Improved motorcycle wiring harness structure

Abstract

The utility model discloses an improved generation motorcycle wire harness structure, including wire harness body and the connecting terminal of both ends thereof. The innovation lies in, and wire harness body's at least one local vulnerable section is covered with compound reinforcing cover. The compound reinforcing cover includes flexible inner lining layer, metal braided layer and outer cladding layer with axial corrugated structure gradually from inside to outside. Flexible inner lining layer can effectively absorb vibration and provide bending buffer, and metal braided layer gives structure excellent wear resistance and electromagnetic shielding performance, and outer cladding layer plays the sealing protection and the fixed effect. This structure is especially suitable for handlebar steering, crossing frame hole or approaching engine exhaust pipe and other key sections, and through the synergistic effect of each functional layer, the mechanical strength, the fatigue resistance and the electromagnetic compatibility of wire harness are fundamentally improved, and the service life is effectively prolonged and the safety reliability is enhanced.

Description

Technical Field

[0001] This utility model relates to the field of motorcycle wiring harness technology, specifically an improved motorcycle wiring harness structure. Background Technology

[0002] Motorcycles, as a widely used means of transportation, operate in extremely complex and harsh environments, requiring them to withstand vibration, impact, high temperatures, weathering, and various physical frictions over extended periods. As the "nerve center" of the motorcycle's electrical system, the reliability of the wiring harness directly affects the overall safety and stability of the vehicle. The wiring harness typically consists of multiple wires bundled together, with terminals at both ends for connecting various electrical components on the motorcycle.

[0003] Currently, motorcycle wiring harnesses are typically encased in ordinary PVC corrugated tubing or plastic sheaths for basic protection. However, this conventional protection method has significant shortcomings: First, in specific localized areas such as handlebar steering, areas passing through metal holes in the frame, and areas near the engine exhaust pipe, the wiring harness is subject to frequent bending, continuous friction with hard components, or prolonged exposure to high temperatures. This causes the ordinary sheath to age, wear down, and even melt through, leading to exposed internal wires, short circuits, electrical faults, and safety hazards. Second, the operation of motorcycle components such as the engine generates strong electromagnetic interference, which may affect the transmission accuracy of sensor signals and the operational stability of the electronic control unit. Ordinary sheaths do not provide electromagnetic shielding.

[0004] In existing technologies, although there are solutions that use metal braided sheaths to improve wear resistance or shielding performance, the metal sheaths are relatively hard and do not match the flexibility of the internal wire harness. Under long-term vibration, the internal wires are prone to breakage due to stress concentration.

[0005] Therefore, we propose an improved motorcycle wiring harness structure. Utility Model Content

[0006] (a) Technical problems to be solved To address the shortcomings of existing technologies, this utility model provides an improved motorcycle wiring harness structure. Through a composite reinforcing sleeve consisting of a flexible inner lining layer, a metal braided layer, and an outer covering layer, it integrates buffering, wear resistance, shielding, and sealing functions, thereby improving the mechanical strength, fatigue resistance, and electromagnetic compatibility of the motorcycle wiring harness in vulnerable areas. This extends its service life and enhances safety and reliability, effectively solving the problems in the background technology.

[0007] (II) Technical Solution To achieve the above objectives, the technical solution adopted by this utility model is as follows: an improved motorcycle wiring harness structure, including a wiring harness body and connecting terminals disposed at both ends thereof, wherein at least one local section of the wiring harness body is fitted with a composite reinforcing sleeve; the composite reinforcing sleeve comprises, from the inside to the outside: a flexible inner liner layer, the tube wall of which is provided with an axially extending corrugated structure; a metal braided layer, fitted outside the flexible inner liner layer; and an outer covering layer, covering outside the metal braided layer.

[0008] Preferably, the braiding density of the metal braided layer is greater at its two axial ends than at its middle section.

[0009] Preferably, the corrugated structure of the flexible inner liner is disposed on its outer wall and contacts the inner surface of the metal braided layer.

[0010] Preferably, the outer covering layer is an integral structure formed by molding process, which completely encapsulates both ends of the metal braided layer.

[0011] Preferably, the outer surface of the outer covering layer is integrally formed with a fixing structure for connecting with the vehicle frame, the fixing structure being a cable tie hole.

[0012] Preferably, the composite reinforcing sleeve is disposed on the section of the wiring harness body corresponding to the handlebar steering, passing through the frame hole, or near the engine exhaust pipe.

[0013] Preferably, the flexible inner liner is made of high-temperature resistant silicone.

[0014] Preferably, the metal braided layer is made of stainless steel.

[0015] Preferably, the thickness of the flexible inner lining layer is 0.3mm to 0.8mm; the thickness of the metal braided layer is 0.2mm to 0.5mm; and the thickness of the outer covering layer is 0.4mm to 1.0mm.

[0016] (III) Beneficial Effects Compared with the prior art, this utility model provides an improved motorcycle wiring harness structure, which has the following beneficial effects: 1. This improved motorcycle wiring harness structure achieves integrated "buffering-wear resistance-sealing" functions through a composite structure of a flexible inner liner, a metal braided layer, and an outer covering layer. The flexible inner liner effectively absorbs vibration energy and provides buffering; the metal braided layer, as the core protective layer, provides excellent wear resistance and mechanical strength; and the outer covering layer plays a role in sealing, fixing, and corrosion prevention. This synergistic effect fundamentally improves the technical problems of easy wear, aging, and short circuits in local sections of the wiring harness, such as handlebars, frame holes, and near the engine, thus extending the service life of the wiring harness.

[0017] 2. This improved motorcycle wiring harness structure features an axially extending corrugated structure on the outer wall of the flexible inner liner, which enables the composite reinforcing sleeve to have excellent elastic deformation capability in the axial direction. When applied to parts such as handlebars that require frequent turning, the corrugated structure can effectively release bending stress, prevent the wiring harness from undergoing plastic fatigue fracture due to long-term repeated bending, and improve reliability in dynamic usage scenarios.

[0018] 3. This improved motorcycle wiring harness structure uses a gradually increasing braiding density at both ends of the metal braided layer, combined with a molded outer covering layer to completely encapsulate both ends, forming a robust mechanical interlocking structure, which improves the problem of easy fraying at the ends of the metal braided layer.

[0019] 4. This improved motorcycle wiring harness structure eliminates the need for additional fasteners by integrally forming cable tie holes on the outer surface of the outer covering layer, avoiding secondary wear caused by insecure fastening, resulting in high installation efficiency and reliable connection. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of an improved motorcycle wiring harness according to this utility model.

[0021] Figure 2 This is a cross-sectional schematic diagram of one end of the composite reinforcing sleeve in an improved motorcycle wiring harness structure according to this utility model.

[0022] Figure 3 This is a side cross-sectional view of the flexible inner liner layer in an improved motorcycle wiring harness structure according to this utility model.

[0023] Figure 4 This is a side view of the metal braided layer in an improved motorcycle wiring harness structure according to this utility model.

[0024] In the diagram: 1. Wire harness body; 2. Connecting terminal; 3. Composite reinforcing sleeve; 4. Fixing structure; 5. Flexible inner lining layer; 6. Metal braided layer; 7. Outer covering layer; 8. Corrugated structure. Detailed Implementation

[0025] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments.

[0026] Example 1: like Figure 1-4 As shown, this embodiment provides an improved motorcycle wiring harness structure, mainly used to solve the problems of easy wear, susceptibility to electromagnetic interference, and bending fatigue in specific local sections of motorcycle wiring harnesses.

[0027] The wiring harness structure includes a harness body 1 and connecting terminals 2 crimped or soldered to both ends of the harness. The harness body 1 is made of multiple wires bundled together. Crucially, at least one local section of the harness body 1 corresponding to the handlebar steering area, the area passing through the metal holes in the frame, and the high-temperature area near the engine exhaust pipe is tightly fitted with a composite reinforcing sleeve 3.

[0028] See Figure 2 The composite reinforced sleeve 3 consists of a flexible inner lining layer 5, a metal braided layer 6, and an outer covering layer 7, from the inside out.

[0029] The flexible inner liner 5 is made of high-temperature resistant silicone material through extrusion molding, and its thickness is preferably 0.5 mm. (See also...) Figure 3 The outer wall of the flexible inner liner 5 is provided with a continuous and uniformly distributed axially extending corrugated structure 8. This corrugated structure 8 not only increases the flexibility and elasticity of the inner liner itself, enabling it to better absorb vibrations from the motorcycle during operation, but also effectively releases stress through the expansion and contraction of the corrugations in bending scenarios such as handlebar steering, preventing the wires inside the harness from breaking due to stress concentration.

[0030] The metal braided layer 6, tightly fitted outside the flexible inner liner layer 5, is made of stainless steel wire and preferably has a thickness of 0.3 mm. This metal braided layer 6 provides excellent mechanical strength and abrasion resistance, effectively preventing the wire harness from being cut or worn when passing through frame holes or rubbing against other components. Simultaneously, the stainless steel metal braided layer 6 constitutes a good electromagnetic shielding layer, suppressing the impact of external electromagnetic interference on the signal transmission within the wire harness and reducing electromagnetic radiation generated by the wire harness itself. Furthermore, the braiding density of the metal braided layer 6 is higher at its axial ends than in its middle section. This gradual braiding density design gives the ends of the composite reinforcing sleeve 3 higher structural strength and resistance to loosening.

[0031] The outer covering layer 7 is formed by molding thermoplastic elastomer (TPE) material over the metal braided layer 6 to create an integral structure, with a preferred thickness of 0.7 mm. The molding process allows the molten TPE material to fully penetrate the mesh of the metal braided layer 6, forming a fully encapsulated structure at both axial ends. This firmly bonds the metal braided layer 6 and the flexible inner liner layer 5 into a single unit, effectively preventing fraying at the ends of the metal braided layer 6 and providing excellent sealing and environmental corrosion resistance. Furthermore, during the molding process, a fixing structure 4 is integrally formed on the outer surface of the outer covering layer 7. In this embodiment, the fixing structure 4 is a cable tie hole (see...). Figure 1 By using nylon cable ties to pass through the cable tie holes, the composite reinforcing sleeve 3 and the internal wiring harness body 1 can be conveniently and reliably fixed to the predetermined position on the motorcycle frame.

[0032] Example 2: This embodiment has the same basic structure as Embodiment 1. The main difference lies in the dimensional parameters of each layer of the composite reinforcing sleeve 3 and the form of the fixing structure.

[0033] In this embodiment, the flexible inner liner 5 has a thickness of 0.3 mm, the metal braided layer 6 has a thickness of 0.5 mm, and the outer covering layer 7 has a thickness of 1.0 mm. This combination is suitable for sections with higher requirements for wear resistance and mechanical protection, while allowing for a slightly larger bending radius.

[0034] In addition, the fixing structure 4 integrally formed on the outer surface of the outer covering layer 7 can be designed as a fixing lug with mounting bolt holes so that it can be directly connected to the frame by bolts, providing a more rigid fixation.

[0035] Working Principle: When this improved wiring harness structure is installed on a motorcycle, its composite reinforcing sleeve 3 covers the most protected sections. The flexible inner liner 5 first contacts the wiring harness body 1, buffering vibration and bending stress through its corrugated structure 8. The metal braided layer 6 serves as the main load-bearing layer, resisting external friction, compression, and cutting, and providing electromagnetic shielding. The outer sheath 7 protects the metal layer from corrosion and ensures stable fixation of the entire wiring harness section through the integrally molded fixing structure 4. These three elements work together to improve the durability and reliability of the wiring harness under harsh operating conditions.

[0036] It should be noted that, in this document, relational terms such as first and second (number one, number two), etc., are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, 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 said element.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model.

Claims

1. An improved motorcycle wiring harness structure, comprising a wiring harness body (1) and connecting terminals (2) disposed at both ends thereof, characterized in that: At least one local section of the wire harness body (1) is fitted with a composite reinforcing sleeve (3). The composite reinforced sleeve (3) comprises, from the inside out: The flexible inner liner (5) has an axially extending corrugated structure (8) on its pipe wall. A metal braided layer (6) is fitted over the flexible inner lining layer (5); The outer covering layer (7) covers the metal braided layer (6).

2. The improved motorcycle wiring harness structure according to claim 1, characterized in that: The braided metal layer (6) has a higher braiding density at both ends of its axial direction than at its middle section.

3. An improved motorcycle wiring harness structure according to claim 1 or 2, characterized in that: The corrugated structure (8) of the flexible inner lining layer (5) is disposed on its outer wall and is in contact with the inner surface of the metal braided layer (6).

4. An improved motorcycle wiring harness structure according to claim 1 or 2, characterized in that: The outer covering layer (7) is an integral structure formed by molding process, which completely encapsulates both ends of the metal braided layer (6).

5. An improved motorcycle wiring harness structure according to claim 4, characterized in that: The outer surface of the outer covering layer (7) is integrally formed with a fixing structure (4) for connecting with the frame, the fixing structure (4) being a cable tie hole.

6. The improved motorcycle wiring harness structure according to claim 1, characterized in that: The composite reinforcement sleeve (3) is disposed on the wiring harness body (1) in the section corresponding to the handlebar steering, passing through the frame hole or near the engine exhaust pipe.

7. The improved motorcycle wiring harness structure according to claim 1, characterized in that: The flexible inner liner (5) is made of high-temperature resistant silicone.

8. The improved motorcycle wiring harness structure according to claim 1, characterized in that: The metal braided layer (6) is made of stainless steel.

9. An improved motorcycle wiring harness structure according to claim 1, characterized in that: The thickness of the flexible inner lining layer (5) is 0.3 mm to 0.8 mm; the thickness of the metal braided layer (6) is 0.2 mm to 0.5 mm; and the thickness of the outer covering layer (7) is 0.4 mm to 1.0 mm.

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