Intelligent entry system door handle switch harness

Abstract

The utility model discloses an intelligent entering system door handle switch wiring harness, including first wire, second wire, heat shrink sleeve, inside position switch, outer position switch and connector, the heat shrink sleeve is covered in first wire, second wire outside, both ends of first wire, second wire all stretch out both ends outside heat shrink sleeve, inside position switch, outer position switch have same structure, the bottom of inside position switch, outer position switch all are fixed with the guard frame through ultrasonic welding, one end of first wire stretches into corresponding guard frame and is connected in inside position switch through the terminal, one end of second wire stretches into corresponding guard frame and is connected in outer position switch through the terminal, the guard frame is filled with epoxy resin glue, the other end of first wire, the other end of second wire all are connected in connector, by this, it has better sealing performance, has guaranteed the reliability and service life of product.

Description

Technical Field

[0001] This utility model relates to the field of automotive wiring harness technology, and in particular to a wiring harness for a smart entry system door handle switch. Background Technology

[0002] A wiring harness is a group of metal wires and cables bundled together, used for signal and power connections between transport devices. It is a wiring component in automotive circuitry that connects various electrical devices, consisting of an insulating sheath, terminals, wires, and insulating wrapping material. Automotive wiring harnesses are the foundation for the operation of automotive electronic networks and power transmission, connecting various electronic components within the vehicle to enable them to receive and execute operational commands.

[0003] With the development of automotive technology, cars have gradually added many new functions. For example, door handles are the control devices for opening car doors. Currently, the market demand for invisible door handles is to design them to improve aesthetics. However, to achieve invisible door handles, a push-button control is currently used. In this case, the door handle is normally attached to the door body, and the door opening function is executed by pressing a position switch. The position switch is connected to the wiring harness via a terminal block. Since car doors are exposed to the outside environment for a long time, rainwater will get on the door and door handle when it rains. This can easily cause rainwater to seep into the inside of the door handle when it is opened. Because the sealing of existing car door handle switch wiring harnesses is not good, rainwater can easily seep in, making it difficult to guarantee the reliability and service life of the product.

[0004] Therefore, a new technology needs to be developed to solve the above problems. Utility Model Content

[0005] In view of this, the present invention addresses the deficiencies of the existing technology, and its main purpose is to provide a door handle switch wiring harness for an intelligent entry system, which has better sealing performance, ensuring the reliability and service life of the product.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A wiring harness for a smart entry system door handle switch includes a first wire, a second wire, a heat-shrink tubing, an inner position switch, an outer position switch, and connectors. The heat-shrink tubing covers the first and second wires, with both ends of the first and second wires extending beyond the ends of the heat-shrink tubing. The inner and outer position switches have identical structures, and their bottoms are each ultrasonically welded with a protective frame. One end of the first wire extends into the corresponding protective frame and is connected to the inner position switch via a terminal block. One end of the second wire extends into the corresponding protective frame and is connected to the outer position switch via a terminal block. The protective frames are filled with epoxy resin. The other ends of the first and second wires are connected to connectors.

[0008] As a preferred embodiment, one end of the first wire and one end of the second wire respectively pass through the side wall openings of the corresponding protective frame and extend into the protective frame, and the epoxy resin filling the protective frame seals the side wall openings of the protective frame.

[0009] As a preferred embodiment, the length of the first wire is greater than the length of the second wire.

[0010] As a preferred embodiment, the connector includes a plastic housing and a plurality of connecting terminals installed inside the plastic housing, wherein the other end of the first wire and the other end of the second wire are respectively connected to the connecting terminals.

[0011] As a preferred embodiment, the end of the plastic shell away from the wire has a plug-in cavity, and the end of the connecting terminal away from the wire is exposed in the plug-in cavity.

[0012] As a preferred embodiment, a waterproof plug is provided inside the plug cavity, one end of which abuts against the inner wall of the plug cavity near the wire, and a through hole is provided on the waterproof plug corresponding to the connection terminal.

[0013] Compared with the prior art, this utility model has obvious advantages and beneficial effects. Specifically, as can be seen from the above technical solution, it mainly involves ultrasonically welding protective frames to the bottom of both the inner and outer position switches, allowing one end of the first wire to extend into the corresponding protective frame and connect to the inner position switch via a terminal block, and allowing one end of the second wire to extend into the corresponding protective frame and connect to the outer position switch via a terminal block. Epoxy resin is then filled into the protective frames. In this way, the ultrasonic welding and epoxy resin filling achieve a sealing effect, thereby providing better sealing performance and ensuring the reliability and service life of the product.

[0014] To more clearly illustrate the structural features, technical means, and specific objectives and functions of this utility model, the following detailed description of this utility model is provided in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present utility model;

[0016] Figure 2 This is a side view of a connector according to an embodiment of the present utility model;

[0017] Figure 3 This is a side view of the assembly structure of the inner position switch and the protective frame according to an embodiment of the present utility model;

[0018] Figure 4 This is a side view of the inner position switch according to an embodiment of the present invention.

[0019] Explanation of reference numerals in the attached diagram:

[0020] 10. First wire; 20. Second wire

[0021] 30. Heat shrink tubing; 40. Internal position switch

[0022] 50. External position switch 60. Connector

[0023] 61. Plastic housing; 62. Connecting terminal

[0024] 70, protective frame; 80, terminal block

[0025] 90. Waterproof plug. Detailed Implementation

[0026] In the description of this utility model, it should be noted that if terms such as "center", "upper", "lower", "left", "right", "front", "back", "vertical", "horizontal", "inner", and "outer" appear to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0027] Please refer to Figures 1 to 4 As shown, it illustrates the specific structure of the door handle switch wiring harness for the intelligent entry system provided in an embodiment of the present invention.

[0028] The door handle switch wiring harness of the intelligent entry system includes a first wire 10, a second wire 20, a heat shrink tubing 30, an inner position switch 40, an outer position switch 50, and a connector 60; the heat shrink tubing 30 covers the first wire 10 and the second wire 20, and both ends of the first wire 10 and the second wire 20 extend beyond the two ends of the heat shrink tubing 30; the length of the first wire 10 is greater than the length of the second wire 20.

[0029] The inner position switch 40 and the outer position switch 50 have the same structure. The bottom of both the inner position switch 40 and the outer position switch 50 are ultrasonically welded to a protective frame 70. One end of the first wire 10 extends into the corresponding protective frame 70 and is connected to the inner position switch 40 via a terminal block 80. One end of the second wire 20 extends into the corresponding protective frame 70 and is connected to the outer position switch 50 via a terminal block 80. The protective frame 70 is filled with epoxy resin. This allows for a sealing effect through ultrasonic welding and epoxy resin filling, resulting in superior sealing performance and ensuring product reliability and service life. Furthermore, the inner position switch 40 and the outer position switch 50 can be commercially available Alps / Omron position switches.

[0030] One end of the first wire 10 and one end of the second wire 20 respectively pass through the side wall openings of the corresponding protective frame 70 and extend into the protective frame 70. The protective frame 70 is filled with epoxy resin to seal the side wall openings. The protective frame 70 has an opening structure at both the top and bottom. During manufacturing, one end of the wire can be passed through the side wall opening of the protective frame 70 first, and then the other end of the wire can be connected to the position switch through the terminal block 80. Then, the upper end of the protective frame 70 is welded to the bottom of the position switch by ultrasonic welding. After welding, the bottom of the protective frame 70 is sealed by filling it with epoxy resin.

[0031] The other end of the first wire 10 and the other end of the second wire 20 are both connected to a connector 60, which is a connector. The connector 60 includes a plastic shell 61 and a plurality of connecting terminals 62 installed inside the plastic shell 61. The other end of the first wire 10 and the other end of the second wire 20 are respectively connected to the connecting terminals 62. The end of the plastic shell 61 away from the wire has a plug cavity, and the end of the connecting terminal 62 away from the wire is exposed in the plug cavity. A waterproof plug 90 is provided in the plug cavity to achieve waterproofing. One end of the waterproof plug 90 abuts against the inner wall of the plug cavity near the wire. The waterproof plug 90 has a through hole corresponding to the connecting terminal 62 for the terminal of an external connector to be inserted and connected to the connecting terminal 62 of the connector 60.

[0032] Furthermore, the door handle switch wiring harness of this intelligent entry system has the following characteristics:

[0033] 1. After the switch has been subjected to ≥200,000 cycles of durability testing, the product must meet the requirements of insulation resistance >500MΩ and circuit continuity. The switch must also pass a 50,000-cycle underwater (20±5cm) durability test while energized. After the test, water must not enter the switch.

[0034] 2. The protective frame 70 of the switch potting compound is ultrasonically welded to the electronic switch. The working temperature requirements are: -40~130℃; volume resistivity: ≥1.0×10Ω·cm; dielectric constant: ≥3.1±0.1; thermal conductivity: ≥0.6W / m·K; curing shrinkage rate: ≤0.5%; hardness requirement: Shore D 80-90. A two-component room temperature curing potting compound is selected. After potting, the compound must be filled completely without overflow or insufficient glue.

[0035] 3. Waterproof ratings are IPX7, IPX8, and IPX9K. IPX7 and IPX8 are mandatory, while IPX9K is a preliminary requirement. After the waterproof test, the conductivity resistance must be ≤1Ω and the insulation resistance >10MΩ.

[0036] 4. Small samples (size less than 250mm): Turntable speed (5±1) rpm, water spraying at 0℃, 30℃, 60℃, and 90℃, distance from the sample (100~150)mm. Flow rate 14~16L / min. Pressure approximately 8000~10000kPa. Water temperature (80±5)℃. 30s per position.

[0037] 5. Large specimens (size greater than 250mm): The entire surface of the test frame 70 will be sprayed, covering the entire surface of the frame 70 from all directions (full surface coverage can be achieved in multiple applications). Spraying distance: Spray from a distance of (175±25)mm. Pressure: Approximately 8000~10000kPa. Water temperature: (80±5)℃. Test duration: 1min / m2, minimum 3min.

[0038] 6. Airtightness characteristics:

[0039] (1) Prepare 10 pairs of connectors using wires with the minimum specifications and thinnest insulation layer applicable to the terminals. The connectors should include all accessories, such as TPA, CPA, seals, etc. Number each pair of connectors;

[0040] (2) Insert two tubes of sufficient strength into the connector, and there should be no leakage between the outer surface of the tubes and the sealing plug;

[0041] (3) Prepare a salt solution by adding 15-16 grams of salt and 10 ml of liquid detergent per liter of water, add appropriate pigment, stir the solution evenly and pour it into the test container;

[0042] (4) Seal all wire ends to eliminate any leakage that may occur through the wire strands;

[0043] (5) Connect one tube to the pressure / vacuum gauge and the other tube to the pressure / vacuum gauge. Immerse the sample in the saline solution prepared in step (c);

[0044] (6) Adjust the pressure / vacuum source to provide a pressure of 10 kPa and maintain it for 5 min; then adjust it to a pressure of 50 kPa at a rate of 10 kPa / min and maintain it for 5 min; observe the sample and record whether bubbles appear during the entire pressure maintenance process;

[0045] (7) Adjust the pressure / vacuum source to provide a pressure of -10 kPa and maintain it for 5 min; then adjust it to a pressure of -50 kPa at a rate of 10 kPa / min and maintain it for 5 min; observe the sample and record whether bubbles appear during the entire pressure maintenance process.

[0046] (8) Repeat steps (e) to (g);

[0047] (9) Remove the sample from the salt solution, wipe the surface dry, and immediately perform the insulation resistance test.

[0048] In summary, the key design feature of this utility model lies in the fact that protective frames are ultrasonically welded to the bottom of both the inner and outer position switches. One end of the first wire extends into the corresponding protective frame and is connected to the inner position switch via a terminal block. Similarly, one end of the second wire extends into the corresponding protective frame and is connected to the outer position switch via a terminal block. Epoxy resin is then filled into the protective frames. This ultrasonic welding and epoxy resin filling achieve a sealing effect, resulting in superior sealing performance and ensuring product reliability and lifespan.

[0049] The above description is merely a preferred embodiment of the present utility model and does not constitute any limitation on the technical scope of the present utility model. Therefore, any minor modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model shall still fall within the scope of the technical solution of the present utility model.

Claims

1. A wiring harness for a door handle switch in an intelligent entry system, characterized in that: The device includes a first wire, a second wire, a heat-shrink tubing, an inner position switch, an outer position switch, and connectors. The heat-shrink tubing covers the first and second wires, with both ends of the first and second wires extending beyond the ends of the heat-shrink tubing. The inner and outer position switches have identical structures, and their bottoms are both ultrasonically welded with protective frames. One end of the first wire extends into the corresponding protective frame and is connected to the inner position switch via a terminal block. One end of the second wire extends into the corresponding protective frame and is connected to the outer position switch via a terminal block. The protective frames are filled with epoxy resin. The other ends of the first and second wires are connected to connectors.

2. The door handle switch wiring harness for the intelligent entry system according to claim 1, characterized in that: One end of the first wire and one end of the second wire respectively pass through the side wall openings of the corresponding protective frame and extend into the protective frame. The epoxy resin filling the protective frame seals the side wall openings of the protective frame.

3. The door handle switch wiring harness for the intelligent entry system according to claim 1, characterized in that: The length of the first wire is greater than the length of the second wire.

4. The door handle switch wiring harness for the intelligent entry system according to claim 1, characterized in that: The connector includes a plastic shell and several connecting terminals installed inside the plastic shell, with the other end of the first wire and the other end of the second wire respectively connected to the connecting terminals.

5. The door handle switch wiring harness for the intelligent entry system according to claim 4, characterized in that: The end of the plastic shell away from the wire has a plug-in cavity, and the end of the connecting terminal away from the wire is exposed in the plug-in cavity.

6. The door handle switch wiring harness for the intelligent entry system according to claim 5, characterized in that: A waterproof plug is provided inside the plug cavity. One end of the waterproof plug abuts against the inner wall of the plug cavity near the wire. A through hole is provided on the waterproof plug corresponding to the connection terminal.

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