Anti-electromagnetic interference shielding wire harness

Abstract

The utility model relates to the technical field of wire harnesses, in particular to an anti-electromagnetic interference shielding wire harness, which comprises an outer sheath and a plurality of strands of conductive core wires, the plurality of strands of conductive core wires are arranged inside the outer sheath, protective layers are coated outside the conductive core wires, and insulating layers are arranged among the exteriors of the plurality of groups of protective layers. The multi-layer shielding structure is arranged outside the multi-strand conductive core wire, the multi-layer shielding structure is composed of an inner shielding layer, a middle shielding layer and an outer shielding layer, the inner shielding layer is formed by spirally winding a 0.05 mm copper foil belt, the middle shielding layer is a tinned copper wire woven mesh with the weaving density larger than or equal to 85%, the outer shielding layer is a nickel metallization conductive rubber layer with the surface resistivity smaller than or equal to 0.1 omega.cm, and the outer shielding layer is a nickel metallization conductive rubber layer with the surface resistivity smaller than or equal to 0.1 omega.cm. The stress buffer layer is arranged between the inner shielding layer and the insulating layer. The beneficial effects of the utility model lie in that the shielding effectiveness of the multi-layer shielding structure on 10kHz-10GHz electromagnetic interference is greater than or equal to 80dB, strict standards such as CISPR25Class5 and the like are satisfied, the three shielding layers are matched with the stress buffer layer, so that the crosstalk attenuation among multiple cables is greater than or equal to 60dB, and the multi-layer shielding structure is suitable for a high-density wiring scene.

Description

Technical Field

[0001] This utility model relates to the field of wire harness technology, and in particular to electromagnetic interference shielded wire harnesses. Background Technology

[0002] In modern electronic devices, wire harnesses serve as important carriers for signal and energy transmission, and their electromagnetic interference resistance directly affects the normal operation of the equipment.

[0003] Electromagnetic interference shielded wire harnesses are suitable for applications with high electromagnetic compatibility requirements, such as automotive electronics, medical equipment, and aerospace. They can effectively suppress electromagnetic interference and ensure the stability and reliability of signal transmission.

[0004] Existing shielding layers mostly use a single woven mesh structure, which is prone to stress concentration under bending or vibration environments, leading to shielding layer breakage and the formation of electromagnetic leakage channels. The grounding structure uses single-point grounding, which increases grounding impedance under high-frequency interference, resulting in a significant decrease in shielding effectiveness.

[0005] To address the above issues, we have introduced electromagnetic interference shielded wire harnesses. Utility Model Content

[0006] This utility model discloses an anti-electromagnetic interference shielded 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] An electromagnetic interference shielded wire harness includes an outer sheath and multiple conductive core wires, all of which are disposed inside the outer sheath. Each conductive core wire is covered with a protective layer, and an insulating layer is provided between the outer surfaces of the multiple sets of protective layers. The harness also includes a multi-layer shielding structure disposed outside the multiple conductive core wires. This multi-layer shielding structure consists of an inner shielding layer, a middle shielding layer, and an outer shielding layer. The inner shielding layer is a spirally wound 0.05mm copper foil strip. The middle shielding layer is a tin-plated copper wire braided mesh with a braiding density ≥85%. The outer shielding layer is a nickel-metallized conductive rubber layer with a surface resistivity ≤0.1Ω·cm. Finally, a stress buffer layer is disposed between the inner shielding layer and the insulating layer, made of corrugated silicone rubber and containing stainless steel wire.

[0009] In the complex electromagnetic environment of a data center, the multi-layer shielding structure of this wire harness effectively blocks external electromagnetic interference. The inner shielding layer, middle shielding layer, and outer shielding layer work together to ensure stable data signal transmission. When the equipment is running, the stress buffer layer absorbs vibration stress and protects the internal structure.

[0010] In a preferred embodiment, both ends of the outer sheath are fixedly connected to a connecting shield connector, and both ends of the conductive core wire are connected to the connecting shield connector.

[0011] During the assembly of aerospace equipment, multiple shielded wire harnesses are quickly connected by connecting shielded connectors. Their shielding characteristics ensure the integrity of electromagnetic shielding at the connection point, prevent signal leakage and interference, and meet the high reliability requirements of aerospace equipment for signal transmission.

[0012] In a preferred embodiment, a grounding lead is ultrasonically welded to the outer side of the outer shielding layer. The grounding lead is a 28AWG silver-plated copper wire, and the welding area of ​​the grounding lead is ≥2mm². 2 At 100MHz, the grounding impedance is ≤0.1Ω.

[0013] In medical MRI equipment, the grounding lead reliably grounds the outer shielding layer. The low grounding impedance ensures that the electromagnetic shielding layer can quickly discharge induced current, prevent electromagnetic interference between devices, and ensure the accurate operation of medical equipment and patient safety.

[0014] In a preferred embodiment, the braiding angle of the middle shielding layer is 45°±5°.

[0015] The 402 middle shielding layer is a woven mesh with a braiding angle of 45°±5°. Even under vibration, it can maintain good shielding performance, effectively resist electromagnetic interference between vehicle electronic devices, and ensure the stable operation of the vehicle control system.

[0016] In a preferred embodiment, the silicone rubber of the stress buffer layer has a hardness of 50 Shore A.

[0017] In wiring scenarios with frequent movement, a stress buffer layer with a hardness of 50 Shore A can effectively absorb the stress generated by mechanical movement, preventing damage to the internal structure of the wiring harness, while also possessing suitable flexibility.

[0018] In a preferred embodiment, anti-bending sleeves are provided at both ends of the outer sheath and between the outer sheath and the connecting shielding joint.

[0019] In wiring scenarios where communication base station antennas frequently need to be adjusted in angle, the anti-bending sheath protects the connection between the wire harness and the connecting shielded connector, preventing the connector from becoming loose or the wire harness from breaking due to frequent bending.

[0020] The electromagnetic interference shielded wire harness provided by this utility model has the following advantages:

[0021] In this utility model:

[0022] 1. The multi-layer shielding structure provides shielding effectiveness of ≥80dB against electromagnetic interference from 10kHz to 10GHz, meeting stringent standards such as CISPR25 Class 5. The three shielding layers, combined with the stress buffer layer, reduce crosstalk between multiple cables by ≥60dB, making it suitable for high-density cabling scenarios.

[0023] 2. The stress buffer layer improves the practical bending life of the multi-layer shielding structure, making it suitable for vibration environments. The grounding lead reduces the grounding impedance to below 0.1Ω, effectively suppressing high-frequency common-mode interference. Compared with traditional devices, it greatly improves the quality of operation and efficiency of use. Attached Figure Description

[0024] Figure 1 This is a first-view perspective three-dimensional schematic diagram of the anti-electromagnetic interference shielded wire harness proposed in this utility model.

[0025] Figure 2 This is a second-view perspective three-dimensional schematic diagram of the anti-electromagnetic interference shielded wire harness proposed in this utility model.

[0026] Figure 3 This is an exploded structural diagram of the electromagnetic interference shielded wire harness proposed in this utility model.

[0027] Figure 4 This is a side cross-sectional view of the electromagnetic interference shielded wire harness proposed in this utility model.

[0028] Figure 5 for Figure 4 Enlarged view of point A in the middle.

[0029] In the attached diagram: 1. Outer sheath; 2. Conductive core wire; 3. Protective layer; 4. Multi-layer shielding structure; 401. Inner shielding layer; 402. Middle shielding layer; 403. Outer shielding layer; 5. Insulation layer; 6. Stress buffer layer; 7. Connecting shielding connector; 8. Grounding lead; 9. Bending-resistant sheath. Detailed Implementation

[0030] 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.

[0031] The electromagnetic interference shielded wire harness disclosed in this utility model is mainly used in wire harness applications.

[0032] Reference Figures 1-5 The electromagnetic interference shielding harness includes an outer sheath 1 and multiple conductive core wires 2, all of which are located inside the outer sheath 1. Each conductive core wire 2 is covered with a protective layer 3. An insulating layer 5 is provided between the outer surfaces of the multiple sets of protective layers 3. The harness also includes a multi-layer shielding structure 4, which is located outside the multiple conductive core wires 2. The multi-layer shielding structure 4 consists of an inner shielding layer 401, a middle shielding layer 402, and an outer shielding layer 403. The inner shielding layer 401 is a spirally wound 0.05mm copper foil strip. The middle shielding layer 402 is a tinned copper wire braided mesh with a braiding density of ≥85%. The outer shielding layer 403 is a nickel-metallized conductive rubber layer with a surface resistivity of ≤0.1Ω·cm. A stress buffer layer 6 is located between the inner shielding layer 401 and the insulating layer 5. The stress buffer layer 6 is made of wavy silicone rubber and has stainless steel wire inside.

[0033] In this embodiment, in the complex electromagnetic environment of a data center, the multi-layer shielding structure 4 of the wire harness effectively blocks external electromagnetic interference. The inner shielding layer 401, the middle shielding layer 402, and the outer shielding layer 403 work together to ensure stable data signal transmission. When the equipment is running, the stress buffer layer 6 absorbs vibration stress and protects the internal structure.

[0034] In a preferred embodiment, both ends of the outer sheath 1 are fixedly connected to a connecting shield connector 7, and both ends of the conductive core wire 2 are connected to the connecting shield connector 7.

[0035] In this embodiment, during the assembly of aerospace equipment, multiple shielded wire harnesses are quickly connected by connecting shielded connectors 7. Their shielding characteristics ensure the integrity of electromagnetic shielding at the connection point, prevent signal leakage and interference, and meet the high reliability requirements of aerospace equipment for signal transmission.

[0036] In a preferred embodiment, a grounding lead 8 is ultrasonically welded to the outer side of the outer shielding layer 403. The grounding lead 8 is a 28AWG silver-plated copper wire, and the welding area of ​​the grounding lead 8 is ≥2mm². 2 At 100MHz, the grounding impedance is ≤0.1Ω.

[0037] In this embodiment, in a medical MRI machine, the grounding lead 8 reliably grounds the outer shielding layer 403. The low grounding impedance ensures that the electromagnetic shielding layer quickly discharges the induced current, preventing electromagnetic interference between devices and ensuring the precise operation of medical equipment and patient safety.

[0038] In a preferred embodiment, the braiding angle of the middle shielding layer 402 is 45°±5°.

[0039] In this embodiment, the woven mesh formed by the middle shielding layer 402 with a braiding angle of 45°±5° can still maintain good shielding performance under vibration environment, effectively resist electromagnetic interference between vehicle electronic devices, and ensure the stable operation of the vehicle control system.

[0040] In a preferred embodiment, the silicone rubber of the stress buffer layer 6 has a hardness of 50 Shore A.

[0041] In this embodiment, in wiring scenarios with frequent movement, the stress buffer layer 6 with a hardness of 50 Shore A can effectively absorb the stress generated by mechanical movement, prevent damage to the internal structure of the wiring harness, and also has suitable flexibility.

[0042] In a preferred embodiment, anti-bending sleeves 9 are provided at both ends of the outer sheath 1 and between the outer sheath and the connecting shielding connector 7.

[0043] In this embodiment, in a wiring scenario where the antenna angle of a communication base station is frequently adjusted, the anti-bending sheath 9 protects the connection between the wire harness and the connecting shielded connector 7, preventing the connector from becoming loose or the wire harness from breaking due to frequent bending.

[0044] Working principle: When using this wire harness, multiple conductive core wires 2 are placed inside the outer sheath 1, and the conductive core wires 2 are covered with a protective layer 3. An insulation layer 5 is set between the outer surfaces of multiple sets of protective layers 3 to ensure the insulation performance of the wire harness. A multi-layer shielding structure 4 is set outside the multiple conductive core wires 2 to effectively shield electromagnetic interference. A stress buffer layer 6 is set between the inner shielding layer 401 and the insulation layer 5 to absorb and disperse the stress generated when the wire harness is bent. A grounding lead 8 ensures effective grounding of the shielding layer. Both ends of the conductive core wires 2 are connected to the connecting shielding connector 7 to ensure the electrical continuity of the wire harness. Bending-resistant sleeves 9 are set between both ends of the outer sheath 1 and the connecting shielding connector 7 to enhance the bending resistance of the wire harness, achieving efficient electromagnetic interference resistance, bending resistance and stable conductivity of the wire harness, ensuring the reliability and stability of the wire harness in complex electromagnetic environments.

[0045] 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. An electromagnetic interference shielded wire harness, comprising an outer sheath (1) and multi-strand conductive core wires (2), characterized in that, The multiple conductive core wires (2) are all disposed inside the outer sheath (1), and the outer surfaces of the conductive core wires (2) are all covered with protective layers (3). An insulating layer (5) is disposed between the outer surfaces of the multiple sets of protective layers (3), and the product further includes: A multi-layer shielding structure (4) is disposed outside the multi-strand conductive core wire (2). The multi-layer shielding structure (4) consists of an inner shielding layer (401), a middle shielding layer (402) and an outer shielding layer (403). The inner shielding layer (401) is a spirally wound 0.05mm copper foil strip. The middle shielding layer (402) is a tin-plated copper wire braided mesh with a braiding density ≥85%. The outer shielding layer (403) is a nickel-metallized conductive rubber layer with a surface resistivity ≤0.1Ω·cm. The stress buffer layer (6) is disposed between the inner shielding layer (401) and the insulating layer (5), and is made of corrugated silicone rubber with built-in stainless steel wire.

2. The electromagnetic interference shielded wire harness according to claim 1, characterized in that, Both ends of the outer sheath (1) are fixedly connected to the connecting shield connector (7), and both ends of the conductive core wire (2) are connected to the connecting shield connector (7).

3. The electromagnetic interference shielded wire harness according to claim 1, characterized in that, The outer shielding layer (403) has a grounding lead (8) ultrasonically welded to its outer side. The grounding lead (8) is a 28AWG silver-plated copper wire, and the welding area of ​​the grounding lead (8) is ≥2mm². 2 At 100MHz, the grounding impedance is ≤0.1Ω.

4. The electromagnetic interference shielded wire harness according to claim 1, characterized in that, The braiding angle of the middle shielding layer (402) is 45°±5°.

5. The electromagnetic interference shielded wire harness according to claim 1, characterized in that, The silicone rubber hardness of the stress buffer layer (6) is 50 Shore A.

6. The electromagnetic interference shielded wire harness according to claim 2, characterized in that, Both ends of the outer sheath (1) are provided with anti-bending sheaths (9) between them and the connecting shielding connector (7).

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