Polymer composite wire harness and polymerization system
By using polymer composite wire harnesses and designing braided and coated layers in PMMA composite materials, high strength and high impact resistance of PMMA materials are achieved, solving the problem of insufficient mechanical properties in existing technologies and meeting market demands.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- HAIYAN HUASHUAITE PLASTIC ELECTRICAL APPLIANCES CO LTD
- Filing Date
- 2025-05-09
- Publication Date
- 2026-04-21
AI Technical Summary
The mechanical properties of existing black wire harnesses are insufficient, resulting in PMMA composite materials exhibiting low tensile strength and impact resistance, making it difficult to meet the increasingly demanding performance requirements of the market.
The high-polymer composite wire harness includes a core material, a braided layer, and a covering layer. The braided layer surrounds the core material and fits it tightly, while the covering layer fixes the braided layer. Through a polymerization reaction, a fully bonded PMMA material is formed, increasing the bonding surface area.
It enhances the tensile strength and impact resistance of PMMA composite materials, meets the ever-increasing safety standards, and reduces material and labor costs.
Smart Images
Figure CN224153150U_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of polymer composite materials technology, and in particular to a polymer composite wire harness and polymerization system. Background Technology
[0002] Polymethyl methacrylate (PMMA), a transparent polymer material with excellent comprehensive performance, has been widely used in traffic noise barriers, transparent buildings, thermal insulation curtain walls, and aircraft windows. Specifically, taking noise reduction facilities for high-speed rail or urban rail transit as an example, if PMMA sheets of a predetermined thickness are used alone as the main material of the sound barrier, there are dual risks related to traffic safety and the ecological environment. The former mainly manifests in the fact that the hard and brittle nature of PMMA makes it prone to generating a large number of flying debris upon impact, endangering the safety of pedestrians and vehicles on nearby or below roads. The latter mainly considers the risk of birds accidentally colliding with the transparent sheets during flight due to their difficulty in identifying them.
[0003] To address this, existing technology incorporates black wire bundles at appropriate intervals into the PMMA composite material during the manufacturing process. This moderately improves impact resistance while creating a drag effect to reduce debris splashing or falling, and the black wire bundles are easily identifiable by birds, thus resolving the aforementioned hazards.
[0004] Nevertheless, in the current existing technologies mentioned above, due to the gradual improvement of safety levels and technical requirements, the mechanical properties expressed by using only black wire harnesses are still insufficient, resulting in certain deficiencies in tensile strength and impact resistance of PMMA composite materials. With the market demand for continuously improving specifications, corresponding improvements must be made to the embedded black wire harnesses to further enhance the tensile strength and impact resistance of PMMA composite materials. Utility Model Content
[0005] The purpose of this application is to provide a polymer composite wire harness and polymerization system, which aims to solve the problem that the mechanical properties of existing black wire harnesses are insufficient, resulting in PMMA composite materials obtained by using them as reinforcement exhibiting low tensile strength and impact resistance, making it difficult to meet the increasingly demanding performance indicators of the market.
[0006] To achieve the above objectives, this application provides a polymer composite wire harness, comprising: a wire harness core material, a braided layer, and a covering layer. The braided layer surrounds the wire harness core material and is tightly attached to the wire harness core material. The covering layer is used to cover the two ends of the braided layer onto the two ends of the wire harness core material, so that the braided layer is fixed to the wire harness core material.
[0007] Optionally, the wire harness core material includes a central region and two edge regions located outside the two ends of the central region, the braided layer surrounds the wire harness core material and is tightly attached to the central region, and the covering layer is used to cover the edge regions and the two ends of the central region so that the braided layer is fixed to the central region.
[0008] Optionally, the length of the intermediate region is greater than the sum of the lengths of the two edge regions.
[0009] Optionally, the cross-section of the wire harness core material is circular, and the diameter of the wire harness core material is less than or equal to 5 mm.
[0010] Optionally, the thickness of the braided layer is 0.01~1.5 mm.
[0011] Optionally, the core material of the wire harness is made of nylon, modified nylon, or ultra-high molecular weight polyethylene.
[0012] Optionally, the material of the braided layer is polyester, nylon, spandex, polypropylene, aramid, glass fiber, carbon fiber or metal wire.
[0013] Optionally, the coating layer is made of polyester resin, epoxy resin, acrylic resin, or polyurethane resin.
[0014] This application also provides a polymerization system, including a mold, a liquid phase material, and a polymer composite wire bundle as described above. The number of polymer composite wire bundles is multiple, and the multiple polymer composite wire bundles are fixed at intervals in the mold. The liquid phase material is poured into the mold and completely covers the polymer composite wire bundles, thereby allowing the mold filled with the liquid phase material to undergo a polymerization reaction to obtain a plate with the polymer composite wire bundles embedded in it.
[0015] Optionally, the mold includes an upper template, an elastic frame, and a lower template. The elastic frame is sandwiched between the upper template and the lower template. Multiple sets of parallel through holes are centrally formed on the two opposite side walls of the elastic frame. The spacing between any two adjacent through holes is equal. The two ends of the polymer composite wire bundle are respectively disposed in the through holes.
[0016] This application involves tightly bonding a braided layer to the surface of the wire harness core material, and then covering both ends of the braided layer with a coating layer to fix the braided layer onto the wire harness core material, thereby obtaining a polymer composite wire harness. In this process of preparing PMMA composite materials containing wire harnesses from polymer composite wire harnesses, the liquid MMA monomer can fully wet the braided layer and enter the textured spatial structure. After the polymerization reaction is completed, the formed solid PMMA can achieve all-round bonding with the braided layer, effectively increasing the bonding surface area and further improving tensile strength and impact resistance, meeting the market demand for increasingly stringent safety standards. Attached Figure Description
[0017] Figure 1 A schematic diagram of the main structure of a polymer composite wire harness provided in an embodiment of the present invention. Figure 1 .
[0018] Figure 2 A schematic diagram of the main structure of a polymer composite wire harness provided in an embodiment of the present invention. Figure 2 .
[0019] Figure 3 This is a schematic diagram of the spatial decomposition structure of an aggregation system provided in an embodiment of the present invention.
[0020] Explanation of reference numerals in the attached figures:
[0021] 1. Polymer composite wire harness; 11. Wire harness core material; 111. Middle area; 112. Edge area; 12. Braided layer; 13. Covering layer; 300. Mold; 310. Upper template; 320. Elastic frame; 330. Lower template; 325. Through hole. Detailed Implementation
[0022] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.
[0023] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, components, features, and elements with the same names in different embodiments of this application may have the same meaning or different meanings, the specific meaning of which must be determined by its interpretation in that specific embodiment or further in conjunction with the context of that specific embodiment.
[0024] It should be understood that although the terms first, second, third, etc., may be used herein to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this document, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if," as used herein, can be interpreted as "when," "when," or "in response to determination." Furthermore, as used herein, the singular forms "a," "an," and "the" are intended to also include the plural forms unless the context indicates otherwise. It should be further understood that the terms "comprising," "including," indicate the presence of the stated feature, step, operation, element, component, item, kind, and / or group, but do not exclude the presence, occurrence, or addition of one or more other features, steps, operations, elements, components, items, kinds, and / or groups. The terms "or" and "and / or" as used herein are to be interpreted as inclusive, or mean any one or any combination thereof. Therefore, "A, B, or C" or "A, B, and / or C" means "any one of the following: A; B; C; A and B; A and C; B and C; A, B, and C". Exceptions to this definition will only occur if the combination of elements, functions, steps, or operations is inherently mutually exclusive in some way.
[0025] It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit this application.
[0026] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustration and has no specific meaning in itself. Therefore, "module," "part," or "unit" may be used interchangeably.
[0027] Please refer to Figure 1 , Figure 1 A schematic front view of a polymer composite wire harness 1 is shown, including: a wire harness core material 11, a braided layer 12, and a covering layer 13. The braided layer 12 surrounds the wire harness core material 11 and is tightly adhered to it. The covering layer 13 is used to cover both ends of the braided layer 12 onto both ends of the wire harness core material 11, thereby fixing the braided layer 12 onto the wire harness core material 11. Specifically, in this embodiment, the braided material can be tightly wrapped around the surface of the wire harness core material 11 in a circular manner according to a specific braiding texture, forming a braided layer 12 with a certain textured pattern, either manually or with a braiding device. Furthermore, by covering both ends of the braided layer 12 with a covering layer 13, the braided layer 12 is fixed to the wire harness core material 11, effectively preventing the braided layer 12 from falling off the wire harness core material 11 during subsequent use.
[0028] The black wire bundles used in existing technologies are typically made of nylon. In the actual preparation of PMMA composites, the degree of bonding between the nylon black wire bundles and the MMA monomers is also related to the ambient temperature. With seasonal changes, the yield of PMMA composites obtained through polymerization also fluctuates, thus affecting their tensile strength and impact resistance.
[0029] It is easy to understand that by replacing the existing black wire harness with the polymer composite wire harness obtained through the above embodiments, compared with the existing technology, in the process of preparing PMMA composite material, the liquid MMA monomer can fully wet the braided layer 12 and enter the texture space structure of the braided layer 12. After the polymerization reaction is completed, the solid PMMA formed can achieve all-round bonding with the braided layer 12, increasing the contact area of bonding, further improving tensile strength and impact resistance, and completely avoiding the interference caused by daily fluctuations in room temperature, thus meeting the market demand for continuously improving safety indicators.
[0030] Please refer to Figure 2 The wire harness core material 11 includes a central region 111 and two edge regions 112 located outside the two ends of the central region 111. A braided layer 12 surrounds the wire harness core material 11 and is tightly attached to the central region 111. A covering layer 13 is used to cover the edge regions 112 and the two ends of the central region 111, so that the braided layer 12 is fixed to the central region 111. Specifically, in this embodiment, the braided layer 12 is only wrapped around the central region 111 of the wire harness core material 11, leaving the two edge regions 112 empty. The covering layer 13 is used to cover the edge regions 112 and the ends of the braided layer 12 in sequence, so as to fix the braided layer 12 to the central region 111.
[0031] On the one hand, the above embodiments can reduce the amount of material used in the braided layer 12, thereby reducing labor and material costs. On the other hand, since the covering layer 13 itself has a certain thickness, during the preparation of PMMA composite materials, the end of the wire harness core 11 covered with the braided layer 12 is difficult to pass through the fixing holes in the mold, making subsequent processes impossible. Therefore, by winding the braided layer 12 only around the middle region 111 of the wire harness core 11, the edge region 112 covered by the covering layer 13 can directly mate with the fixing holes in the mold, achieving interference fit.
[0032] Optionally, the length of the middle region 111 is greater than the sum of the lengths of the two edge regions 112. Specifically, in this embodiment, the length of the braided layer 12 determines the yield of the polymer composite wire harness 1 in the subsequent PMMA composite material. Therefore, for the wire harness core material 11, the length of the middle region 111 with the braided layer 12 wound around it needs to be long enough, while the edge regions 112 at both ends only need to be able to fit with the fixing holes in the mold. Preferably, the length of the middle region 111 is greater than the sum of the lengths of the two edge regions 112.
[0033] Optionally, the cross-section of the wire harness core material 11 is circular, and the diameter of the wire harness core material 11 is less than or equal to 5 mm (and greater than 0.5 mm). Specifically, in this embodiment, the wire harness core material 11 is a long cylindrical strip with a circular cross-section and a diameter less than or equal to 5 mm. The diameter can be 1.7 mm, 2.4 mm, 3.5 mm, 4.8 mm, 5 mm, etc., and is not limited to a single value. By limiting the diameter of the wire harness core material 11 to the above-mentioned range, it is possible to ensure that the wire harness core material 11 has sufficient mechanical strength while also possessing sufficient toughness, thereby effectively extending its service life.
[0034] Optionally, the thickness of the braided layer 12 is 0.01~1.5 mm. Specifically, in this embodiment, the thickness of the braided layer 12 can be: 0.01 mm, 0.06 mm, 0.09 mm, 0.1 mm, 0.63 mm, 0.79 mm, 0.99 mm, 1.1 mm, 1.35 mm, 1.47 mm, or 1.5 mm, and is not limited to any single value. By limiting the thickness of the braided layer 12 to the above range, it is ensured that the braided layer 12 is fully impregnated with the liquid MMA monomer, thereby achieving the purpose of omnidirectional bonding between the solid PMMA formed in subsequent processes and the braided layer 12.
[0035] Optionally, the wire harness core material 11 is made of nylon, modified nylon, or ultra-high molecular weight polyethylene. Specifically, in this embodiment, the wire harness core material 11 can be made of at least one of nylon, modified nylon, and ultra-high molecular weight polyethylene. It is understood that the above-mentioned materials all possess advantages such as high strength, high toughness, high wear resistance, high impact strength, and excellent fatigue resistance. Thus, by using the wire harness core material 11 made of at least one of the above-mentioned materials as a reinforcement in the preparation of PMMA composite materials, the resulting PMMA composite material will possess excellent tensile strength and impact strength, not only meeting stringent market requirements but also further extending its service life.
[0036] Optionally, the braided layer 12 can be made of polyester, nylon, spandex, polypropylene, aramid, glass fiber, carbon fiber, or metal wire. Specifically, in this embodiment, the braided layer 12 can be made of at least one of polyester, nylon, spandex, polypropylene, aramid, glass fiber, carbon fiber, and metal wire. It is understood that the above materials possess advantages such as high strength, high toughness, high abrasion resistance, high durability, and high temperature resistance. For example, if polyester and nylon are selected, the resulting braided layer 12 combines high strength and abrasion resistance; if spandex and polyester are selected, the resulting braided layer 12 combines elasticity and abrasion resistance; if aramid and glass fiber are selected, the resulting braided layer 12 combines high temperature resistance and chemical corrosion resistance; if carbon fiber and metal wire are selected, the resulting braided layer 12 combines high specific strength and electrical conductivity. Thus, at least one of the above materials can be adaptively selected to prepare the braided layer 12 according to the actual application scenario of the PMMA composite material, thereby obtaining a polymer composite wire harness 1 with optimal functional adaptability.
[0037] Optionally, the coating layer 13 is made of polyester resin, epoxy resin, acrylic resin, or polyurethane resin. Specifically, in this embodiment, the coating layer 13 can be made of at least one of polyester resin, epoxy resin, acrylic resin, and polyurethane resin. It is understood that the above materials possess ideal wear resistance, chemical corrosion resistance, weather resistance, as well as advantages such as high strength, high adhesion, high elasticity, and high flexibility. For example, if polyester resin and epoxy resin are selected, the resulting coating layer 13 simultaneously possesses the weather resistance and wear resistance provided by polyester resin and the high strength and high adhesion provided by epoxy resin; if acrylic resin and polyurethane resin are selected, the resulting coating layer 13 simultaneously possesses the weather resistance provided by acrylic resin and the high elasticity and wear resistance provided by polyurethane resin. Thus, at least one of the above materials can be adaptively selected to prepare the coating layer 13 according to the actual application scenario of the PMMA composite material, thereby obtaining a polymer composite wire harness 1 with optimal functional compatibility.
[0038] Please refer to Figure 3 , Figure 3A schematic diagram of the spatial decomposition structure of a polymerization system is shown, including a mold 300, a liquid phase material (not shown in the figure), and a polymer composite wire bundle 1 as described above. Multiple polymer composite wire bundles 1 are spaced apart and fixed within the mold 300. The liquid phase material (not shown in the figure) is poured into the mold 300, completely covering the polymer composite wire bundles 1. The mold, filled with liquid phase material (not shown in the figure), undergoes a polymerization reaction to obtain a sheet material embedded with the polymer composite wire bundles 1. Specifically, in this embodiment, the mold 300 has a cubic structure. Multiple polymer composite wire bundles 1 are spaced apart and fixed inside the cavity formed by the mold 300. After the liquid phase material (not shown in the figure) is poured into the cavity of the mold 300, completely immersing and filling the cavity with the multiple polymer composite wire bundles 1, a polymerization reaction is carried out on the mold 300 filled with liquid phase material (not shown in the figure). After the reaction, a sheet material embedded with the polymer composite wire bundles 1, i.e., a PMMA composite material, is obtained.
[0039] Optionally, the mold 300 includes an upper template 310, an elastic frame 320, and a lower template 330. Multiple sets of parallel through holes 325 are centrally located on the two opposite sidewalls of the elastic frame 320, with equal spacing between any two adjacent through holes 325. The two ends of the polymer composite wire bundle 1 are respectively disposed within the through holes 325. Specifically, in this embodiment, multiple sets of parallel through holes 325 are spaced apart along the length of the two opposite sidewalls of the elastic frame 320. For the multiple through holes 325 on a single sidewall, the spacing between any two adjacent through holes 325 is equal. Furthermore, when the two ends of the polymer composite wire bundle 1 are respectively interference-fitted into the through holes 325 on the two sidewalls, the multiple polymer composite wire bundles 1 can be fixed in the mold 300 at equal intervals along the length of the sidewalls, forming a parallel arrangement. Thus, compared to polymer composite wire harnesses 1 being scattered within the mold 300, PMMA composite materials made from polymer composite wire harnesses 1 arranged at equal intervals have better tensile strength and impact resistance.
[0040] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.
Claims
1. A high molecular composite harness characterized by, include: The wire harness core material, the braided layer, and the covering layer are provided. The braided layer surrounds the wire harness core material and is tightly attached to the wire harness core material. The covering layer is used to cover the two ends of the braided layer onto the two ends of the wire harness core material, so that the braided layer is fixed to the wire harness core material.
2. The high molecular composite harness according to claim 1, characterized by The wire harness core material includes a central region and two edge regions located outside the two ends of the central region. The braided layer surrounds the wire harness core material and is tightly attached to the central region. The covering layer is used to cover the edge regions and the two ends of the central region so that the braided layer is fixed to the central region.
3. The high molecular composite wire harness according to claim 2, characterized by The length of the middle region is greater than the sum of the lengths of the two edge regions.
4. The polymer composite harness of claim 1, wherein The cross-section of the wire harness core material is circular, and the diameter of the wire harness core material is less than or equal to 5 mm.
5. The polymer composite harness of claim 1, wherein The thickness of the braided layer is 0.01~1.5 mm.
6. The polymer composite harness of claim 1, wherein, The core material of the wire harness is made of nylon, modified nylon, or ultra-high molecular weight polyethylene.
7. The high molecular composite wire harness according to claim 1, characterized by, The material of the braided layer is polyester, nylon, spandex, polypropylene, aramid, glass fiber, carbon fiber, or metal wire.
8. The polymer composite harness of claim 1, wherein, The coating layer is made of polyester resin, epoxy resin, acrylic resin or polyurethane resin.
9. A polymerization system characterized by, The invention includes a mold, a liquid phase material, and a polymer composite wire harness as described in any one of claims 1 to 8. The number of polymer composite wire harnesses is multiple, and the multiple polymer composite wire harnesses are fixed at intervals within the mold. The liquid phase material is poured into the mold and completely covers the polymer composite wire harnesses. The mold filled with the liquid phase material undergoes a polymerization reaction to obtain a plate containing the polymer composite wire harnesses.
10. The polymerization system of claim 9, wherein, The mold includes an upper template, an elastic frame, and a lower template. The elastic frame is sandwiched between the upper template and the lower template. Multiple sets of parallel through holes are centrally located on the two opposite side walls of the elastic frame. The spacing between any two adjacent through holes is equal. The two ends of the polymer composite wire bundle are respectively disposed in the through holes.