Superfine automobile sensor composite wire

Abstract

The utility model discloses a kind of superfine automobile sensor composite wire, it is related to the technical field of automobile wiring harness, including inner core layer, insulating layer, shielding layer and outer protective layer, the inner core layer is made of multiple superfine silver-plated copper wire strands, the diameter of each silver-plated copper wire is 0.05~0.1mm;The insulating layer is tightly wrapped outside the inner core layer, is made of polytetrafluoroethylene material, and the thickness is 0.1~0.2mm;The shielding layer is arranged outside the insulating layer, and is composed of inner layer copper foil shielding layer and outer layer braided copper wire shielding layer, the thickness of the inner layer copper foil shielding layer is 0.02~0.03mm, and the braiding density of the outer layer braided copper wire shielding layer is greater than 90%;The outer protective layer is wrapped outside the shielding layer, is made of polyurethane material, and the thickness is 0.2~0.3mm.The utility model can improve the conductivity of wire, flexibility and anti-interference ability, ensure that sensor can accurately, stably transmit signal, improve the overall performance and safety of automobile.

Description

Technical Field

[0001] This utility model relates to the field of automotive wiring harness technology, specifically to an ultra-fine automotive sensor composite wire. Background Technology

[0002] With the rapid development of the automotive industry, the application of automotive sensors is becoming increasingly widespread, and the performance requirements for sensor wires are also rising. In automotive sensor systems, wires are key components for signal transmission, and their performance directly affects the stability and reliability of the sensor's operation. Existing automotive sensor wires have several problems, such as: insufficient conductivity of ordinary wires, leading to signal attenuation and interference during transmission, affecting the sensor's detection accuracy; poor flexibility of some wires, making them difficult to arrange flexibly in the complex wiring environment of a car, and prone to breakage due to vibration and bending during vehicle operation, reducing the wire's lifespan; furthermore, some wires have weak anti-interference capabilities, unable to effectively withstand the complex electromagnetic environment inside the car, resulting in unstable signal transmission and affecting the normal operation of the automotive electronic system. Utility Model Content

[0003] In view of the problems existing in the current ultra-fine automotive sensor composite wires, this utility model is proposed.

[0004] Therefore, the purpose of this invention is to provide an ultra-fine composite wire for automotive sensors, which solves the problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] An ultra-fine automotive sensor composite wire includes an inner core layer, an insulation layer, a shielding layer, and an outer sheath. The inner core layer is composed of multiple strands of ultra-fine silver-plated copper wire, each strand having a diameter of 0.05–0.1 mm. The insulation layer, made of polytetrafluoroethylene (PTFE), tightly wraps around the inner core layer and has a thickness of 0.1–0.2 mm. The shielding layer, located outside the insulation layer, consists of an inner copper foil shielding layer and an outer braided copper wire shielding layer. The inner copper foil shielding layer has a thickness of 0.02–0.03 mm, and the outer braided copper wire shielding layer has a braiding density greater than 90%. The outer sheath, made of polyurethane, wraps around the shielding layer and has a thickness of 0.2–0.3 mm.

[0007] Preferably, the number of silver-plated copper wires in the inner core layer is 20-30, and the twisting pitch is 3-6 mm.

[0008] Preferably, the insulating layer is wrapped around the inner core layer using an extrusion process.

[0009] Preferably, the braiding density of the outer braided copper wire shielding layer is 92% to 95%.

[0010] Preferably, the outer protective layer is wrapped around the shielding layer by injection molding, with an injection molding temperature of 200-230℃ and a pressure of 10-13MPa.

[0011] Preferably, the silver layer thickness of each silver-plated copper wire in the inner core layer is 0.005 to 0.01 mm.

[0012] Preferably, the outer wall of the outer protective layer is fixedly fitted with a plurality of wear-resistant rings from front to back, and the outer wall of the wear-resistant rings is provided with a plurality of anti-slip grooves arranged in a ring array with the center of the wear-resistant ring as the axis.

[0013] The technical effects and advantages provided by this utility model in the above technical solution are as follows:

[0014] 1. This utility model, by using multiple strands of ultra-fine silver-plated copper wires twisted together in the inner core layer, significantly reduces the resistance of the wires, improves the conductivity, reduces the attenuation during signal transmission, ensures the accurate transmission of sensor signals, and improves the detection accuracy of the sensor.

[0015] 2. This utility model, through the multi-stranded inner core layer and the polyurethane outer sheath, gives the wire excellent flexibility, which can be easily laid in the complex wiring environment of automobiles, and is not easy to break under the frequent vibration and bending conditions during vehicle operation, thus extending the service life of the wire.

[0016] 3. This utility model, through its double-layer shielding structure, uses an inner copper foil layer to shield low-frequency electromagnetic interference and an outer braided copper wire layer to shield high-frequency electromagnetic interference. This effectively resists the complex electromagnetic environment inside the car, ensures stable transmission of sensor signals, and improves the reliability of the automotive electronic system.

[0017] 4. This utility model uses polytetrafluoroethylene for the insulation layer and polyurethane for the outer sheath, which has good chemical stability, wear resistance and oil resistance. It can resist the corrosion of various chemical substances inside the car and external mechanical damage, ensuring the long-term stable operation of the wire in harsh environments. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this utility model. For those skilled in the art, other drawings can be obtained based on these drawings.

[0019] Figure 1 This is a schematic diagram of the structure of an ultra-fine automotive sensor composite wire proposed in this utility model;

[0020] Figure 2 for Figure 1 Enlarged structural diagram of part A in the middle section;

[0021] Figure 3 for Figure 1 A top view of the wear-resistant ring structure.

[0022] Explanation of reference numerals in the attached figures:

[0023] 1. Outer protective layer; 2. Wear-resistant sleeve; 3. Inner core layer; 4. Insulation layer; 5. Shielding layer; 6. Anti-slip groove. Detailed Implementation

[0024] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0025] This utility model discloses an ultra-fine automotive sensor composite wire.

[0026] Example 1

[0027] Reference Figure 1-3 An ultra-fine automotive sensor composite wire includes an inner core layer 3, an insulation layer 4, a shielding layer 5, and an outer sheath 1. The inner core layer 3 is made of multiple strands of ultra-fine silver-plated copper wires twisted together, with each silver-plated copper wire having a diameter of 0.05–0.1 mm. The insulation layer 4 is tightly wrapped around the inner core layer 3 and is made of polytetrafluoroethylene (PTFE) material with a thickness of 0.1–0.2 mm. The shielding layer 5 is disposed outside the insulation layer 4 and consists of an inner copper foil shielding layer and an outer braided copper wire shielding layer. The thickness of the inner copper foil shielding layer is 0.02–0.03 mm, and the braiding density of the outer braided copper wire shielding layer is greater than 90%. The outer sheath 1 is wrapped around the shielding layer 5 and is made of polyurethane material with a thickness of 0.2–0.3 mm.

[0028] The number of silver-plated copper wires in the inner core layer 3 is 20-30, and the twisting pitch is 3-6 mm.

[0029] The insulation layer 4 is wrapped around the inner core layer 3 using an extrusion process.

[0030] The braiding density of the outer braided copper wire shielding layer is 92%–95%.

[0031] The outer protective layer 1 is wrapped around the shielding layer 5 by injection molding. The injection molding temperature is 200-230℃ and the pressure is 10-13MPa.

[0032] The silver layer thickness of each silver-plated copper wire in the inner core layer 3 is 0.005 to 0.01 mm.

[0033] Example 2

[0034] Reference Figure 1-3 Multiple wear-resistant rings 2 are fixedly fitted onto the outer wall of the outer sheath 1 from front to back, allowing the outer sheath 1 to be suspended in the air, thus achieving wear protection for the outer sheath 1. Multiple anti-slip grooves 6 are arranged in a ring array around the center of the wear-resistant ring 2, which improves the anti-slip performance of the wear-resistant ring 2 and thus improves the stability of the conductor.

[0035] In this invention, the inner core layer 3 is made of multiple strands of ultra-fine silver-plated copper wires twisted together. The silver plating layer can effectively improve conductivity and reduce signal loss during transmission, allowing the signals collected by the sensor to be accurately transmitted to the automotive electronic control system. The multi-strand twisting design, combined with the ultra-fine diameter of 0.05 to 0.1 mm per strand, gives the inner core layer 3 excellent flexibility. When the main body 1 of the wire is wired in a narrow and complex space such as the engine compartment and chassis of a car, it can be easily bent and folded to adapt to various wiring paths, avoiding difficulty in installation due to excessive rigidity.

[0036] The insulation layer 4 is made of polytetrafluoroethylene (PTFE) and is tightly wrapped around the inner core layer 3. It can not only reliably isolate the inner core layer 3 from the external current conduction and prevent short circuits, but also PTFE has the characteristics of high and low temperature resistance and chemical corrosion resistance. In environments with drastic temperature changes and the presence of oil and other chemicals, such as the car engine compartment, it can maintain stable insulation performance for a long time. The thickness of 0.1 to 0.2 mm also ensures the insulation effect without excessively increasing the overall diameter of the wire, which is conducive to the compact arrangement of the wire.

[0037] The inner copper foil shielding layer and the outer braided copper wire shielding layer of shielding layer 5 work together. The thickness of the inner copper foil shielding layer is 0.02 to 0.03 mm, which can effectively block low-frequency electromagnetic interference. The braided copper wire shielding layer has a braiding density of more than 90%, especially at a density of 92% to 95%, which provides better shielding effect against high-frequency electromagnetic interference. There are many electronic devices inside the car, such as engine control unit and vehicle radar. These devices generate a lot of electromagnetic signals when they work. The double-layer shielding structure can isolate these interference signals outside the wires, ensuring that the sensor signals are not interfered with and are transmitted stably.

[0038] The outer sheath is made of polyurethane material with a thickness of 0.2-0.3mm, which has good wear resistance and tensile strength. When the car is in motion, the wire will inevitably rub and collide with other parts. The outer sheath can provide reliable protection for the inner shielding layer 5, insulation layer 4 and inner core layer 3, reducing wear and damage. At the same time, multiple wear-resistant rings 2 fixedly sleeved on the outer wall of the outer sheath further enhance the wear resistance of the outer sheath. The anti-slip grooves 6 on the outer wall of the wear-resistant rings 2 can increase the friction when the wire is fixed, prevent the wire from shifting in the vibration environment, and ensure that the wire is always in a stable working position.

[0039] In addition, the outer sheath is wrapped around the shielding layer 5 using injection molding at 200-230℃ and 10-13MPa, which makes the outer sheath and the shielding layer 5 tightly bonded and not easy to fall off. This further improves the overall structural stability of the wire, allowing the wire to function stably under the complex conditions of vibration and impact during long-term operation of the car, ensuring the normal operation of the sensor, and thus improving the overall performance and safety of the car.

[0040] The foregoing description only illustrates certain exemplary embodiments of the present invention. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A composite wire for an ultra-fine automotive sensor, comprising an inner core layer (3), an insulation layer (4), a shielding layer (5), and an outer sheath (1), characterized in that, The inner core layer (3) is made of multiple strands of ultra-fine silver-plated copper wires twisted together, with each strand having a diameter of 0.05 to 0.1 mm. The insulating layer (4) is tightly wrapped around the inner core layer (3) and is made of polytetrafluoroethylene material with a thickness of 0.1 to 0.2 mm. The shielding layer (5) is disposed outside the insulating layer (4) and consists of an inner copper foil shielding layer and an outer braided copper wire shielding layer. The inner copper foil shielding layer has a thickness of 0.02 to 0.03 mm, and the outer braided copper wire shielding layer has a braiding density greater than 90%. The outer protective layer (1) is wrapped around the shielding layer (5) and is made of polyurethane material with a thickness of 0.2 to 0.3 mm.

2. The ultra-fine automotive sensor composite wire according to claim 1, characterized in that, The number of silver-plated copper wires in the inner core layer (3) is 20-30, and the twisting pitch is 3-6 mm.

3. The ultra-fine automotive sensor composite wire according to claim 1, characterized in that, The insulating layer (4) is wrapped around the inner core layer (3) by an extrusion process.

4. The ultra-fine automotive sensor composite wire according to claim 1, characterized in that, The braiding density of the outer braided copper wire shielding layer is 92% to 95%.

5. The ultra-fine automotive sensor composite wire according to claim 1, characterized in that, The outer protective layer (1) is wrapped around the shielding layer (5) by injection molding process. The injection molding temperature is 200-230℃ and the pressure is 10-13MPa.

6. The ultra-fine automotive sensor composite wire according to claim 1, characterized in that, The silver layer thickness of each silver-plated copper wire in the inner core layer (3) is 0.005 to 0.01 mm.

7. The ultra-fine automotive sensor composite wire according to claim 1, characterized in that, The outer wall of the outer protective layer (1) is fixedly fitted with multiple wear-resistant rings (2) from front to back. The outer wall of the wear-resistant rings (2) is provided with multiple anti-slip grooves (6) arranged in a ring array with the center of the wear-resistant rings (2) as the axis.

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