low temperatures, while fluororubber has excellent chemical corrosion resistance. The dynamic buffer layer 14 uses a corrugated TPU elastomer, which is axially stretchable by 10-30% and radially compressive strength of 40-70 MPa. It is used to absorb energy through deformation to protect the internal structure when subjected to axial tension or radial pressure. The protective layer 15 is a Kevlar / graphene composite braided layer. Kevlar has high strength and high modulus, while graphene has good electrical and thermal conductivity. This protective layer provides mechanical protection and electromagnetic shielding for the wire harness. The corrugated sealing sleeve 21 is made of nickel-titanium shape memory alloy and has temperature-triggered contraction characteristics. When the temperature reaches a set value, the corrugated sealing sleeve contracts to compensate for the sealing gap and improve the sealing effect. The inner flexible silicone layer of the dual-phase sealant 22 has good vibration resistance, while the outer epoxy-polyurethane layer has excellent chemical corrosion resistance, which can simultaneously meet the sealing requirements of the wire harness end under vibration and corrosion environments.
[0036] Furthermore, the aforementioned wire harness structure is manufactured using an in-situ polymerization winding process, during which ultraviolet light curing is performed simultaneously to achieve chemical cross-linking between layers and improve interlayer bonding strength.
[0037] Example 2
[0038] Based on the structural foundation of Embodiment 1 and above, such as Figure 1 , 2 As shown in Figure 3.
[0039] The safety sealed wire harness structure with winding molding described in this utility model has a carbon nanotube material doping amount of 3~5wt% in the basic insulation layer 12.
[0040] Furthermore, the gradient sealing layer 13 adopts a 7-layer alternating winding structure, including 4 layers of silicone rubber close to the base insulation layer 12 for preferential absorption of thermal expansion stress, and 3 layers of fluororubber close to the dynamic buffer layer 14 for providing chemical protection. The thickness of a single layer is 0.2~0.5mm, and the cross-winding angle is 45°, which can reduce interlayer shear stress.
[0041] Furthermore, the geometric parameters of the dynamic buffer layer 14 are set as follows: the ripple wavelength λ is 5~10mm, the ripple amplitude h is 1~3mm, and the wall thickness t is 1~2mm.
[0042] Furthermore, the phase transformation temperature of the nickel-titanium shape memory alloy of the corrugated sealing sleeve 21 is set to 80°C, which can cover common working conditions. That is, when the temperature reaches 80°C, the corrugated sealing sleeve will undergo a phase transformation and shrink to compensate for the sealing gap.
[0043] Furthermore, the fabrication of the safety-sealed wire harness structure formed by winding according to this utility model includes the following steps:
[0044] Step 1: Select a conductor 11 that meets the specifications and clean the conductor 11 to remove impurities, oil, etc. from the surface to ensure that the subsequent base insulation layer can adhere well to the conductor.
[0045] Step 2: Using an in-situ polymerization winding process, polytetrafluoroethylene-doped carbon nanotube material is wound onto the surface of the conductor 11 to obtain the basic insulation layer 12. During the winding process, ultraviolet light curing is performed simultaneously to achieve chemical cross-linking between the basic insulation layer 12 and the conductor 11, thereby improving the bonding strength.
[0046] Step 3: The gradient sealing layer 13 is made of alternating silicone rubber and fluororubber, using a 7-layer alternating winding structure. The 4 layers closest to the base insulation layer are silicone rubber, and the 3 layers closest to the dynamic buffer layer are fluororubber. The cross winding angle is 45°. The in-situ polymerization winding process is also used. Ultraviolet light curing is carried out during the winding process to achieve chemical cross-linking between the layers.
[0047] Step 4: Place the corrugated TPU elastomer onto the wire harness as a dynamic buffer layer 14, ensuring that the dynamic buffer layer 14 is tightly fitted with the gradient sealing layer 13 and can absorb energy through deformation when the wire harness is subjected to axial tension or radial pressure.
[0048] Step 5: A Kevlar / graphene composite braided layer is used as the protective layer 15. Kevlar fibers and graphene materials are tightly woven together on the outside of the dynamic buffer layer of the wire harness using a braiding process. Kevlar has high strength and high modulus, while graphene has good electrical and thermal conductivity. The composite braiding of the two can provide reliable mechanical protection and electromagnetic shielding for the wire harness.
[0049] Step 6: At the sealing interface between the wire harness body 1 and the composite sealing structure 2, use laser etching technology to etch micron-level trenches with a depth of 10~50μm. Laser etching can precisely control the depth and shape of the trenches, increase the anchoring effect, and improve the stability of the seal.
[0050] Step 7: Place the corrugated sealing sleeve 21, made of nickel-titanium shape memory alloy, on both ends of the wire harness body 1. The nickel-titanium shape memory alloy has the characteristic of temperature-triggered shrinkage, and its phase transition temperature is set to 80°C.
[0051] Step 8: Fill the corrugated sealing sleeve 21 with dual-phase sealant, which consists of an inner flexible silicone layer and an outer epoxy polyurethane layer. First, fill the inner flexible silicone layer to ensure it adheres evenly to the surface of the wire harness, and then fill the outer epoxy polyurethane layer to ensure that the dual-phase sealant can fully fill the internal space of the corrugated sealing sleeve and achieve a good sealing effect.
[0052] As can be seen from the above, the safety sealed wire harness structure of this utility model has excellent insulation performance, good sealing performance, good buffering performance, reliable protection performance, and stable sealing interface. It can meet the safety and sealing requirements of wire harnesses in different fields and environments, and has broad application prospects.
[0053] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements can be made without departing from the principle of the present utility model, and these improvements should also be considered within the protection scope of the present utility model.
Claims
1. A safety sealed wire harness structure of a wrap forming, characterized by, The wire harness includes a wire harness body (1) and a composite sealing structure (2) arranged at both ends of the wire harness body (1); the wire harness body (1) sequentially includes a wire (11), a basic insulation layer (12), a gradient sealing layer (13), a dynamic buffer layer (14) and a protective layer (15) from inside to outside, and the composite sealing structure (2) includes a corrugated sealing sleeve (21) and a two-phase sealing glue (22) filled in the corrugated sealing sleeve (21).
2. The wrap formed security seal wire harness structure of claim 1, wherein, The basic insulation layer (12) is made of polytetrafluoroethylene doped carbon nanotube material.
3. The wrap formed security seal wire harness structure of claim 1, wherein, The gradient sealing layer (13) is formed by alternately winding silicon rubber and fluororubber.
4. The wrap formed security seal wire harness structure of claim 3, wherein, The gradient sealing layer (13) adopts a 7-layer alternately wound structure, which includes 4 layers of silicon rubber close to the basic insulation layer (12) and 3 layers of fluororubber close to the dynamic buffer layer (14), and the thickness of each layer is 0.2-0.5 mm, and the cross-winding angle is 45°.
5. The wrap formed security seal wire harness structure of claim 1, wherein, The dynamic buffer layer (14) is made of corrugated TPU elastomer, and the geometric parameters are set as follows: the corrugated wavelength λ is 5-10 mm, the corrugated wave amplitude h is 1-3 mm, and the wall thickness t is 1-2 mm.
6. The wrap formed security seal wire harness structure of claim 1, wherein, The protective layer (15) is made of a Kevlar / graphene composite woven layer.
7. The wrap formed security seal wire harness structure of claim 1, wherein, The corrugated sealing sleeve (21) is made of nickel-titanium shape memory alloy.
8. The wrap formed security seal wire harness structure of claim 1, wherein, The two-phase sealing glue (22) includes flexible silicone glue in the inner layer and epoxy-polyurethane in the outer layer.