INJECTION-MOLDED WIRING HARNESS AND MOLDING METHOD

Abstract

An injection-molded wire harness and a molding method. The wire harness includes a terminal (1) and at least one conductor (2). One end of the terminal (1) is connected to an electrical circuit of an electrical device, and the other end of the terminal (1) is connected to the conductor (2). The wire harness is provided with a protective layer (7) that is injection-molded and encloses the conductor (2), and at least one injection-molded positioning device (5) for fixing the position of the wire harness and / or at least one injection-molded sealing device (4) for waterproofing. The method can reduce manual operation, improve the consistency of wire harness products, reduce the production cost of wire harness products, and extend the service life of the wire harness.

Description

INJECTION-MOLDED WIRING HARNESS AND MOLDING METHOD APPLICATION RELATED TO THE INVENTION This application claims priority over Chinese Patent Application No. 202010283020.X, filed on April 10, 2020 and entitled “MOLDED WIRE BUNDLE AND MOLDING METHOD”. TECHNICAL FIELD OF THE INVENTION This description refers to the technical field of wire harnesses and specifically to an injection-molded wire harness and a molding method. BACKGROUND OF THE INVENTION In the field of electrical connection, the wiring harness functions as a bridge for the connection of electrical circuits, connecting to a power source and appliances; and exchanging data in such a way that the wiring harness is an important component in a car, an aircraft, a ship, various household appliances and equipment. Wire harnesses are constructed in a variety of shapes and materials, but the main structure consists of wires, terminals, sheaths, fasteners, waterproofing devices, and similar components. A wire consists of a conductor and an insulating layer wrapped around the conductors. Today, wire harness processing technology is complex, including cutting, stripping, terminal crimping, soldering, pipe threading, blind plugging, terminal plugging, sheath plugging, subassembly, wiring, glue wrapping, branch fixing, installation and positioning, component installation, routing, appearance inspection, packaging, and similar processes.Among these processes, subassembly, wiring, glue wrapping, branch attachment, installation, device positioning, and part installation occupy the majority of working hours in wire harness production and are currently performed manually rather than using automated production equipment. This results in a high failure rate, high production costs, and an inability to guarantee product consistency, which has become a bottleneck in the development of the wire harness industry. In conventional wire harness processing technology, there are two methods for installing the positioning device: one using adhesive tape and the other using cable ties.However, both methods have the disadvantages of imprecise installation size and the positioning device detaching quickly. Furthermore, in conventional cable harness processing technology, a cable harness sealing device is made of rubber and needs to be stretched before installation to ensure it can pass through the cable and be secured. To ensure a proper seal, concrete and sealant must be added between the sealing device and the cable, which complicates the process and makes the sealing device easily damaged, resulting in sealing failure. Furthermore, several parts of a conventional wiring harness, including the cable and its protective sheath, are not securely coupled. The cable is connected to the sheath via a terminal, the positioning device is secured with adhesive tape or floral tape, and the waterproofing device is attached to the harness using elastic rubber components. Over time, the connection of these various parts will gradually fail, resulting in wear of the cable and sheath, detachment of the cable from the sheath, inaccurate or detached positioning of the device, and breakage or separation of the waterproofing device. Consequently, the functions of the components are lost, leading to the failure of the wiring harness, which in a serious incident could cause an accident. Therefore, today, the wire harness industry is in urgent need of a new method that can simplify wire harness assembly and the production process, reduce manual operation, improve product consistency, and lower the product production cost. To this end, Chinese Patent Application CN 104149770 A describes an injection-molded anti-lock brake sensor system wiring harness, in which the injection-molded positioning member is added to the base of the original signal transmission cable. However, it is only suitable for the anti-lock brake system detection wiring harness and has limitations in its use. This patent application requires the purchase of pre-finished wires, which are then processed into the main wiring harness body, thus not saving on the cost of the wiring harness itself. Furthermore, the cable is not protected, and after installation in the vehicle, the cable's insulating coating can be damaged by vibration and friction at the installation site, potentially leading to a short circuit and, in severe cases, a fire.Moreover, in this patent application, the added injection-molded part has only one function and cannot fulfill other complex needs in the wiring harness. Therefore, in the technical field of wire harnesses, there is an urgent need for wire harnesses with a simple production process, high dimensional accuracy, and long service life, and a molding method that can reduce the cost of wire harnesses, increase the degree of waterproofing, improve production efficiency, and reduce the product failure rate. defective C / QZLn / ZZnZ / B / YILI and extend the life of the wiring harness. BRIEF DESCRIPTION OF THE INVENTION In light of previous technical challenges, and to overcome the shortcomings of the prior art, this description provides a new injection molding and molding method that can significantly reduce the processing time for wire harnesses, minimize manual operations, improve product consistency, enhance waterproofing, and lower production costs. This method enables single-step processing and assembly of the wire harness assembly, improving production efficiency and expanding its application.In the present description, the cable bundle with the sealing requirement can be molded in one go, so that the sealing property of the cable bundle is increased, the use of materials such as concrete, sealant and the like is reduced, the service life of the waterproofing area is extended and the safety performance in use is greatly improved. The objective of this description is achieved through the following technical solution. This description provides an injection-molded wire harness comprising a terminal and at least one conductor. One end of the terminal connects to an electrical circuit of an electrical device, and the other end connects to the conductor. The wire harness is provided with an injection-molded protective layer that encloses the conductor, and at least one injection-molded positioning device to fix the harness's position and / or at least one injection-molded sealing device for waterproofing. It should be noted that the wire harness described here differs from a conventional wire harness and may use either a cable with an insulating layer or an injection-molded conductor.The conductor can be processed in a variety of ways, such as cutting coiled conductors, cutting copper sheets, conductor printing, 3D printing, and the like, which can be selected and optimized according to different cable harness usage environments, thereby saving raw materials greatly, reducing processing time, and improving product quality. In the injection-molded wire harness described herein, the parts are joined together by being heated, melted, and then cooled and molded into an integrated structure. There is no mutual wear between the parts, and the relative positioning dimensions between the parts are also precise. The service life is greatly improved compared to a conventional wire harness, and safety is guaranteed. For example, an insulating layer is arranged outside the conductor and the protective layer. C / QZLn / ZZnZ / B / YILI is injection molded outside the insulating layer. For illustrative purposes, the positioning device includes a first fixing device connected to the wire harness and an adjustment device coupled and connected with a mounting end for installing the wire harness with the adjustment device being connected to the first fixing device. It should be noted that when a wiring harness is installed over a certain length, a positioning device is attached to the mounting end to ensure the harness is securely fixed to a mounting surface, such as a gear, sheet metal bracket, or other tubing. Without a positioning device, the wiring harness will shift relative to each other at the mounting end, increasing wear and tear. Furthermore, this movement will also produce unusual noises, negatively impacting the user experience in automobiles, aircraft, boats, or various electrical appliances. For illustrative purposes, the first fastening device is a cylindrical structure, and an inner wall of the cylindrical structure fits with an outer surface of the protective layer and wraps around the outer surface of the protective layer. The cylindrical structure is to strengthen the fastening device and prevent the positioning device from detaching from the cable harness under tension. For illustrative purposes, the adjustment device is a columnar structure that has an inverted toothed structure on the outer periphery of the columnar structure. When the columnar structure is compatible with a mounting end hole, the inverted toothed structure can prevent the columnar structure from detaching from the mounting hole. For illustrative purposes, the adjustment device includes a clip-shaped structure. For example, the clip-shaped structure has a groove with tabs on both inner side walls. The tabs engage in the groove so that when the C-shaped structure is fitted to a sheet metal edge at the mounting end, the clip-shaped structure grips the edge and prevents it from disengaging. Similarly, the adjusting device may include either a circular ring or a C-shaped ring. When the adjusting device is fitted to a tube at the mounting end, the circular ring or C-shaped ring prevents the adjusting device from disengaging from the tube. For illustrative purposes, the positioning device is a plastic component manufactured by injection molding. Because the positioning device is rigidly connected to the mounting end, using a rubber component would result in significant deformation and an unreliable connection. Therefore, a plastic component with good hardness and elasticity can be used. C / QZLn / ZZnZ / Β / YILI For illustrative purposes, the sealing device includes a second fixing device connected to the wire harness and a waterproofing device, one end of which is connected to the second fixing device. For illustrative purposes, the second fastening device is a cylindrical structure. Its inner wall is fitted to the outer surface of the protective layer and wraps around it. The cylindrical structure reinforces the fastening device and prevents the sealing device from detaching from the wire harness under tension. For illustrative purposes, the sealing device is a rubber element processed by injection molding. Since the sealing device needs to seal the sealed end of the wire harness, elastic material such as a rubber element or similar is used to seal the sealed end of the wire harness by injection molding, thus preventing water from the external environment from entering the inside of the wire harness. Such water ingress can cause corrosion of the wire harness conductors, a serious reduction in the harness's lifespan, and, in severe cases, a safety hazard. It should be noted that the sealed end of the wire harness, which can be referred to as the end from when the overall wire harness was installed, will pass through the through-holes in the divider plate between the dry and wet areas. To prevent water from the wet areas from entering the dry areas, a waterproofing device is required on the wire harness to fit the sealing connection to the through-holes in the divider plate. Additionally, when the wire harness is in a wet area, the conductor between the protective sheath and the wire harness terminal may be exposed. A sealing device is required to seal and encase the exposed conductor and terminal to prevent corrosion of the conductor and terminal from water in the external environment.Furthermore, when the coating is in the wet area, in order to prevent water from entering the coating and causing corrosion of the terminal and conductor, a sealing device is required to seal the hole in the coating. For illustrative purposes, the wire harness is also provided with at least one sheath that is mutually inserted with an electrical device and the terminal fits into a corresponding hole in the sheath. For illustrative purposes, the coating is injection molded integrally on at least the terminal. The conductor connects to the sheath via the terminal to which it is attached. To ensure a secure connection between the conductor and the sheath, the conductor and sheath can be bonded together with the protective layer during the injection molding of the protective layer, thereby extending the service life of the wiring harness. For illustrative purposes, the conductor is a solid conductor, a flat conductor, or a conductor composed of multiple strands of wire. The conductor can have different structures depending on the different environments in which the wire harness is used. For illustrative purposes, the terminal is connected to a solid conductor, a flat conductor, or a conductor made up of multiple strands of wire by crimping or welding. Generally, when the conductor and terminal are made of the same or similar materials, crimping is used. When the conductor and terminal are made of very different materials, welding is used. For illustrative purposes, a cross-section of a conductive part of the conductor is a circular, elliptical, polygonal, wavy, or profiled structure. According to the conductor structure in the wire harness, conductive parts with different cross-sections can be selected to form a conductive circuit. For illustrative purposes, when at least one conductor is more than two conductors belonging to the same circuit, the conductors on one non-terminal side are connected according to the circuit requirement by crimping or welding to form a conductor connection point. For illustrative purposes, the conductor connection point is integrally wrapped and sealed by injection molding. With conductor connection points, the amount of conductor material used can be greatly reduced, and the current is diverted through different conductors in appropriate positions. Due to the use of crimping or welding, the conductor stress is concentrated on both sides of the connection point. In subsequent use, this stress can cause the conductor connection point to break, rendering the wire harness ineffective. Therefore, integral injection molding is necessary to encase and protect the conductor connection point. In humid environments, integral injection molding at the conductor connection point can also act as a sealant or waterproofing agent. This description outlines a method for preparing a wire harness that includes: A. Prepare a semi-finished cable bundle, B. Put the required raw materials into an injection molding machine and dry them, then put the semi-finished cable bundle in step A into an injection mold or put the semi-finished cable bundle in step A into an injection mold and then put the required raw materials into an injection molding machine and dry them. C. Start the injection molding equipment to heat and melt the raw materials and inject the raw materials into the injection mold for molding. For illustrative purposes, in the case of a single conductor, the preparation of the semi-finished wire harness includes connecting the terminal to the conductor using a crimping device or C / QZLn / ZZnZ / B / YILI welding, the protective layer or the positioning device or the sealing device is injection molded in accordance with step B to step C. By way of illustration, in the case of more than one conductor, preparing the wire harness includes connecting the terminal to the conductors using a crimping or welding device, the protective layer is injection molded off the conductors arranged at intervals in accordance with step B to step C, and the positioning device or sealing device is injection molded in accordance with step B to step C. For illustrative purposes, in the case of more than one of the conductors belonging to the same circuit, preparing the semi-finished wire harness includes connecting the conductors according to the circuit requirement by crimping or soldering to form a conductor connection point, a wire harness protection device is first injection molded in accordance with step B to step C, then the protective layer is injection molded and finally the positioning device or sealing device is injection molded in accordance with step B to step C. For illustrative purposes, when the semi-finished wire harness is provided with a covering, the terminal connected to the conductor is inserted into a corresponding hole in the covering and then injection molding is performed, or the semi-finished wire harness is first injection molded and then the terminal connected to the conductor is inserted into a corresponding hole in the covering. The semi-finished wire harness is placed in the injection mold and a coating is integrally injection molded onto at least the terminal. Compared to the state of the art, the present description has the following advantageous effects. 1. In the conventional wire harness design method, various raw materials such as wire, terminals, sheathing, fastening devices, waterproofing devices, adhesive tape, support line grooves, and the like are purchased and processed separately, then assembled into a finished wire harness. This method allows the raw material manufacturer and the wire harness factory to work together, each performing their respective functions. However, the process flow is particularly complex, with numerous processing steps and a high defect rate during production, making it difficult to guarantee the size and performance of the finished wire harness. The inventor of this description has found that, except for the conductor, other wire harness components are primarily made of plastic and rubber.Today, plastic and rubber components are largely produced by injection molding; thus, the injection molding described herein is used to prepare the protective layer of the cable harness, the positioning device, and the waterproofing device, which includes the cost of the. C / QZLn / ZZnZ / B / YILI wire harness, improves production efficiency, reduces the rate of defective products and prolongs the service life of the wire harness. 2. In this description, the wire harness is injection-molded directly using conductors. The conductors can be processed into a variety of shapes, which can be selected and optimized according to the different wiring harness usage environments. This significantly saves raw materials, reduces processing time, and improves product quality. It also provides a wide range of design options for wire harness designers, enabling them to reduce costs and improve product stability. The injection-molded protective layer described here replaces the manual application of the sheath and adhesive tape in conventional wire harnesses, allowing for automated production. The more branches of the wire harness, the more labor hours can be saved.Furthermore, the protective layer made using the injection molding method avoids the defects of imprecise size from manual application of adhesive tape and insufficient connection protection, and can better ensure the quality of the wire harness and extend the service life of the wire harness. 3. In the description, the wire harness is processed by integral injection molding, so that the protective layer, positioning device, sealing device, and other components of the wire harness can be strongly combined, thus achieving an IP67 level of waterproofing. After the wire harness is subjected to salt spray testing, high and low temperature testing, vibration testing, and aging testing, the mechanical and electrical properties between the conductor and the terminal of the wire harness are minimally affected, which can better ensure the quality of the wire harness and extend its service life.Meanwhile, injection molding materials are more varied, and different injection molding materials can be selected according to different application environments. This makes the wire harness more flexible, improves its anti-vibration effect, and allows it to be used in harsh vibration environments, thus significantly extending the service life of the wire harness and improving its safety. 4. In the wiring harness described herein, an insulated wire can also be used. When the wiring harness circuit is smaller, or the wire length is long and the sealing requirement is not high, using an insulated wire can reduce the cost of the injection mold. 5. The injection molding method described herein is used to process the positioning device instead of using adhesive tape or ties. The size and position of the positioning device are ensured by the mold, making it precise and consistent, which better guarantees product quality. C / QZLn / ZZnZ / B / YILI of the wiring harness. Meanwhile, since the positioning device is integrally molded into the wiring harness, the combination is stronger, the positioning device does not easily detach, and the positioning effect is better. Even in a relatively harsh vibration environment, the positioning device rarely experiences dimensional deviation or detachment from the wiring harness, which could cause the wiring harness's positioning function to fail, thus significantly extending the wiring harness's service life. The adjustment device is processed by injection molding and can be configured in different styles according to different shapes of the wiring harness's mounting end, making the wiring harness more convenient to install and significantly improving the efficiency of the wiring harness installation.The positioning device can be a plastic component that can be conveniently injection molded. When the plastic component fits onto the mounting end of the wiring harness, its elasticity allows for a tighter fit, significantly improving the installation efficiency of the positioning device and greatly extending the service life of the wiring harness due to the plastic component's high corrosion resistance. 6. The injection molding method described herein is used to process the sealing device. In the wiring harness's operating environment, the wet and dry areas are sealed by the sealing device, which prevents water from the wet areas from entering the dry areas or the electrical circuit, damaging the electrical lines in the dry areas, resulting in electrical malfunction and, in severe cases, a safety hazard. The injection molding method described herein is used to inject the sealing device as a single unit, thus eliminating the need for pre-stretching the sealing device and then inserting the wiring harness through it as in normal wiring harness processing.This ensures precise positioning and sizing of the sealing device, allowing for a stronger bond between the sealing device and the protective layer without the need for concrete or sealant, thus saving material costs and installation time. Because it is manufactured in one piece using injection molding, the sealing device is not easily damaged and bonds more strongly with the protective layer of the wire harness. Even in relatively harsh vibration environments, the sealing device will not experience dimensional deviation or detachment from the wire harness, which could lead to failure of the wire harness's positioning function, thereby significantly extending the service life of the wire harness.Meanwhile, the sealing device can also be placed between the terminal and the conductor, between the sheath and the protective layer, to better seal the conductor, prevent corrosion from water in the outdoor environment, and significantly extend the service life of the wire harness. The sealing device can be... C / QZLn / ZZnZ / B / YILI is a rubber element which bonds better to other parts and while the elasticity of the rubber element can improve the sealing performance of the wire harness, thereby obviously improving the service life of the wire harness. 7. In the wiring harness described herein, either a separate jacket or an integrally molded jacket is used. This allows for faster installation and compatibility with electrical devices, improving installation efficiency, facilitating the replacement of damaged wiring harnesses, enhancing repair efficiency, and reducing labor costs. The integrally molded jacket is manufactured more quickly and bonds more strongly with the terminal, protective layer, or insulating layer, thereby significantly improving the sealing of the wiring harness. 8. The conductor can be a solid conductor, a flat conductor, or a conductor composed of multiple strands of wire, and can have a conductive portion of varying cross-sections. The conductor structure can be adapted to the actual operating environment of the wire harness, thereby saving on the cost of the wire harness and improving its installation efficiency. Meanwhile, the different conductor structures and the different cross-sections of the conductive portions can be adapted to terminals with different connection methods, which makes it convenient for the wire harness designer to select the appropriate terminal and conductor, further optimizing the cost of the wire harness and improving the overall stability of the wire harness. 9. In the wire harness of the present description, when more than two conductors belong to the same circuit, the non-terminal side conductors are connected as a conductor connection point according to the circuit requirement by crimping or welding, so that in the design of the wire harness, the amount of conductor used can be reduced and the cost of the wire harness can be significantly reduced.The conductor connection points are wrapped and sealed using integral injection molding to ensure that the conductor connection point is not damaged during installation and use of the wire harness, even in a harsh, vibrating environment. This wrapping and sealing process prevents breakage due to vibration and can also prevent corrosion of the conductor connection point in the outdoor environment, significantly extending the service life of the wire harnesses. 10. The present description further provides a method of preparing an injection-molded wire harness in an integral manner, in which different process flows can be adopted according to the different structures of the wire harness, thereby significantly improving the efficiency of wire harness production and reducing the cost of the wire harness. C / QZLn / ZZnZ / Β / YILI The preceding description is merely an overview of the technical solution described herein. To better understand the technical features of this description and to implement them according to the specification, and to make the objectives, features, and advantages mentioned above and others easier to understand, a detailed description will be provided below, combining illustrative methods with accompanying figures. BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a schematic view of a single-conductor, uncoated cable bundle with a positioning device and a sealing device according to the present description. Figure 2 is a schematic view of a multi-conductor cable bundle with a coating and with a positioning device and a sealing device according to the present description. Figure 3A is a schematic cross-sectional view of a single-conductor wire harness with a protective layer according to the present description. Figure 3B is a cross-sectional schematic view of a cable bundle with multiple connectors arranged in a linear direction and with a protective layer according to the present description. Figure 3C is a schematic cross-sectional view of a cable bundle with multiple conductors arranged in a circumferential direction and with a protective layer according to the present description. Figure 3D is a schematic cross-sectional view of a cable bundle with multiple conductors, insulating layers, and a protective layer according to the present description. Figure 4 is a schematic view of a wire harness with multiple conductors and conductor connection points according to the present description. Figure 5 is a structural schematic diagram of a positioning device according to the present description. Figure 6 is a schematic view of an adjustment device with an inverted toothed structure. Figure 7 is a schematic view of an adjustment device with a clip-shaped structure. Figure 8 is a schematic view of an adjustment device with a C-shaped ring structure. Figure 9A is a structural schematic diagram of a wire harness with a sealing device compatible with a through-hole in a divider plate according to c / azLn / zznz / e / γΐΛΐ the present description. Figure 9B is a schematic diagram of the partial sectional structure of Figure 9A. Figure 10 is a structural schematic diagram of a sealing device for a conductor, a terminal, and a protective layer according to the present description. Figure 11 is a schematic structural diagram of a sealing device for a coating according to the present description. Figure 12 is a schematic structural diagram of an integrally molded coating according to the present description. In the figures, the reference numbers are: 1. terminal; 2. conductor; 3. insulating layer; 4. Sealing device; 5. Positioning device; 6. Coating; 7. Protective layer; 8. Wire harness protection device; 9. Waterproofing device; 10. Second fixing device; 11. Adjustment device; 12. First fixing device; 13. Waterproofing cover; 14. Locking slot. DETAILED DESCRIPTION OF THE INVENTION In order to further illustrate the characteristics and technical effects of the present description to achieve the intended purpose of the present description, the modalities, structures, characteristics and specific functions of the same according to the present description will now be described in detail together with the figures and illustrative modalities as follows. The First Modality As shown in Figures 1 and 3A, the wire harness includes a single conductor (2), and both ends of conductor (2) are connected to a terminal (1). Terminal (1) is a copper terminal made of a copper alloy with a copper content of 60%, ensuring good electrical conductivity and workability. The surface of terminal (1) may be plated with one of the following metals: nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, and gold. The plating reduces corrosion and extends the terminal's service life. One end of terminal (1) is connected to conductor (2), and the other end is connected to an electrical circuit of an electrical device when in use.In this embodiment, the conductor (2) is composed of multiple core wires, and the cross-section of the multiple core wires is circular. In other embodiments, the conductor (2) may also be a solid conductor or a flat conductor. The cross-section of the conductive portion of the conductor (2) may also be elliptical, polygonal, wavy, or profiled. The wire harness is provided with a protective layer (7). C / QZLn / ZZnZ / B / YILI, which is injection-molded and surrounds the conductor (2). The protective layer (7) is made of plastic or rubber. In this embodiment, the material of the protective layer (7) is PVC. The wire harness is also provided with at least one injection-molded positioning device (5) for fixing the position of the wire harness and / or at least one injection-molded sealing device (4) for waterproofing. The conductor (2) can be an externally purchased electrical cable with an insulating layer (3), and the protective layer (7) is injection-molded outside the insulating layer (3). Alternatively, the protective layer (7) can be injection-molded directly outside the conductor (2). As shown in Figure 3A, the single conductor (2) is arranged in the middle, and the protective layer (7) is injection-molded on the periphery of the single conductor (2). After the conductor (2) is cut to a predetermined length, both ends of the conductor (2) are connected to the terminal (1) by pressing or welding to obtain a semi-finished product. The semi-finished product is then placed in an injection mold, and the protective layer (7), positioning device (5), and sealing device (4) are formed by injection molding according to predetermined dimensions. The specific injection molding method is as follows: A. Prepare the semi-finished cable harness, B. Place the required raw materials in an injection molding machine and dry them, then place the semi-finished cable bundle prepared in step A into an injection mold or place the semi-finished cable bundle prepared in step A into an injection mold and then place the required raw materials in an injection molding machine and dry them, C. Start the injection molding equipment to heat and melt the raw materials and inject the raw materials into the injection mold for molding. The positioning device (5) is made of PA66, and in other embodiments, it may be a plastic element processed by injection molding. As shown in Figure 5, the positioning device (5) includes a first fixing device (12) connected to the wiring harness and a compatible adjustment device (11) connected to a mounting end for installing the wiring harness. The adjustment device (11) is connected to the first fixing device (12). The first fixing device (12) is a cylindrical structure, and an inner wall of the cylindrical structure fits with and encloses an outer surface of the protective layer (7). The specific structure of the adjustment device (11) may include an inverted toothed structure that interlocks with a mounting hole for installing the wiring harness.Specifically, the adjustment device is a columnar structure and the outer periphery of the columnar structure is provided with one. The C / QZLn / ZZnZ / B / YILI inverted toothed structure is inserted and interlocks with the mounting hole (as shown in Figure 6). In other embodiments, the adjusting device can also be provided with a clip-like structure (as shown in Figure 7) for compatibility with and connection to a plate. Specifically, the adjusting device (11) is provided with a groove on two inner side lines, from which tabs for engaging with the plate are provided. Alternatively, the adjusting device (11) is provided with a circular ring structure or a C-shaped ring structure for compatibility with a tubular or cylindrical structure (as shown in Figure 8). It should be noted that the sealing device material is EPDM, and in other embodiments, the sealing device (4) may be a rubber element processed by injection molding. Typically, during installation, the cable bundle needs to pass through holes in a partition plate located between the dry and wet areas. To prevent water from the wet areas from entering the dry areas, as shown in Figures 9A and 9B, the sealing device (4) in this embodiment includes a second fastening device (10) connected to the cable bundle, and a waterproofing device (9) is connected to the second fastening device. The second fastening device (10) is a cylindrical structure, and an inner wall of the cylindrical structure is fitted with and wrapped around an outer surface of the protective layer (7).The waterproofing device (9) includes a waterproofing cover (13) having one end connected to the second fixing device (10) and a locking slot (14) connected to the other end of the waterproofing cover (13) and used to fit with a waterproofing hole. In this configuration, when the wire harness is in a wet area, a sealing device is provided between the protective layer (7), the conductor (2), and the terminal (1) of the wire harness to seal and enclose the protective layer (7), the conductor (2), and the terminal (1). As shown in Figure 10, the sealing device (4) is injection-molded onto the conductor (2), a connection point between the terminal (1) and the conductor (2), and the outside of the protective layer. The portion of the sealing device (4) corresponding to the conductor (2) and the terminal (1) is the waterproofing device (9), and the portion of the sealing device (4) corresponding to the protective layer (7) is the second fastening device (10). The Second Modality As shown in Figures 2, 3B, and 3C, the wire harness includes more than one conductor (2), and both ends of each conductor (2) are respectively connected to the terminal (1). The surface of the terminal (1) may be plated with one selected from the group of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver, and gold. The conductor (2) and the terminal (1) in this embodiment are the same as those in the First Embodiment, so they will not be described in detail. The difference The difference between this modality and the First Modality is that the wire harness is also provided with at least one cover (6) for mutual insertion with an electrical device. After the conductor (2) is connected to the terminal (1), the terminal (1) is fitted into the cover (6), and the different terminals (1) correspond to different holes in the cover (6) according to the design requirements, as well as connecting different circuits and also protecting the terminal (1) from damage. The cover (6) is injection-molded integrally with the terminal (1). After the multiple conductors (2) are cut to a predetermined length, both ends of each conductor (2) are connected to the terminal (1) by crimping or welding to obtain a semi-finished product. The semi-finished product is then placed in an injection mold, and the protective layer (7), positioning device (5), and sealing device (4) are formed by injection molding according to predetermined dimensions. Specifically, the protective layer of the wire harness (7) is injection molded first, then the protective device of the wire harness (8) is injection molded, and finally either the positioning device (5) or the sealing device (4) is injection molded. In this modality, when the wire harness is in a humid area, the sealing device (4) is provided between the protective layer (7), the conductor (2), and the terminal (1) of the wire harness to seal and enclose the protective layer (7), the conductor (2), and the terminal (1). As shown in Figure 10, the sealing device (4) is injection-molded onto the conductor (2) at a connection point between the terminal (1) and the conductor, and outside the protective layer (7). The portion of the sealing device (4) corresponding to the conductor (2) and the terminal (1) is the waterproofing device (9), and the portion of the sealing device (4) corresponding to the protective layer (7) is the second fastening device (10). The specific injection molding method is as follows: A. Prepare a semi-finished cable bundle, B. Place the required raw materials in an injection molding machine and dry them, then place the prepared wire harness from step A into an injection mold or place the semi-finished wire harness from step A into an injection mold and then place the required raw materials in an injection molding machine and dry them, C. Start the injection molding equipment to heat and melt the raw materials and inject the raw materials into the injection mold for molding. Injection molding parameters include heating temperature, cooling temperature, injection molding pressure, and injection molding time. The injection molding operation is performed according to the conventional operating method of the existing injection molding equipment. The requirements are that the injection-molded products must be free of defects such as impurities, holes, flashes, porosity, etc. As shown in Figures 3B and 3C, the multiple connectors (2) are arranged in the middle, and the protective layer (7) is molded around the periphery of the multiple conductors (2). Therefore, in one aspect, the multiple connectors (2) are joined together by the protective layer (7) to prevent the conductors (2) from scattering during installation of the wire harness. In another aspect, the multiple conductors (2) are insulated by the protective layer (7) to prevent them from short-circuiting each other and from being damaged by an external force such as scraping after the wire harness is installed. In this embodiment, the conductor (2) is a solid or flat conductor, and the cross-section of the conductive portion of the conductor (2) is a profiled, oval, or corrugated structure. The protective layer (7) is made of PVC.The positioning device (5) and the sealing device (4) are the same as those of the First Mode and are not described here in detail. The Third Modality As shown in Figure 4, the wire harness includes more than one conductor (2). The ends of some conductors (2) are connected to the terminal (1), and the ends of other conductors (2) are connected according to a circuit requirement by crimping or soldering to form a conductor connection point. The surface of the terminal (1) is plated with one of the following metals: silver, nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, and gold. After the conductors (2) are connected to the terminal (1), the terminal (1) is fitted into a cover (6) for insertion into an electrical device. The different terminals (1) correspond to different holes in the cover (6) according to the design requirements.At the time of preparation, the conductor connection point is completely sealed by the wire harness protection device (8), which is a rubber or injection-molded plastic element. As shown in Figure 3D, an insulating layer (3) is disposed outside the conductors (2), and a protective layer (7) is injection-molded outside the insulating layer (3). The terminal (1) and the covering (6) in this embodiment are the same as those in the First Embodiment and are not described here in detail. After the multiple conductors (2) are cut to a predetermined length according to a design requirement, some conductors (2) are connected to the terminals (1) by crimping or welding, respectively. When the other conductors (2) are two or more conductors belonging to the same circuit, the conductors on one non-terminal side are connected to form a conductor connection point by crimping or welding according to the circuit requirement, thus obtaining a semi-finished product. The semi-finished product is then placed in an injection mold, and according to predetermined dimensions, the protective layer (7) is first injection-molded, followed by the wire harness protection device (8). C / QZLn / ZZnZ / B / YILI and finally the positioning device (5) and / or the sealing device (4) are injection molded according to the injection molding steps described in the Second Modality. In this modality, the conductor (2) comprises multiple wire strands, and the transverse and conductive portion of the conductor (2) is a polygonal structure. The material of the wire harness protection device (8) is plastic, and in other applications, the material of the wire harness protection device (8) may be rubber. The protective layer (7), the positioning device (5), and the sealing device (4) in this modality are the same as those of the Second Modality and are not described here in detail. In the method of preparing the wire harness by injection molding, when the semi-finished wire harness is provided with a covering (6), the terminal (1) connected to the conductor (2) is inserted into the corresponding hole in the covering (6) and then injection molding is performed, or first the wire harness is injection molded and then the terminal (1) connected to the conductor (2) is inserted into the corresponding hole in the covering (6). As shown in Figure 11, when the coating (6) is in humid areas, to prevent water from entering the coating (6), a sealing device (4) is provided to seal the holes in the coating (6). To further prevent water from entering the coating (6), a waterproofing device (9) is injection-molded into the spaces between the coating (6) and the conductors (2) to seal the coating (6) and waterproof it. A second fastening device (10) is connected to the ends of the waterproofing device (9) and the coating (6). The waterproofing device (9) is formed by injection molding, and the second fastening device (10) is a sleeve structure to be compatible with the protective layer (7) outside the conductors (2).As shown in Figure 12, the coating (6) described in this embodiment can also be integrally injection molded. The semi-finished wire harness is placed in an injection mold, and the coating (6) is integrally injection molded onto at least the terminal (1). In other embodiments, the coating (6) can also be integrally injection molded onto the terminal (1) and the conductor (2), or the coating (6) can be integrally injection molded onto the terminal (1), the conductor (2), and the protective layer (7). In order to demonstrate the influences of the wire harness processed by the conventional method and the integrally injection-molded wire harness according to the First, Second, and Third Modalities of the present description on the mechanical and electrical properties of the terminal and conductor of the wire harness, the inventor of the present application has conducted a series of experiments on mechanical properties, electrical properties, and service life of two types of wire harnesses processed by the two different methods above. C / QZLn / ZZnZ / Β / YILI The specific experimental process is as follows: the actual operating environment of the wiring harness is simulated, but the test conditions are increased to a much more stringent level than those of the actual operating environment, in order to obtain test results in a short time, which can be achieved over a long period under the actual operating environment. The series of experiments includes: 1) testing the initial pull-out strength and voltage drop of the terminal (1) and conductor (2) of two types of wiring harnesses obtained using two different methods previously used to determine the mechanical and electrical properties of the wiring harnesses; 2) conducting a salt spray experiment for 1000 hours by spraying salt water on two types of wiring harnesses using the experimental salt spray chamber, which can replace ten years of salt spray resistance testing in the actual coastal environment;3) Conduct a high and low temperature experiment for 200 hours, by placing two types of wire harnesses under the highest and lowest temperatures of the operating environment for one hour respectively with a temperature change time of less than 5 seconds and the temperature change is carried out for 100 cycles, which can replace the high and low temperature resistance test for 10 years in an external environment that alternates cold-hot; 4) Conduct the vibration test for 120 hours by fixing two types of wire harnesses on a vibration experiment table, selecting a vibration amplitude according to the operating environment and the vibration of two types of wire harnesses in three directions, which can replace the vibration test for 10 years in the real vibration environment;5) Conduct an aging test for 6,000 hours by placing two types of wire harnesses in an aging experiment box to simulate an environment exceeding nominal usage conditions, which can replace a 20-year aging test in the actual usage environment. The voltage drop value and the pull-out force value of the terminal (1) and conductor (2) of the two types of wire harnesses are tested after each experiment. The experimental results are shown in Tables 1-1, 1-2, and 1-3. C / QZLn / ZZnZ / Β / YILI Table 1-1: Influence of conventional wire harness and integrally injection-molded wire harness on pull-out strength and voltage drop of terminal and conductor (before experiment and after 1000-hour salt spray test) c / oztn / zznz / e / YiAi Wire harness type Conventional wire harness Integral injection molded wire harness Conventional wire harness Integral injection molded wire harness Status After processing is complete After 1,000 hours of salt spray experiment Test Extraction force (N) Voltage drop (mV) Extraction force (N) Voltage drop (mV) Extraction force (N) Voltage drop (mV) Extraction force (N) Voltage drop (mV) 1 2343 0.35 2456 0.34 2057 0.42 2388 0.37 2 2567 0.37 2547 0.35 2136 0.46 2436 0.37 3 2476 0.37 2458 0.36 2085 0.45 2384 0.38 4 2541 0.38 2572 0.35 2064 0.45 2492 0.36 5 2347 0.37 2438 0.36 2088 0.43 2397 0.38 6 2463 0.39 2589 0.35 2126 0.46 2416 0.37 7 2389 0.37 2548 0.34 2063 0.45 2404 0.36 8 2554 0.34 2490 0.33 2081 0.43 2426 0.35 9 2487 0.38 2561 0.32 2066 0.45 2484 0.38 10 2454 0.36 2548 0.33 2083 0.46 2438 0.35 Average value 2462.1 0.368 2520.7 0.343 2084.9 0.446 2426.5 0.367 Table 1-2: Influence of conventional wire harness and integrally injection-molded wire harness on pull-out force and voltage drop of the terminal and conductor (200 hours of high and low temperature experiment and 120 hours of c / aztn / zznz / e / YiAi vibration experiment) Type of wiring harnesses Conventional wiring harness Integral injection molded wiring harness Conventional wiring harness Integral injection molded wiring harness Condition After 200 hours of temp experiment. High and low After 20 hours of vibration experiment Test Extraction force (N) Voltage drop (mV) Extraction force (N) Voltage drop (mV) Extraction force (N) Voltage drop (mV) Extraction force (N) Voltage drop (mV) 1 2046 0.43 2373 0.38 2072 0.42 2385 0.36 2 2074 0.45 2426 0.37 2045 0.43 2433 0.36 3 2125 0.44 2387 0.36 2131 0.45 2369 0.37 4 2052 0.46 2448 0.37 2077 0.44 2435 0.37 5 2077 0.43 2372 0.38 2094 0.45 2364 0.38 6 2054 0.45 2435 0.37 2048 0.44 2466 0.37 7 2098 0.46 2416 0.36 2093 0.44 2425 0.38 8 2125 0.45 2462 0.39 2084 0.46 2432 0.36 9 2058 0.43 2469 0.37 2038 0.44 2479 0.36 10 2064 0.44 2415 0.37 2047 0.47 2447 0.38 Average value 2077.3 0.444 2420.3 0.372 2072.9 0.444 2423.5 0.369 Table 1-3: Influence of conventional wire harness and integrally injection-molded wire harness on pull-out strength and voltage drop of terminal and conductor (600 hours aging experiment) c / aztn / zznz / e / YiAi Wire harness type Conventional wire harness Integrally injection molded wire harness Condition After 600 hours of aging experiment Test Pulling force (N) Voltage drop (mV) Pulling force (N) Voltage drop (mV) 1 2064 0.48 2345 0.38 2 2037 0.47 2443 0.37 3 2024 0.47 2354 0.37 4 2034 0.48 2447 0.36 5 2072 0.46 2358 0.38 6 2047 0.48 2349 0.37 7 2052 0.47 2432 0.37 8 2034 0.47 2438 0.36 9 2036 0.48 2475 0.38 10 2049 0.47 2449 0.36 Average value 2044.9 0.473 2409 0.37 As can be seen from the results in Tables 1-1, 1-2 and 1-3 above, the values ​​of the initial pull-out force and the voltage drop values ​​of the terminal (1) and conductor (2) of the wire harness processed by the conventional method are close to those of the wire harness processed by the integral injection molding method. After being subjected to 1,000 hours of salt spray experiment, 200 hours of high and low temperature experiment, 120 hours of vibration experiment and 6,000 hours of aging experiment, respectively, the pull-out force values ​​of the terminal (1) and conductor (2) of the integrally injection-molded wire harness are much higher than those of the terminal (1) and conductor (2) of the wire harness processed by the conventional method and are also close to the initial pull-out force values. However, in the wire harness processed by the conventional method, the pulling force of the terminal (1) and conductor (2) after the experiments is obviously reduced, the mechanical property is not stable, the terminal (1) and conductor (2) of the wire harness can be disconnected, resulting in a short circuit of the wire harness, which can lead to functional failure in a mild case and a fire accident in a severe case. The voltage drop of the terminal (1) and conductor (2) of the integrally injection-molded wire harness after the experiments are basically the same as the initial voltage drop of the terminal (1) and conductor (2) of the wire harness processed by a conventional method. However, in the processor wiring harness using the conventional method, the voltage drop of terminal (1) and conductor (2) is obviously reduced, the electrical performance is not stable, and the contact resistance between terminal (1) and conductor (2) is increased, which causes the terminal (1) and conductor (2) of the wiring harness to generate heat and turn red when conducting electricity, and in severe cases, terminal (1) and conductor (2) will burn due to excessive temperature, resulting in serious accidents. Therefore, the mechanical and electrical properties of the integrally injection-molded wire harness after the experiments are much better than those of the wire harness processed by the conventional method, thereby reducing the product defect rate and extending the service life of the wire harness. To demonstrate the positioning effect of the fastening devices for cable harnesses processed by the conventional method and by the injection molding method according to the First, Second, and Third Modalities of this description under a vibration environment (100), two types of cable harnesses were selected, and a vibration test was performed on the fastening devices of each type. The results are shown in the following table. c / azLn / zznz / e / γΐΛΐ Table 2: Influence of conventional wire harness and injection-molded wire harness on the performance of the fastening device through vibration testing (120 hours of vibration experiment) c / azLn / zznz / e / YiAi Conventional wire harness Integral injection-molded wire harness Tie-down strapping Tie-down strapping Columnar structure Clip-shaped structure Circular or C-ring structure Positioning size deviation Disconnection of wire harnesses Positioning size deviation Disconnection of wire harnesses Positioning size deviation Disconnection of wire harnesses Positioning size deviation Disconnection of wire harnesses Positioning size deviation Disconnection of wire harnesses Positioning size deviation Disconnection of wire harnesses 52% 11% 69% 24% 0% 0% 1% 0% 1% 0% As can be seen from the table above, in the conventional wire harness with the positioning device (5) secured using floral tape, the number of wire harnesses with deviations in the positioning size of the positioning device (5) accounts for 52% of the total number of wire harnesses, and the total number of disconnected wire harnesses accounts for 11% of the total number of wire harnesses with a very high defect rate. In the conventional wire harness with the positioning device (5) secured using adhesive tape, the number of wire harnesses with deviations in the positioning size of the positioning device (5) accounts for 69% of the total number of wire harnesses, and the number of disconnected wire harnesses accounts for 24% of the total number of wire harnesses with a very high defect rate.The high defect rate seriously affects the installation and function of the wiring harness and can cause the wiring harness to fail in severe cases. However, for three types of positioning devices (5) of the integrally injection-molded wire harness, the number of wire harnesses with size deviations from the positioning of the positioning device (5) represents only 0%, 1%, and 1% of the total number of wire harnesses, respectively, and the number of disconnected wire harnesses represents 0% of the total number of wire harnesses. Therefore, in the integrally injection-molded wire harness, the positioning device (5) is more firmly bonded to the wire harness, the positioning device (5) is less likely to detach, and the positioning effect is better.Even in a relatively harsh vibration environment, failure of the wire harness positioning function caused by deviation from the positioning size of the positioning device (5) or disconnection of the wire harness rarely occurs, which can significantly prolong the service life of the wire harness. In order to demonstrate the protection levels of the sealing devices (4) in the cable harness processed by the conventional method and in the injection-molded cable harness in accordance with the First, Second, and Third Modalities of this description against external dust and water attack (100), two types of cable harnesses are tested. The results are shown in the following table. Table 3: Through-the-wall proportions of the protection level of the sealing devices in the conventional wire harness and the injection-molded wire harness c / azLn / zznz / e / γΐΛΐ Conventional wiring harness Integral injection-molded wiring harness Sealing of the weight hole in the divider plate Sealing of the terminal and conductor Sealing of the sheath Sealing of the weight hole in the divider plate Sealing of the terminal and conductor Sealing of the sheath IP54 IP67 IP54 IP67 IP54 IP67 IP54 IP67 IP54 IP67 IP54 IP67 89% 68% 92% 75% 88% 71% 100% 99% 100% 100% 100% 100% As can be seen in the table above, in the IP54 protection level test, the pass rates of three types of sealing devices (4) in the conventional cable harness are only 89%, 92% and 88% respectively, and in the IP67 protection level test, the pass rates are only 68%, 75% and 71% respectively. Thus, the low pass rates of the protection level make it impossible to ensure the sealing performance of the cable harness or prevent corrosion of the conductor (2) by dust and water from the external environment, which causes the failure of the cable harness function. In the IP54 protection level test, the pass rates of three types of sealing devices (4) of the injection-molded wire harness are 100%, and in the IP67 protection level test, the pass rates are 99%, 100%, and 100% respectively, which fully meets the requirement for the sealing performance of the wire harness, making the sealing performance of the wire harness better, preventing dust and water in the outdoor environment from corroding the conductor, and significantly improving the service life of the wire harness. To demonstrate the influence of the conductor connection point wrapping on the risk of breakage of the conductor connection points in wire harnesses processed using the conventional method and integrally injection-molded wire harnesses according to the First, Second, and Third Modalities described herein, 100 of each of the two types of wire harnesses were selected. A 120-hour vibration experiment was then conducted on each type of wire harness, and the breakage rates of the conductor connection points were measured. The results are shown in the table below. c / azLn / zznz / e / γΐΛΐ Table 4: Breakage rates of the conductor connection points in the harness Conventional wire harness Integral injection-molded wire harness Conductor connection points wrapped with adhesive tape Conductor connection points with heat-shrink tubing Wrapped conductor connection points wrapped by injection molding 26% 18% 0% As can be seen in the table above, there are two ways to wrap the conductor connection point of a conventional wire harness. After the wire harness was subjected to a 120-hour vibration experiment, the breakage rate of the conductor connection points wrapped with adhesive tape was 26%. This high breakage rate does not guarantee the electrical conductivity of the wire harness in the harsh vibration environment, resulting in a significant risk of wire harness failure. However, the proportion of breakage of the conductor connection wrapped by injection molding of the injection-molded wire harness is 0%, which can fully meet the performance requirement of the wire harness's conduction development in the harsh vibration environment and significantly improves the wire harness's service life. The foregoing modalities are merely illustrative of the present description, and the scope of protection of the present description is not limited to them. Any non-essential changes or substitutions made by those skilled in the art based on the present description are within the scope of the claimed invention.

Claims

CLAIMS 1. An injection-molded wire harness comprising a terminal and at least one conductor, wherein one end of the terminal is connected to an electrical circuit of an electrical device and another end of the terminal is connected to the conductor; the wire harness is provided with a protective layer which is injection-molded and encloses the conductor and at least one injection-molded positioning device for fixing the position of the wire harness and / or at least one injection-molded sealing device for waterproofing.

2. The injection-molded wire harness according to claim 1, wherein the insulating layer is disposed outside the conductor and the protective layer is injection-molded outside the insulating layer.

3. The injection-molded wire harness according to claim 1, wherein the positioning device comprises a first fixing device connected to the wire harness, and a compatible fixing device connected with a mounting end for installing the wire harness with the adjusting device being connected to the first fixing device.

4. The injection-molded cable harness according to claim 3, wherein the first fastening device is a cylindrical structure in an inner wall of the cylindrical structure is fitted with an outer surface of the protective layer and wraps around the outer surface of the protective layer.

5. The injection-molded cable harness according to claim 3, wherein the adjustment device is a columnar structure having an inverted toothed structure on the outer periphery of the columnar structure.

6. The injection-molded wire harness according to claim 3, wherein the adjustment device comprises a clip-shaped structure.

7. The injection-molded cable harness according to claim 6, wherein the clip-shaped structure is provided with a groove in which the tabs are arranged on both inner side walls.

8. The injection-molded wire harness according to claim 3, wherein the adjustment device comprises a circular ring structure or a C-shaped ring structure.

9. The injection-molded wire harness according to claim 3, wherein the positioning device is a plastic element processed by injection molding.

10. The injection-molded cable harness according to claim 1, wherein the sealing device comprises a second fixing device connected to the cable harness and a waterproofing device, one end of which is connected to the second fixing device.

11. The injection-molded cable harness according to claim 10, wherein the second fastening device is a cylindrical structure in an inner wall of the cylindrical structure is fitted with an outer surface of the protective layer and wrapped the outer surface of the protective layer.

12. The injection-molded cable harness according to claim 10, wherein the sealing device is a rubber element processed by injection molding.

13. The injection-molded wire harness according to claim 1, wherein the wire harness is further provided with at least one mutually insertable cover with an electrical device and the terminal fits into a corresponding cover hole.

14. The injection-molded cable harness according to claim 13, wherein the covering is injection-molded entirely on at least the terminal.

15. The injection-molded wire harness according to claim 1, wherein the conductor is a solid conductor, a flat conductor, or a conductor composed of multiple strands of wire.

16. The injection-molded wire harness according to claim 1, wherein the terminal is connected to a solid conductor, a flat conductor, or a conductor composed of multiple strands of wire by crimping or welding.

17. The injection-molded cable bundle according to claim 1, wherein a cross-section of a conductive portion of the conductor is circular, elliptical, polygonal, or corrugated profiled.

18. The injection-molded wire harness according to claim 1, wherein when at least one conductor or more than two conductors belong to the same circuit, the conductors on one side of the terminal are connected according to a circuit requirement by crimping or welding to form a conductor connection point.

19. The injection-molded wire harness according to claim 18, wherein the conductor connection point is wrapped and sealed by integral injection molding.

20. A method of preparing the wire harness according to any of claims 1 to 19, comprising: A. preparing a semi-finished wire harness, B. placing the required raw materials prepared in step A into an injection mold or placing the semi-finished wire harness prepared in step A into an injection mold and then placing the required raw materials into an injection molding machine and drying them, C. starting the injection molding machine to heat and melt the raw materials and injecting the raw materials into the injection mold for molding.

21. The method according to claim 20, wherein in the case of a single conductor, preparing the semi-finished cable bundle comprises connecting the terminal to the conductor using a crimping or welding apparatus, and the insulating layer of the positioning device or sealing device is injection molded in accordance with step B and step C.

22. The method according to claim 20, wherein, in the case of more than one conductor, preparing the semi-finished cable bundle comprises connecting the conductor terminals using a crimping or welding apparatus, the protective layer is injection molded off the conductors arranged at intervals in accordance with step B to step C, and the positioning device or the sealing device is injection molded in accordance with step B or step C.

23. The method according to claim 20, wherein, in the case of more than two conductors belonging to the same circuit, preparing the semi-finished wire harness comprises connecting the conductors according to a circuit requirement by crimping or welding to form a conductor connection point; a wire harness protection device is first injection molded according to step B to step C, then the protective layer is injection molded, and finally the positioning device or sealing device is injection molded according to step B to step C.

24. The method according to any of claims 20 to 23, wherein the semi-finished wire harness is provided with a covering, the terminal connected to the conductor is inserted into a corresponding hole in the covering and then injection molding is performed, or the semi-finished wire harness is first injection molded and then the terminal connected to the conductor is inserted into a corresponding hole in the covering.

25. The method according to any of claims 20 to 23, wherein the semi-finished wire harness is placed in the injection mold and a coating is integrally injection-molded onto at least the terminal.

Images