High-performance noise reduction air conditioner wire harness

Abstract

The utility model relates to the technical field of air-conditioning wire harnesses, in particular to a high-performance noise-reduction air-conditioning wire harness, which comprises a conductor core wire which is of a multi-strand fine copper wire stranded structure. The inner insulating layer is made of a modified polyethylene material; the electromagnetic shielding layer comprises an inner-layer metal woven mesh and an outer-layer conductive polymer film; the damping noise reduction layer is composed of a butyl rubber matrix and a microcapsule damping material dispersed in the butyl rubber matrix; and the outer sheath layer is made of a thermoplastic polyurethane elastomer material. According to the utility model, the inner insulating layer, the electromagnetic shielding layer, the damping noise reduction layer and the outer sheath layer are arranged, so that electromagnetic interference noise and mechanical vibration noise suffered by the air-conditioning wire harness during the operation of an air-conditioning system are reduced.

Description

Technical Field

[0001] This utility model relates to the field of air conditioning wiring harness technology, specifically a high-performance noise-reducing air conditioning wiring harness. Background Technology

[0002] An air conditioning wiring harness is an electrical connection component that integrates multiple wires and is responsible for power supply, control signal transmission, and data communication between various modules within an air conditioning system.

[0003] When an air conditioning system is running, the air conditioning wiring harness connecting various components will generate electromagnetic interference during current transmission. At the same time, mechanical noise may also be generated due to vibration transmission. Although these noises may not be significant, they may affect the user's sleep in the quiet of the night. Therefore, this utility model aims to provide a high-performance noise-reducing air conditioning wiring harness that can reduce electromagnetic interference noise and suppress mechanical vibration noise of the air conditioning wiring harness. Utility Model Content

[0004] (a) Technical problems to be solved

[0005] To address the shortcomings of existing technologies, this invention provides a high-performance noise-reducing air conditioner wiring harness that can reduce electromagnetic interference noise and suppress mechanical vibration noise, thereby solving the problem that electromagnetic interference noise and mechanical vibration noise of air conditioner wiring harnesses may affect users' sleep.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, this utility model provides a high-performance noise-reducing air conditioning wiring harness, comprising a conductor core wire with a multi-strand fine copper wire stranded structure; an inner insulation layer made of modified polyethylene material; an electromagnetic shielding layer comprising an inner metal braided mesh and an outer conductive polymer film; a damping noise reduction layer composed of a butyl rubber matrix and microcapsule damping material dispersed therein; and an outer sheath layer made of thermoplastic polyurethane elastomer material.

[0008] Optionally, the surface of the conductor core is silver-plated.

[0009] Optionally, the stranding structure of the conductor core wire adopts a concentric layer stranding method, and the stranding pitch ratio is 12-18.

[0010] Optionally, the thickness of the inner insulating layer is 0.8-1.2 mm.

[0011] Optionally, the microcapsule damping material has a particle size of 50-200 μm and a mass fraction of 15%-25%.

[0012] Optionally, the microcapsule damping material is a polyurea microcapsule coated with silicone oil, wherein the viscosity of the silicone oil is 1000-5000 cSt.

[0013] Optionally, the Shore hardness of the outer sheath layer is 75A-85A.

[0014] Optionally, the outer sheath layer has a spiral groove on its surface, and the depth of the spiral groove is 0.3-0.8 mm.

[0015] Optionally, the metal woven mesh is woven with tin-plated copper wire with a weaving density of 85%-95%, and the conductive polymer film contains nano-silver particles with a mass fraction of 3%-8%.

[0016] Optionally, a conductive contact layer is provided between the metal woven mesh and the conductive polymer film, and the conductive contact layer is a nonwoven fabric coated with conductive silver paste.

[0017] (III) Beneficial Effects

[0018] Compared with the prior art, this utility model provides a high-performance noise-reducing air conditioner wiring harness, which has the following beneficial effects:

[0019] 1. This utility model reduces electromagnetic interference noise and mechanical vibration noise experienced by the air conditioning wiring harness during the operation of the air conditioning system by setting an inner insulation layer, an electromagnetic shielding layer, a damping noise reduction layer and an outer sheath layer.

[0020] 2. By setting a conductive contact layer, this utility model ensures a good electrical connection between the metal braided mesh and the conductive polymer film, eliminating the reduction in shielding effect caused by contact resistance and poor contact. The conductive silver paste provides a stable low-impedance channel, and the non-woven fabric substrate provides flexibility and mechanical support, ensuring the integrity and reliability of the shielding layer.

[0021] 3. This utility model provides additional flexibility and heat dissipation by setting a spiral groove. Attached Figure Description

[0022] Figure 1 A three-dimensional structural schematic diagram of the present invention is shown;

[0023] Figure 2 The diagram shows a front view sectional view of the present invention.

[0024] In the diagram: 1. Conductor core wire; 2. Inner insulation layer; 3. Electromagnetic shielding layer; 4. Metal braided mesh; 5. Conductive polymer film; 6. Damping and noise reduction layer; 7. Outer sheath layer; 8. Spiral groove; 9. Conductive contact layer. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] Example: Please refer to Figures 1 to 2 According to an embodiment of the present invention, a technical solution is provided: a high-performance noise-reducing air conditioner wiring harness, comprising a conductor core wire 1, which adopts a multi-strand fine copper wire stranded structure; an inner insulation layer 2, which is made of modified polyethylene material; an electromagnetic shielding layer 3, which includes an inner metal braided mesh 4 and an outer conductive polymer film 5; a damping noise reduction layer 6, which is composed of a butyl rubber matrix and microcapsule damping material dispersed therein; and an outer sheath layer 7, which is made of thermoplastic polyurethane elastomer material.

[0027] The high-performance noise-reducing air conditioning wiring harness with the above structure specifically uses a multi-strand fine copper wire stranding structure for the conductor core wire 1 to reduce the diameter of a single conductor and optimize the stranding pitch, effectively reducing the skin effect of high-frequency current and reducing the intensity of electromagnetic radiation sources. The electromagnetic shielding layer 3 adopts a dual shielding mechanism of "reflection + absorption", that is, the inner metal braided mesh 4 reflects and attenuates the incident electromagnetic waves, and the outer conductive polymer film 5 converts the transmitted electromagnetic energy into heat energy through dielectric loss for absorption and attenuation. The two layers work together to achieve a shielding effectiveness of more than 60dB. In addition, the butyl rubber matrix in the damping and noise reduction layer 6 has excellent viscoelasticity, which can effectively absorb the mechanical vibration energy transmitted by the air conditioning wiring harness. The microcapsule damping material dispersed in the matrix undergoes reversible deformation when subjected to vibration. Through the friction and flow of the internal damping medium, the vibration kinetic energy is converted into heat energy dissipation, which significantly improves the system damping ratio. Finally, the thermoplastic polyurethane elastomer material of the outer sheath layer 7 further provides a buffering and vibration reduction effect, thereby reducing the electromagnetic interference noise and mechanical vibration noise of the air conditioning wiring harness during the operation of the air conditioning system.

[0028] In this embodiment, the surface of conductor core 1 is silver-plated; the electrical conductivity of silver reaches 63 × 10⁻⁶. 6 With a S / m ratio approximately 6% higher than that of copper, it performs superiorly in high-frequency signal transmission, effectively reducing transmission loss and signal distortion.

[0029] In this embodiment, the stranding structure of the conductor core wire 1 adopts a concentric layer stranding method with a stranding pitch ratio of 12-18. This setting can optimize electromagnetic performance while ensuring structural compactness. Too small a pitch ratio will increase manufacturing difficulty and cost, while too large a pitch ratio will reduce the ability to resist electromagnetic interference. The range of 12-18 ensures good flexibility and minimizes electromagnetic coupling between adjacent conductors, effectively suppressing crosstalk and radiated emission.

[0030] In this embodiment, the thickness of the inner insulation layer 2 is 0.8-1.2mm. This setting satisfies the insulation requirement of withstand voltage ≥2500V and controls the overall diameter of the wire harness. If the thickness is less than 0.8mm, the insulation margin is insufficient, and if it exceeds 1.2mm, it will increase the cost and installation space requirements. This thickness range achieves the best cost performance while ensuring electrical safety.

[0031] In this embodiment, the particle size of the microcapsule damping material is 50-200 μm, and the mass fraction is 15%-25%. This setting ensures the uniform dispersion and maximum specific surface area of ​​the damping material. If the particle size is too small, agglomeration will affect the effect, while if it is too large, the distribution will be uneven. The mass fraction of 15%-25% ensures the damping effect without excessively affecting the mechanical properties and processing properties of the matrix material.

[0032] In this embodiment, the microcapsule damping material is a polyurea microcapsule coated with silicone oil, wherein the viscosity of the silicone oil is 1000-5000 cSt. This viscosity range provides the best viscoelastic damping effect within the target frequency band. If the viscosity is too low, the damping performance is insufficient, and if it is too high, it will affect the response speed and temperature stability of the microcapsule. 1000-5000 cSt ensures effective noise reduction performance over a wide frequency band.

[0033] In this embodiment, the Shore hardness of the outer sheath layer 7 is 75A-85A. This setting ensures sufficient wear resistance and mechanical protection while maintaining good flexibility for easy installation and bending. Too low a hardness will affect durability, while too high a hardness will reduce vibration damping effect and installation convenience. This hardness range achieves the best balance between protective performance and operational performance.

[0034] In this embodiment, a spiral groove 8 is formed on the surface of the outer sheath layer 7, and the depth of the spiral groove 8 is 0.3-0.8mm. This setting increases the surface area to improve the heat dissipation effect. At the same time, the spiral structure can provide additional flexibility when bending. If the depth is too shallow, the heat dissipation effect is limited, and if it is too deep, it will weaken the strength of the sheath. The depth of 0.3-0.8mm maximizes the heat dissipation and flexibility effect while ensuring the structural strength.

[0035] In this embodiment, the metal braided mesh 4 is woven with tin-plated copper wire with a weaving density of 85%-95%, and the conductive polymer film 5 contains nano-silver particles with a mass fraction of 3%-8%. The tin plating treatment improves the oxidation resistance and welding performance of the copper wire, the 85%-95% weaving density ensures excellent shielding effect while maintaining flexibility, and the 3%-8% nano-silver content provides sufficient conductivity while controlling cost. The two layers work together to achieve a shielding effectiveness of ≥60dB.

[0036] In this embodiment, a conductive contact layer 9 is provided between the metal braided mesh 4 and the conductive polymer film 5. The conductive contact layer 9 is a non-woven fabric coated with conductive silver paste. This arrangement ensures a good electrical connection between the metal braided mesh 4 and the conductive polymer film 5, eliminates the reduction in shielding effect caused by contact resistance and poor contact, provides a stable low-impedance channel for the conductive silver paste, and provides flexibility and mechanical support for the non-woven fabric substrate, thus ensuring the integrity and reliability of the shielding layer.

[0037] Working principle: The conductor core 1 uses a multi-strand fine copper wire stranded structure to reduce the diameter of a single conductor and optimize the stranding pitch, effectively reducing the skin effect of high-frequency current and reducing the intensity of electromagnetic radiation sources. The electromagnetic shielding layer 3 adopts a "reflection + absorption" dual shielding mechanism, namely: the inner metal braided mesh 4 reflects and attenuates the incident electromagnetic waves, and the outer conductive polymer film 5 absorbs and attenuates the transmitted electromagnetic energy by converting it into heat energy through dielectric loss. The two layers work together to achieve a shielding effectiveness of more than 60dB. In addition, the butyl rubber matrix in the damping and noise reduction layer 6 has excellent viscoelasticity, which can effectively absorb the mechanical vibration energy transmitted by the wiring harness. The microcapsule damping material dispersed in the matrix undergoes reversible deformation when subjected to vibration, and the vibration kinetic energy is converted into heat energy dissipation through the friction and flow of the internal damping medium, significantly improving the system damping ratio. Finally, the thermoplastic polyurethane elastomer material of the outer sheath layer 7 further provides a buffering and vibration reduction effect, thereby reducing the electromagnetic interference noise and mechanical vibration noise experienced by the air conditioning wiring harness during the operation of the air conditioning system.

[0038] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-performance noise-reducing air conditioning wiring harness, characterized in that, include: The conductor core (1) adopts a multi-strand fine copper wire stranded structure; The inner insulation layer (2) is made of modified polyethylene material; The electromagnetic shielding layer (3) includes an inner metal braided mesh (4) and an outer conductive polymer film (5); The damping noise reduction layer (6) is composed of a butyl rubber matrix and microcapsule damping material dispersed therein; The outer sheath layer (7) is made of thermoplastic polyurethane elastomer material.

2. The high-performance noise-reducing air conditioning wiring harness according to claim 1, characterized in that: The surface of the conductor core (1) is silver-plated.

3. The high-performance noise-reducing air conditioning wiring harness according to claim 2, characterized in that: The conductor core (1) adopts a concentric layer stranding method with a stranding pitch ratio of 12-18.

4. The high-performance noise-reducing air conditioning wiring harness according to claim 1, characterized in that: The thickness of the inner insulation layer (2) is 0.8-1.2 mm.

5. The high-performance noise-reducing air conditioning wiring harness according to claim 1, characterized in that: The microcapsule damping material has a particle size of 50-200 μm and a mass fraction of 15%-25%.

6. The high-performance noise-reducing air conditioning wiring harness according to claim 5, characterized in that: The microcapsule damping material is a polyurea microcapsule coated with silicone oil, wherein the viscosity of the silicone oil is 1000-5000 cSt.

7. The high-performance noise-reducing air conditioning wiring harness according to claim 1, characterized in that: The outer sheath layer (7) has a Shore hardness of 75A-85A.

8. A high-performance noise-reducing air conditioning wiring harness according to claim 7, characterized in that: The outer sheath layer (7) has a spiral groove (8) on its surface, and the depth of the spiral groove (8) is 0.3-0.8 mm.

9. A high-performance noise-reducing air conditioning wiring harness according to claim 1, characterized in that: The metal woven mesh (4) is woven with tin-plated copper wire with a weaving density of 85%-95%, and the conductive polymer film (5) contains nano silver particles with a mass fraction of 3%-8%.

10. A high-performance noise-reducing air conditioning wiring harness according to claim 9, characterized in that: A conductive contact layer (9) is provided between the metal woven mesh (4) and the conductive polymer film (5), and the conductive contact layer (9) is a non-woven fabric coated with conductive silver paste.

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