A high-temperature resistant wire harness for new energy vehicles

Abstract

This utility model discloses a high-temperature resistant wiring harness for new energy vehicles, including a wiring harness body. The wiring harness body, from the inside out, includes a support member, a conductor, an insulation layer, a conductor shielding layer, a fireproof layer, an armor layer, and an outer sheath. It also includes an end reinforcement structure, comprising a first connector and a second connector. Both first and second connectors are hollow cylinders, connected to opposite sides by a flange. An anti-torsion structure is provided between first and second connectors. This utility model improves the high-temperature resistance and flame retardancy of the outer layer by filling the outer sheath with high-temperature resistant ceramic fiber, providing the first line of defense. The internal fire-resistant rubber, cross-linked polyethylene, and soft copper strip all improve the overall heat resistance, ensuring flame retardancy and safety in high-temperature environments.

Description

Technical Field

[0001] This utility model relates to the field of wire harness technology, specifically to a high-temperature resistant wire harness for new energy vehicles. Background Technology

[0002] Wiring harnesses in new energy vehicles are core components of the vehicle's electrical system, and are mainly divided into low-voltage wiring harnesses and high-voltage wiring harnesses according to their functions. Low-voltage wiring harnesses are not much different from those in traditional fuel vehicles, and are mainly used to transmit low-voltage signals and low-power power supplies, connecting various sensors, controllers, headlights, audio systems, and other low-voltage electrical equipment in the vehicle to realize various control and auxiliary functions of the vehicle.

[0003] High-voltage wiring harnesses are a key component that distinguishes new energy vehicles from traditional fuel vehicles. They are mainly responsible for transmitting high-voltage, high-current electrical energy and connecting key high-voltage components such as battery packs, motors, inverters, and charging devices. Their main application areas and scenarios include power transmission, charging systems, and high-voltage auxiliary equipment.

[0004] In existing technologies, the main structure of high-voltage wiring harnesses consists of an inner conductor and an outer insulation layer, shielding layer, and outer sheath, which provide electromagnetic shielding and insulation protection for the conductor. The outer sheath is usually made of flammable materials such as PVC and PE. To improve durability, a flame-retardant coating is added. However, in cases of abnormal current, conductor temperature rise, or abnormal temperature rise of other electrical components, the wiring harness has a limited time to withstand high temperatures, posing a risk of ignition and leaving room for improvement. Utility Model Content

[0005] This invention aims to solve the aforementioned technical problem that the wire harness has a limited high-temperature resistance time under abnormal current, conductor temperature rise, or other electrical component temperature rise conditions, and provides a high-temperature resistant wire harness for new energy vehicles.

[0006] To solve the above-mentioned technical problems, the technical solution provided by this utility model is as follows: a high-temperature resistant wiring harness for new energy vehicles, comprising a wiring harness body; the wiring harness body comprises, from the inside out, a support member, a conductor, an insulation layer, a conductor shielding layer, a fireproof layer, an armor layer, and an outer sheath; the support member is fire-resistant rubber; the fireproof layer is a double-layer mica tape wrapped around the outside of the conductor shielding layer; the outer sheath is filled with high-temperature resistant ceramic fiber;

[0007] It also includes an end reinforcement structure; the end reinforcement structure includes a connector one fixed to the connection end of the electrical components inside the vehicle, and a connector two fixed to the outer side of the end of the harness body; both connector one and connector two are hollow cylinders, and their opposite sides are connected by a flange; an anti-torsion structure is provided between connector one and connector two.

[0008] Furthermore, the insulating layer is made of cross-linked polyethylene.

[0009] Furthermore, the conductor shielding layer is a soft copper strip, spirally wrapped around the outside of the insulation layer.

[0010] Furthermore, an insulating sealing ring is provided between the first connector and the second connector, and the insulating sealing ring is made of silicone rubber.

[0011] Furthermore, the anti-torsion structure includes a limiting ring at the lower end of the connector, the outer surface of the limiting ring being serrated, and a toothed groove at the upper end of the second connector capable of accommodating the limiting ring.

[0012] Furthermore, the lower end of the connector and the outer side of the limiting ring are provided with several limiting plates, and the upper end of the connector and the outer side of the toothed groove are provided with limiting slots that can accommodate the limiting ring; the limiting plates and limiting slots are all arc-shaped.

[0013] The advantages of this utility model compared with the prior art are as follows:

[0014] By filling the outer sheath with high-temperature resistant ceramic fibers, the high-temperature resistance and flame retardancy of the outer layer are improved, providing the first line of defense. The fire-resistant rubber, cross-linked polyethylene and soft copper strip inside all improve the overall heat resistance and ensure flame retardancy and safety in high-temperature environments.

[0015] An anti-torsion structure is added to the weaker connection end to prevent the end from twisting due to force or wind during use, which would reduce the connection strength and cause the end performance to deteriorate. Attached Figure Description

[0016] Figure 1 This is a cross-sectional schematic diagram of the wire harness body of this utility model.

[0017] Figure 2 This is a schematic diagram of the structure of this utility model.

[0018] Figure 3 This is a schematic diagram of the second connecting component of this utility model.

[0019] Figure 4 This is a structural schematic diagram of the connector of this utility model.

[0020] As shown in the figure: 1. Wire harness body, 2. Support component, 3. Conductor, 4. Insulation layer, 5. Conductor shielding layer, 6. Fireproof layer, 7. Armor layer, 8. Outer sheath, 9. Connector 1, 10. Connector 2, 11. Insulating sealing ring, 12. Limiting ring, 13. Toothed groove, 14. Limiting insert plate, 15. Limiting slot. Detailed Implementation

[0021] The present invention will now be described in further detail with reference to the accompanying drawings.

[0022] Example 1, in conjunction with Appendix Figure 1 A high-temperature resistant wiring harness for new energy vehicles includes a wiring harness body 1; the wiring harness body 1 includes, from the inside to the outside, a support member 2, a conductor 3, an insulation layer 4, a conductor shielding layer 5, a fireproof layer 6, an armor layer 7, and an outer sheath 8.

[0023] Specifically, the support component 2 is made of fire-resistant rubber. Fire-resistant rubber has low smoke and low toxicity. Under flame or high temperature environments, it has good performance in terms of dimensional changes, can maintain structural integrity, and can still maintain good insulation performance under high temperature environments. It forms a support in the middle of the conductor 3, improving the overall structural strength.

[0024] The insulation layer 4 is made of cross-linked polyethylene. Cross-linked polyethylene can withstand high temperatures of 150℃ and has good anti-aging properties. It not only has good insulation performance, but also allows for thinner insulation thickness, which is beneficial for the lightweighting of the wire harness.

[0025] The conductor shielding layer 5 is a soft copper strip, which is spirally wrapped around the outside of the insulation layer 4. The soft copper strip can effectively reduce electromagnetic radiation and interference.

[0026] The fireproof layer 6 consists of a double layer of mica tape wrapped around the outside of the conductor shielding layer 5. Under high temperature conditions, the mica tape can maintain good insulation performance and resistance to high voltage electric field breakdown, and also has good flexibility. Even when burning, it will not produce harmful smoke and has good insulation performance to ensure the integrity of the circuit in the event of a fire.

[0027] The outer sheath 8 is filled with high-temperature resistant ceramic fibers. These fibers can withstand extremely high temperatures, have a low thermal conductivity, and also improve the outer sheath's resistance to acid and alkali corrosion.

[0028] Combined with appendix Figure 2 , 3 4. It also includes an end reinforcement structure; the end reinforcement structure includes connector 9 fixed to the connection end of the electrical component in the vehicle, and connector 10 fixed to the outer side of the end of the wire harness body 1. The upper end of connector 9 is provided with a reinforcement ring, which is fixed to the outer side of the connection end of the electrical component by adhesive; connector 9 and connector 10 are both hollow cylinders, and their opposite sides are connected by flanges; an insulating sealing ring 11 is provided between connector 9 and connector 10. The insulating sealing ring 11 is made of silicone rubber. Silicone rubber has excellent electrical insulation properties and can play a buffer sealing role between connector 9 and connector 10; in addition, silicone rubber also has good high and low temperature resistance, which can protect the end connection of the wire harness.

[0029] Combined with appendix Figure 3 , 4An anti-torsion structure is provided between connector 9 and connector 10. Specifically, the anti-torsion structure includes a limiting ring 12 at the lower end of connector 9, the outer side of the limiting ring 12 is serrated, and a toothed groove 13 is provided at the upper end of connector 10 to accommodate the limiting ring 12. When the limiting ring 12 is inserted into the toothed groove 13, the corresponding teeth will limit each other.

[0030] Based on the above, the lower end of connector 9 and the outer side of the limiting ring 12 are provided with several limiting plates 14, and the upper end of connector 10 and the outer side of the toothed groove 13 are provided with limiting slots 15 that can accommodate the limiting ring 12; the limiting plates 14 and the limiting slots 15 are all arc-shaped; thus, the limiting plates 14 and the limiting slots 15 limit each other, further improving the anti-torsion performance between connector 9 and connector 10; the addition of an anti-torsion structure at the relatively weak connection end can avoid the problem of end torsion due to force or wind during use, which reduces the connection strength and leads to a decrease in end performance.

[0031] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the inventive spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A high-temperature resistant wiring harness for new energy vehicles, comprising a wiring harness body (1); characterized in that: The wire harness body (1) includes, from the inside out, a support member (2), a conductor (3), an insulation layer (4), a conductor shielding layer (5), a fireproof layer (6), an armor layer (7), and an outer sheath (8); the support member (2) is fire-resistant rubber; the fireproof layer (6) is a double-layer mica tape wrapped around the outside of the conductor shielding layer (5); the outer sheath (8) is filled with high-temperature resistant ceramic fiber. It also includes an end reinforcement structure; the end reinforcement structure includes a connector one (9) fixed to the connection end of the electrical components in the car, and a connector two (10) fixed to the outside of the end of the harness body (1); the connector one (9) and the connector two (10) are both hollow cylinders, and their opposite sides are connected by a flange; an anti-torsion structure is provided between the connector one (9) and the connector two (10).

2. The high-temperature resistant wiring harness for new energy vehicles according to claim 1, characterized in that: The insulating layer (4) is made of cross-linked polyethylene.

3. The high-temperature resistant wiring harness for new energy vehicles according to claim 1, characterized in that: The conductor shielding layer (5) is a soft copper strip, which is spirally wrapped around the outside of the insulating layer (4).

4. A high-temperature resistant wiring harness for new energy vehicles according to claim 1, characterized in that: An insulating sealing ring (11) is provided between the first connector (9) and the second connector (10), and the insulating sealing ring (11) is made of silicone rubber.

5. A high-temperature resistant wiring harness for new energy vehicles according to claim 1, characterized in that: The anti-torsion structure includes a limiting ring (12) at the lower end of the connector (9), the outer side of the limiting ring (12) is serrated, and the upper end of the connector (10) is provided with a toothed groove (13) that can accommodate the limiting ring (12).

6. A high-temperature resistant wiring harness for new energy vehicles according to claim 5, characterized in that: The lower end of the first connector (9) and the outer side of the limiting ring (12) are provided with several limiting plates (14), and the upper end of the second connector (10) and the outer side of the toothed groove (13) are provided with limiting slots (15) that can accommodate the limiting ring (12); the limiting plates (14) and the limiting slots (15) are both arc-shaped.

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