High-flexibility anti-bending wire harness
By combining a multi-layered structure with special materials, the problem of insufficient flexibility and bending resistance of traditional wire harnesses is solved, achieving stable transmission and long life of highly flexible and bending-resistant wire harnesses, and adapting to the needs of complex environments.
Patent Information
- Application Number
- CN202522071950.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-26
- Publication Date
- 2026-04-14
- Estimated Expiration
- 2035-09-26
AI Technical Summary
Traditional wire harnesses are insufficient in terms of flexibility and bending resistance. Frequent bending can easily lead to fatigue fracture of metal wires, cracking of insulation layers, and friction damage to internal structures, affecting the normal operation of equipment and posing safety hazards.
The outer sheath design adopts a multi-layer structure, including an insulation layer, a buffer layer, a shielding layer, a tensile layer, and an outer sheath. Combined with a silicone positioning ring and a highly flexible sheath, it utilizes anti-bending silicone grease to buffer bending stress. The conductive core wire is made of multi-strand ultra-fine tinned copper wire spirally twisted together to ensure the flexibility and bending resistance of the wire harness.
It enables stable transmission of wire harnesses in complex environments, reduces the risk of breakage and insulation damage, extends service life, adapts to various harsh environments, and improves equipment operation quality and efficiency.
Smart Images
Figure CN224123143U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of wire harness technology, and in particular to a highly flexible and bend-resistant wire harness. Background Technology
[0002] In modern electronic and mechanical equipment, wire harnesses, as important components connecting various parts, play a crucial role in transmitting electrical signals and energy.
[0003] Highly flexible and bend-resistant wiring harnesses are suitable for applications such as automotive internal wiring connections, electronic device internal wiring, and robot joint moving parts wiring connections. They can stably transmit electrical signals or power in environments with frequent bending and twisting, ensuring the normal operation of the equipment.
[0004] However, traditional wire harnesses have significant shortcomings in terms of flexibility and bending resistance. On the one hand, the conductors of traditional wire harnesses are usually made of a single material of metal wire, which lacks effective dispersion of bending stress. During frequent bending, the metal wire is prone to fatigue fracture, leading to short circuits or open circuits and affecting the normal operation of the equipment. On the other hand, the insulation layer and sheath material of the wire harness have poor flexibility and are prone to cracking when bent, exposing the internal conductors. This not only reduces the insulation performance but also poses safety hazards. In addition, the internal structure design of traditional wire harnesses is unreasonable. There is a lack of effective buffering and fixing measures between conductors and between conductors and insulation layer. During bending, mutual friction and compression are likely to occur, further aggravating the damage to the wire harness.
[0005] Therefore, developing a wire harness with high flexibility and strong bending resistance is of great practical significance. Utility Model Content
[0006] This utility model discloses a highly flexible and bend-resistant wire harness, which aims to solve the technical problems in the background art.
[0007] To achieve the above objectives, the present invention adopts the following technical solution:
[0008] A highly flexible and bend-resistant wire harness includes multiple sets of conductive core wires and an outer sheath. The outer sheath is disposed outside the multiple sets of conductive core wires and consists of an insulation layer, a buffer layer, a shielding layer, a tensile layer, and an outer protective layer. Two silicone positioning rings are disposed on the outside of the outer sheath. Each silicone positioning ring has an adjustable groove on one side. A highly flexible sheath is fixedly connected between the two silicone positioning rings and located outside the outer sheath. The interior of the highly flexible sheath has a spiral groove filled with bend-resistant silicone grease and is in contact with the outside of the outer sheath.
[0009] In wiring scenarios involving frequent bending in automated equipment, the highly flexible outer sheath of the wire harness, combined with the anti-bending silicone grease in the spiral groove, effectively buffers bending stress. The silicone positioning ring can be flexibly adjusted to adapt to different installation requirements, ensuring stable signal and power transmission of the wire harness.
[0010] In a preferred embodiment, the insulating layer is made of thermoplastic elastomer material, tightly wrapped around the outside of the conductive core wire, and has a uniform thickness to ensure insulation effect without increasing the stiffness of the wire harness.
[0011] When wiring inside medical devices that require extremely high flexibility, the insulation layer of thermoplastic elastomer material provides reliable insulation without being too rigid and affecting the bending of the wire harness, ensuring that the internal wiring of the equipment is compactly arranged and operates safely.
[0012] In a preferred embodiment, the buffer layer is made of polyurethane foam with a honeycomb structure, which is placed outside the insulation layer and is used to absorb and disperse the stress generated when the wire harness is bent.
[0013] In the application of wiring harnesses in industrial robot arms, when the arm frequently bends, the honeycomb polyurethane foam material of the buffer layer quickly absorbs bending stress, avoiding stress concentration that could damage the conductive core wires and extending the service life of the wiring harness.
[0014] In a preferred embodiment, the shielding layer is made of tin-plated copper wire braided with a high braiding density and is connected to the conductive core wire via a grounding wire.
[0015] In communication base stations with complex electromagnetic environments, the high-density braided tin-plated copper wire shielding layer effectively isolates external electromagnetic interference. It is connected to the conductive core wire through the grounding wire to ensure stable signal transmission and avoid data loss or errors.
[0016] In a preferred embodiment, the tensile layer is made of Kevlar fiber and is wrapped around the outside of the shielding layer.
[0017] In the application of lifting cables for aerial work platforms, the tensile layer made of Kevlar fiber withstands the tensile force brought about by the lifting of the equipment, preventing the cable harness from being broken, while not affecting the flexibility of the cable harness, thus ensuring the normal operation of the equipment.
[0018] In a preferred embodiment, the outer sheath is made of neoprene rubber and is located on the outermost side of the outer sheath.
[0019] In harsh outdoor power transmission environments, the neoprene rubber outer sheath resists ultraviolet rays, rain erosion, and mechanical wear, protecting the internal structure and ensuring stable performance of the harness during long-term outdoor use.
[0020] In a preferred embodiment, the conductive core wire is formed by spirally stranding multiple strands of ultra-fine tin-plated copper wire to improve its oxidation and corrosion resistance.
[0021] The spirally twisted multi-strand ultra-fine tin-plated copper wire conductive core enhances structural stability, effectively resists salt spray corrosion, and maintains good conductivity.
[0022] The high-flexibility, bend-resistant wire harness provided by this utility model has the following advantages:
[0023] In this utility model:
[0024] 1. The outer sheath design, which uses two silicone positioning rings to position the wire harness externally, along with the high-flexibility sheath and the internal anti-bending silicone grease, plus the special stranding process of multi-strand ultra-fine tinned copper wire, thermoplastic elastomer insulation layer and honeycomb buffer layer, gives the wire harness excellent flexibility. It can be flexibly bent at small bending radii to meet the needs of complex wiring environments.
[0025] 2. The synergistic effect of the various structural layers of the outer sheath effectively disperses and absorbs bending stress, reducing the risk of wire breakage and insulation damage. Even under frequent bending conditions, it can ensure the long-term stable operation of the wire harness and extend its service life.
[0026] 3. The selected materials, such as the neoprene rubber outer sheath and Kevlar fiber tensile layer, have excellent weather resistance, wear resistance, flame retardancy and high strength, enabling the wire harness to adapt to various harsh working environments, reducing maintenance costs, and greatly improving the quality of operation and efficiency compared with traditional devices. Attached Figure Description
[0027] Figure 1 This is a three-dimensional structural diagram of a highly flexible and bend-resistant wire harness proposed in this utility model.
[0028] Figure 2 This is a partial cross-sectional schematic diagram of a highly flexible sheath for a high-flexibility, bend-resistant wire harness proposed in this utility model.
[0029] Figure 3 This is a side sectional view of a highly flexible and bend-resistant wire harness proposed in this utility model.
[0030] Figure 4 This is a schematic diagram of a highly flexible and bend-resistant sheath structure for a wire harness proposed in this utility model.
[0031] In the attached diagram: 1. Conductive core wire; 2. Outer sheath; 201. Insulation layer; 202. Buffer layer; 203. Shielding layer; 204. Tensile layer; 205. Outer sheath; 3. Silicone positioning ring; 4. High-flexibility sheath; 5. Spiral groove; 6. Anti-bending silicone grease. Detailed Implementation
[0032] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and marked in the accompanying drawings can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.
[0033] The high flexibility and bending resistance wire harness disclosed in this utility model is mainly used in wire harness applications.
[0034] Reference Figures 1-4 A highly flexible and bend-resistant wire harness includes multiple sets of conductive core wires 1 and an outer sheath 2. The outer sheath 2 is disposed outside the multiple sets of conductive core wires 1. The outer sheath 2 is composed of an insulation layer 201, a buffer layer 202, a shielding layer 203, a tensile layer 204, and an outer protective layer 205. Two silicone positioning rings 3 are disposed on the outside of the outer sheath 2. Each silicone positioning ring 3 has an adjustable groove on one side. A highly flexible sheath 4 is fixedly connected between the two silicone positioning rings 3 and located outside the outer sheath 2. The interior of the highly flexible sheath 4 has a spiral groove 5. The interior of the spiral groove 5 is filled with bend-resistant silicone grease 6 and is in contact with the exterior of the outer sheath 2.
[0035] In this embodiment, in wiring scenarios where automated equipment frequently bends, the highly flexible sheath 4 on the outside of the wire harness, together with the anti-bending silicone grease 6 in the spiral groove 5, effectively buffers bending stress. The silicone positioning ring 3 can be flexibly adjusted to adapt to different installation requirements, ensuring stable signal and power transmission of the wire harness.
[0036] In a preferred embodiment, the insulation layer 201 is made of thermoplastic elastomer material, which tightly wraps around the outside of the conductive core wire 1 and has a uniform thickness, ensuring insulation effect without increasing the stiffness of the wire harness.
[0037] In this embodiment, when wiring inside medical devices that require extremely high flexibility, the thermoplastic elastomer insulation layer 201 provides reliable insulation without being too rigid and affecting the bending of the wire harness, thus ensuring a compact layout and safe operation of the internal wiring of the device.
[0038] In a preferred embodiment, the buffer layer 202 is made of polyurethane foam material with a honeycomb structure, and is fitted over the outside of the insulation layer 201 to absorb and disperse the stress generated when the wire harness is bent.
[0039] In this embodiment, when the arm frequently bends, the honeycomb polyurethane foam material of the buffer layer 202 quickly absorbs the bending stress, preventing stress concentration from damaging the conductive core wire 1 and extending the service life of the wire harness.
[0040] In a preferred embodiment, the shielding layer 203 is made of tin-plated copper wire with a high braiding density and is connected to the conductive core wire 1 through a grounding wire.
[0041] In this embodiment, in a communication base station with a complex electromagnetic environment, the high-density braided tin-plated copper wire shielding layer 203 effectively isolates external electromagnetic interference and is connected to the conductive core wire 1 through the grounding wire to ensure stable signal transmission and avoid data loss or errors.
[0042] In a preferred embodiment, the tensile layer 204 is made of Kevlar fiber and is wrapped around the outside of the shielding layer 203.
[0043] In this embodiment, in the application of lifting cables for aerial work equipment, the tensile layer 204 made of Kevlar fiber withstands the tensile force brought about by the lifting of the equipment, preventing the cable harness from being broken, while not affecting the flexibility of the cable harness, thus ensuring the normal operation of the equipment.
[0044] In a preferred embodiment, the outer sheath 205 is made of neoprene rubber and is disposed on the outermost side of the outer sheath 2.
[0045] In this embodiment, under harsh outdoor power transmission conditions, the neoprene rubber outer sheath 205 resists ultraviolet rays, rain erosion and mechanical wear, protects the internal structure, and ensures stable performance of the harness during long-term outdoor use.
[0046] In a preferred embodiment, the conductive core wire 1 is made of multiple strands of ultra-fine tin-plated copper wires twisted together using a spiral twisting process to improve its oxidation resistance and corrosion resistance.
[0047] In this embodiment, the spirally stranded multi-strand ultra-fine tin-plated copper wire conductive core 1 enhances structural stability, effectively resists salt spray corrosion, and maintains good conductivity.
[0048] Working principle: The conductive core wire 1 is made of multiple strands of ultra-fine tinned copper wires twisted together using a spiral stranding process, which improves its oxidation and corrosion resistance. The insulation layer 201 is made of thermoplastic elastomer material tightly wrapped around the outside of the conductive core wire 1, ensuring insulation effect without increasing the rigidity of the wire bundle. The buffer layer 202 is made of polyurethane foam material with a honeycomb structure and is placed on the outside of the insulation layer 201 to absorb and disperse the stress generated when the wire bundle is bent. The shielding layer 203 is made of tinned copper wire braided with a high braiding density and is connected to the conductive core wire 1 through a grounding wire, effectively shielding electromagnetic interference. The tensile layer 204 is made of Kevlar fiber braided. The outer sheath 205, made of neoprene rubber, is wrapped around the shielding layer 203 to enhance the tensile strength of the wire harness. It is located on the outermost side of the outer sheath 2, providing good wear resistance and weather resistance. The silicone positioning ring 3 is located on the outside of the outer sheath 2 and fixes the position of the wire harness through an adjustable groove. The high-flexibility sheath 4 is fixedly connected between the two silicone positioning rings 3. The spiral groove 5 inside is filled with anti-bending silicone grease 6 and contacts the outside of the outer sheath 2 to enhance the flexibility and bending resistance of the wire harness. This achieves high flexibility, bending resistance and anti-interference performance of the wire harness, ensuring the stability and durability of the wire harness in complex environments.
[0049] The above description is merely a preferred embodiment of this utility model, but the protection scope of this utility model is not limited thereto. The substitutions may be replacements of some structures, devices, or method steps, or they may be complete technical solutions. Equivalent substitutions or modifications made based on the technical solution and inventive concept of this utility model should all be covered within the protection scope of this utility model.
Claims
1. A highly flexible and bend-resistant wire harness, comprising multiple sets of conductive core wires (1) and an outer sheath (2), characterized in that, The outer sheath (2) is disposed outside the multiple sets of conductive core wires (1). The outer sheath (2) is composed of an insulating layer (201), a buffer layer (202), a shielding layer (203), a tensile layer (204), and an outer sheath (205). Two silicone positioning rings (3) are disposed on the outside of the outer sheath (2). Each silicone positioning ring (3) has an adjustable groove on one side. A high-flexibility sheath (4) is fixedly connected between the two silicone positioning rings (3) and outside the outer sheath (2). A spiral groove (5) is provided inside the high-flexibility sheath (4). The spiral groove (5) is filled with anti-bending silicone grease (6) and is in contact with the outside of the outer sheath (2).
2. The high-flexibility, bend-resistant wire harness according to claim 1, characterized in that, The insulation layer (201) is made of thermoplastic elastomer material, which is tightly wrapped around the outside of the conductive core wire (1) and has a uniform thickness, ensuring insulation effect without increasing the hardness of the wire harness.
3. The high flexibility and bending resistance wire harness according to claim 2, characterized in that, The buffer layer (202) is made of polyurethane foam material in a honeycomb structure, and is fitted outside the insulation layer (201) to absorb and disperse the stress generated when the wire harness is bent.
4. The high flexibility and bending resistance wire harness according to claim 3, characterized in that, The shielding layer (203) is made of tin-plated copper wire with a high braiding density and is connected to the conductive core wire (1) through a grounding wire.
5. A high-flexibility, bend-resistant wire harness according to claim 4, characterized in that, The tensile layer (204) is made of Kevlar fiber and is wrapped around the outside of the shielding layer (203).
6. The high flexibility and bending resistance wire harness according to claim 1, characterized in that, The outer protective layer (205) is made of neoprene rubber and is located on the outermost side of the outer sheath (2).
7. The high flexibility and bending resistance wire harness according to claim 1, characterized in that, The conductive core wire (1) is made of multiple strands of ultra-fine tin-plated copper wires twisted together using a spiral twisting process, which is used to improve the oxidation resistance and corrosion resistance.