Fireproof and flame-retardant automobile wire harness
Patent Information
- Application Number
- CN202522220316.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-21
- Publication Date
- 2026-09-18
- Estimated Expiration
- 2035-10-21
AI Technical Summary
传统汽车线束多采用单一绝缘材料包裹，结构简单，防火与阻燃性能较差，在高温、短路或火灾等极端情况下容易引发燃烧，导致电路失效甚至整车起火事故，存在较大的安全隐患
1、本实用新型通过设置多层复合结构，包括初级硅橡胶绝缘层、防火膨胀填充层、复合阻燃层、复合屏蔽层以及防火水性膨胀涂层，实现了线束在高温或火灾条件下的逐级防护与自阻燃功能，各层材料协同作用，遇火时膨胀填充导体间隙并形成碳化层，有效隔离火焰与热量，显著提升线束的耐火极限和安全性，尤其适用于新能源汽车高压系统中对防火性能要求极高的应用场景。
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Figure CN224773592U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of automotive wiring harness technology, and in particular to a fireproof and flame-retardant automotive wiring harness. Background Technology
[0002] With the rapid development of new energy vehicles and electric vehicles, the voltage level of automotive electrical systems is constantly increasing. As a key component for power and signal transmission in vehicle electrical systems, the safety and stability of wiring harnesses are of paramount importance. Traditional automotive wiring harnesses often use a single insulating material, resulting in a simple structure and poor fire resistance and flame retardancy. Under extreme conditions such as high temperatures, short circuits, or fires, they are prone to combustion, leading to circuit failure or even vehicle fires, posing significant safety hazards. Furthermore, with the widespread application of high-voltage systems, wiring harnesses also face challenges such as increased electromagnetic interference and rising ambient temperatures. Traditional wiring harness structures can no longer meet increasingly stringent safety and performance requirements. Therefore, we propose a fire-resistant and flame-retardant automotive wiring harness. Utility Model Content
[0003] The main objective of this invention is to provide a fireproof and flame-retardant automotive wiring harness that can effectively solve the problems in the background art.
[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A fireproof and flame-retardant automotive wiring harness includes a conductor core braided from multiple tin-plated copper wires, a primary silicone rubber insulation layer disposed outside the conductor core, and a fireproof and flame-retardant layer disposed outside the multiple conductor cores, wherein the gaps between the fireproof and flame-retardant layer and the primary silicone rubber insulation layer are filled with a fireproof expansion filler layer. The fireproof and flame-retardant layer includes a composite flame-retardant layer disposed on the outside of multiple primary silicone rubber insulation layers, a composite shielding layer disposed on the outside of the composite flame-retardant layer, and a fireproof water-based expansion coating sprayed on the outside of the composite shielding layer.
[0005] Preferably, the composite flame-retardant layer includes a flame-retardant glass fiber braided layer disposed outside a plurality of primary silicone rubber insulating layers and a metal wire braided layer disposed outside the flame-retardant glass fiber braided layer.
[0006] By adopting the above technical solution, the composite flame-retardant layer employs a structural design combining a flame-retardant glass fiber braided layer and a metal wire braided layer. The flame-retardant glass fiber braided layer provides basic flame-retardant performance and structural support, exhibiting excellent high-temperature resistance and aging resistance. The metal wire braided layer not only enhances the overall mechanical strength of the wire harness but also possesses good conductivity and electromagnetic shielding capabilities, effectively improving the stability and safety of the wire harness in complex electromagnetic environments, thus achieving integrated flame-retardant and shielding functions.
[0007] Preferably, a halogen-free flame retardant interlayer is filled between the flame-retardant glass fiber braided layer and the metal wire braided layer.
[0008] By adopting the above technical solution, a halogen-free flame retardant interlayer is set between the flame-retardant glass fiber braided layer and the metal wire braided layer, further enhancing the overall fire resistance of the composite flame-retardant layer. This interlayer uses environmentally friendly halogen-free flame-retardant materials, which do not release toxic gases when burning, meeting the environmental and safety requirements of modern automobiles. At the same time, this interlayer can effectively delay the spread of flames, improve the fire resistance limit of the wiring harness, and work synergistically with the inner and outer layer materials to form a multi-level flame-retardant protection system, significantly improving the safety and reliability of the wiring harness in extreme environments.
[0009] Preferably, the composite shielding layer includes a ferrite film layer disposed outside the metal wire braided layer and an aluminum foil film layer disposed outside the ferrite film layer.
[0010] By adopting the above technical solution, the composite shielding layer uses a combination structure of ferrite thin film layer and aluminum foil thin film layer, which achieves dual shielding effect against low-frequency magnetic field and high-frequency electromagnetic interference. The ferrite thin film layer can effectively absorb low-frequency electromagnetic waves and reduce electromagnetic radiation interference; the aluminum foil thin film layer has good conductivity and high-frequency shielding performance. The combination of the two can significantly improve the electromagnetic compatibility of the wiring harness, and is particularly suitable for high-voltage systems of new energy vehicles.
[0011] Preferably, the thickness of the primary silicone rubber insulating layer is 0.2-0.8 mm, and the thickness of the fire-retardant water-based expansion coating is 0.2-0.5 mm.
[0012] By adopting the above technical solutions: the thickness of the primary silicone rubber insulation layer is controlled within the range of 0.2-0.8 mm, which ensures good electrical insulation performance and high temperature resistance, while avoiding affecting the flexibility of the wire harness and wiring space due to excessive thickness; the thickness of the fireproof water-based expansion coating is 0.2-0.5 mm, ensuring that it can quickly expand to form a dense carbonized layer when exposed to fire, achieving effective heat insulation and fire-retardant functions, while also taking into account the convenience of construction and environmental protection.
[0013] Preferably, the thickness of the flame-retardant glass fiber braided layer is 0.1-0.3 mm, and the thickness of the metal wire braided layer is 0.1-0.5 mm.
[0014] By adopting the above technical solution: the thickness of the flame-retardant glass fiber braided layer is controlled between 0.1-0.3 mm, which can provide good flame-retardant support without affecting the bending performance and overall flexibility of the wire harness; the thickness of the halogen-free flame retardant interlayer is 0.1-0.5 mm, which can further improve the overall flame-retardant performance without significantly increasing the weight of the wire harness, while meeting the environmental protection regulations for non-toxic and harmless combustion products.
[0015] Preferably, the thickness of the ferrite film layer is 0.05-0.2 mm, and the thickness of the aluminum foil film layer is 0.02-0.1 mm.
[0016] By adopting the above technical solution: the thickness of the ferrite film layer is controlled between 0.05-0.2 mm, which can effectively absorb low-frequency electromagnetic interference and improve electromagnetic compatibility performance without significantly increasing the weight of the wire harness; the thickness of the aluminum foil film layer is 0.02-0.1 mm, which has excellent high-frequency shielding performance and good flexibility, making it easy to process and lay wire harnesses. The combination of the two can achieve comprehensive shielding against electromagnetic interference of different frequencies.
[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. This utility model, by setting a multi-layer composite structure, including a primary silicone rubber insulation layer, a fire-resistant expansion filling layer, a composite flame-retardant layer, a composite shielding layer, and a fire-resistant water-based expansion coating, achieves step-by-step protection and self-flame-retardant function for the wiring harness under high temperature or fire conditions. The materials of each layer work together to expand and fill the gaps between conductors when exposed to fire and form a carbonized layer, effectively isolating flames and heat, significantly improving the fire resistance limit and safety of the wiring harness, and is especially suitable for application scenarios with extremely high fire resistance requirements in high voltage systems of new energy vehicles.
[0018] 2. This utility model, while fulfilling fireproof and flame-retardant functions, integrates electromagnetic shielding design. Through the combination of a ferrite thin film layer and an aluminum foil thin film layer, it effectively suppresses low-frequency and high-frequency electromagnetic interference, improves the electromagnetic compatibility (EMC) of the wiring harness, and ensures the stable operation of the vehicle's electrical system. Furthermore, all materials used are halogen-free and environmentally friendly, meeting the environmental performance requirements of modern automobiles. Its reasonable structural design facilitates large-scale production and application, giving it significant market potential. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of the overall structure of a fireproof and flame-retardant automotive wiring harness according to this utility model; Figure 2 This is a schematic diagram of the composition structure of a fireproof and flame-retardant automotive wiring harness according to the present invention. Figure 3 This is a schematic diagram of the composite flame-retardant layer for a fireproof and flame-retardant automotive wiring harness according to the present invention. Figure 4 This is a schematic diagram of the structure of a composite shielding layer for a fireproof and flame-retardant automotive wiring harness according to this utility model.
[0020] In the diagram: 1. Conductor core; 2. Primary silicone rubber insulation layer; 3. Fire-retardant layer; 4. Fire-retardant expansion filler layer; 5. Composite flame-retardant layer; 51. Flame-retardant glass fiber braided layer; 52. Metal wire braided layer; 53. Halogen-free flame retardant interlayer; 6. Composite shielding layer; 61. Ferrite film layer; 62. Aluminum foil film layer; 7. Fire-retardant water-based expansion coating. Detailed Implementation
[0021] 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.
[0022] In the description of this utility model, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used 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. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0023] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," and "connected," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0024] Please see Figure 1-4 This utility model provides a technical solution: A fireproof and flame-retardant automotive wiring harness includes a conductor core 1 woven from multiple tin-plated copper wires, a primary silicone rubber insulation layer 2 disposed outside the conductor core 1, and a fireproof and flame-retardant layer 3 disposed outside the multiple conductor cores 1. The gaps between the fireproof and flame-retardant layer 3 and the primary silicone rubber insulation layer 2 are filled with a fireproof expansion filler layer 4.
[0025] In this embodiment, the fire-retardant layer 3 includes a composite flame-retardant layer 5 disposed on the outside of multiple primary silicone rubber insulation layers 2, a composite shielding layer 6 disposed on the outside of the composite flame-retardant layer 5, and a fire-retardant water-based expansion coating 7 sprayed on the outside of the composite shielding layer 6; the thickness of the primary silicone rubber insulation layer 2 is 0.2-0.8 mm, and the thickness of the fire-retardant water-based expansion coating 7 is 0.2-0.5 mm; the composite flame-retardant layer 5 includes a flame-retardant glass fiber braided layer 51 disposed on the outside of multiple primary silicone rubber insulation layers 2 and a metal wire braided layer 52 disposed on the outside of the flame-retardant glass fiber braided layer 51; a halogen-free flame retardant interlayer 53 is filled between the flame-retardant glass fiber braided layer 51 and the metal wire braided layer 52; the thickness of the flame-retardant glass fiber braided layer 51 is 0.1-0.3 mm, and the thickness of the metal wire braided layer 52 is 0.1-0.5 mm.
[0026] Through the above scheme: the composite flame-retardant layer 5 adopts a structural design that combines a flame-retardant glass fiber braided layer 51 and a metal wire braided layer 52. The flame-retardant glass fiber braided layer 51 provides basic flame-retardant performance and structural support, and has good high temperature resistance and aging resistance. The metal wire braided layer 52 not only enhances the overall mechanical strength of the wire harness, but also has good conductivity and electromagnetic shielding function, which can effectively improve the stability and safety of the wire harness in complex electromagnetic environments, and realize the integrated flame-retardant and shielding functions.
[0027] In this embodiment, the composite shielding layer 6 includes a ferrite film layer 61 disposed outside the metal wire braided layer 52 and an aluminum foil film layer 62 disposed outside the ferrite film layer 61; the thickness of the ferrite film layer 61 is 0.05-0.2 mm, and the thickness of the aluminum foil film layer 62 is 0.02-0.1 mm.
[0028] Through the above scheme, the composite shielding layer 6 adopts a combination structure of ferrite thin film layer 61 and aluminum foil thin film layer 62, which achieves a dual shielding effect against low-frequency magnetic fields and high-frequency electromagnetic interference. The ferrite thin film layer 61 can effectively absorb low-frequency electromagnetic waves and reduce electromagnetic radiation interference; the aluminum foil thin film layer 62 has good conductivity and high-frequency shielding performance. The combination of the two can significantly improve the electromagnetic compatibility (EMC) of the wire harness, and is particularly suitable for high-voltage systems of new energy vehicles.
[0029] It should be noted that this utility model is a fireproof and flame-retardant automotive wiring harness, which adopts a multi-layer composite structure design, including, from the inside out, a conductor core 1, a primary silicone rubber insulation layer 2, a fireproof expansion filling layer 4, a composite flame-retardant layer 5, a composite shielding layer 6, and a fireproof water-based expansion coating 7. Its working principle is as follows: When the wire harness is working normally, the conductor core 1, which is braided from multiple tinned copper wires, is responsible for power transmission. The primary silicone rubber insulation layer 2 provides basic electrical insulation and high-temperature protection. When the wire harness encounters high temperature or fire, the fire-resistant expansion filling layer 4, which is filled in the gap between the conductors, expands rapidly when heated, forming a heat insulation barrier to prevent the flame from spreading along the gap between the conductors. At the same time, the flame-retardant glass fiber braided layer 51 and the metal wire braided layer 52 in the composite flame-retardant layer 5 work together to improve the overall flame retardant rating. The halogen-free flame retardant interlayer 53 further enhances the mechanical strength and high-temperature resistance. The ferrite film layer 61 and the aluminum foil film layer 62 in the composite shielding layer 6 work together to shield against low-frequency and high-frequency electromagnetic interference, improving the electromagnetic compatibility (EMC) of the wire harness. The outermost fire-resistant water-based expansion coating 7 expands rapidly when exposed to fire, forming a dense carbonized layer that effectively isolates the flame and heat, preventing the entire wire harness from burning. The entire structure achieves step-by-step protection from the inside out, and has good comprehensive performance in fire resistance, flame retardancy, heat insulation and electromagnetic shielding.
[0030] 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 claims. The scope of protection of this utility model is defined by the appended claims and their equivalents.
Claims
1. A fireproof and flame-retardant automotive wiring harness, characterized in that: It includes a conductor core (1) woven from multiple tin-plated copper wires, a primary silicone rubber insulation layer (2) disposed outside the conductor core (1), and a fire-retardant layer (3) disposed outside the multiple conductor cores (1). The gap between the fire-retardant layer (3) and the primary silicone rubber insulation layer (2) is filled with a fire-resistant expansion filler layer (4). The fireproof and flame-retardant layer (3) includes a composite flame-retardant layer (5) disposed on the outside of multiple primary silicone rubber insulation layers (2), a composite shielding layer (6) disposed on the outside of the composite flame-retardant layer (5), and a fireproof water-based expansion coating (7) sprayed on the outside of the composite shielding layer (6).
2. The fireproof and flame-retardant automotive wiring harness according to claim 1, characterized in that: The composite flame retardant layer (5) includes a flame retardant glass fiber braided layer (51) disposed outside a plurality of primary silicone rubber insulation layers (2) and a metal wire braided layer (52) disposed outside the flame retardant glass fiber braided layer (51).
3. The fireproof and flame-retardant automotive wiring harness according to claim 2, characterized in that: A halogen-free flame retardant interlayer (53) is filled between the flame-retardant glass fiber braided layer (51) and the metal wire braided layer (52).
4. The fireproof and flame-retardant automotive wiring harness according to claim 1, characterized in that: The composite shielding layer (6) includes a ferrite film layer (61) disposed outside the metal wire braided layer (52) and an aluminum foil film layer (62) disposed outside the ferrite film layer (61).
5. The fireproof and flame-retardant automotive wiring harness according to claim 1, characterized in that: The thickness of the primary silicone rubber insulating layer (2) is 0.2-0.8 mm, and the thickness of the fireproof water-based expansion coating (7) is 0.2-0.5 mm.
6. A fireproof and flame-retardant automotive wiring harness according to claim 2, characterized in that: The thickness of the flame-retardant glass fiber braided layer (51) is 0.1-0.3 mm, and the thickness of the metal wire braided layer (52) is 0.1-0.5 mm.
7. A fireproof and flame-retardant automotive wiring harness according to claim 4, characterized in that: The thickness of the ferrite film layer (61) is 0.05-0.2 mm, and the thickness of the aluminum foil film layer (62) is 0.02-0.1 mm.