CN112937473A

CN112937473A - Flexible intelligent automobile wire harness

Info

Publication number: CN112937473A
Application number: CN202110316054.9A
Authority: CN
Inventors: 洪嫣; 陈洁
Original assignee: Shanghai Zanru Enterprise Management Center
Current assignee: Shanghai Linyun Technology Co.,Ltd.
Priority date: 2021-03-25
Filing date: 2021-03-25
Publication date: 2021-06-11

Abstract

The invention belongs to the field of automobiles, and particularly relates to a flexible intelligent automobile wire harness. This super flexible car pencil includes: the unit sheet layer comprises a base layer, a conductor layer and a protective film; an adhesive layer is arranged between the base layer and the conductor layer; the reinforcing layer is arranged on the top of the N unit layers, and the reinforcing layer is adhered to the top unit layer by the adhesive layer; in each unit layer, a plurality of conductors are arranged in parallel on the conductor layer, and a proper gap is formed between every two adjacent conductors. The flexible automobile wire harness is arranged at a relevant part of an automobile; the electric transmission requirements of current and signals can be met, and data and power supply signal transmission is realized. The ultra-soft automobile wire harness realizes automation, standardization and intellectualization of manufacture, and accords with the national development route of industrial 4.0 intelligent manufacture; the wiring harness production can realize modular assembly and test, and can greatly reduce the human input and the complex process links, thereby reducing the cost of the whole vehicle.

Description

Flexible intelligent automobile wire harness

Technical Field

The invention belongs to the technical field of automobiles, and particularly relates to a flexible intelligent automobile wire harness.

Background

With the increasing development of internet technology, chip technology and communication technology, automobiles are being accelerated to evolve along with the trend of electromotion, intellectualization and networking, and in the process, the traditional wire harness is used as a carrier for supplying all electric signals and power supplies, and the following problems exist:

1. the processing technology is complex, and the production automation efficiency is low;

2. the material cost and the processing cost are high;

3. the product consistency is poor;

4. the wiring harness arrangement and the whole vehicle interaction are numerous, and a lot of arrangement space of the whole vehicle is occupied;

5. the whole vehicle assembly process is complex;

6. the weight and price of the wire harness are high, and the cost of the whole vehicle is influenced;

in order to solve the problem, the application provides a super-flexible automobile wire harness.

Disclosure of Invention

The invention aims to solve the technical problems in the background technology and provides a super-flexible automobile wire harness which has the characteristics of convenience and stability in installation, full-automatic production and the like.

The super-flexible automobile wire harness (abbreviated as SFH) provided by the invention adopts a production process similar to FPC, and realizes the electrical transmission requirement of current and signals by widening and thickening the size of the copper foil layer, thereby realizing the transmission of data and power signals. Specifically, the super-flexible automobile wire harness may be of a single-layer (single-sheet) structure or a multi-layer (multi-sheet) structure; the method comprises the following steps: the device comprises N unit layers and a reinforcing layer, wherein each unit layer comprises a base layer, a conductor layer and a protective film; an adhesive layer is arranged between the base layer and the conductor layer to adhere the base layer and the conductor layer together; a protective film over the conductor layer; an adhesive layer is arranged between the upper unit layer and the lower unit layer and adheres the upper unit layer and the lower unit layer together; the reinforcing layer is arranged on the top of the N unit layers, and the reinforcing layer is adhered to the top unit layer by the adhesive layer.

In each unit layer, the conductor layer is provided with a plurality of conductors which are arranged in parallel, and a proper gap is formed between every two adjacent conductors, so that the interference between signals is eliminated, and the heat dissipation between the conductors is facilitated.

In the present invention, when N is 1, it is a single-layer structure, as shown in fig. 4. For a two-layer structure, see FIG. 5. And so on. The size of N can be determined according to specific needs, and can be 3-4 generally.

In the invention, the conductor layer is a copper foil layer, the thickness of the circuit copper layer is 100-200 microns, and the line width is more than 2mm, so that the continuous overcurrent capacity of the traditional vehicle lead wire of more than 5A is realized.

The conductor copper-clad is the main current use of rolled copper or electrolytic copper in FPC. Considering that SFH is used in an automotive environment, it is required to have good mechanical and electrical properties, and therefore, a scheme of high-purity wrought copper is adopted. The thickness of the line copper layer is increased from 12-70 microns of the FPC to 100-200 microns, and the line width is increased from micron level to more than 2mm, so that the continuous overcurrent capacity of the traditional vehicle lead wire of more than 5A is realized. The thickness and the width of the traditional FPC wiring harness copper are 10-20 times of those of the traditional FPC wiring harness copper, so that the application and the requirement of the automobile wiring harness are met. The current-resistant capability is improved to a level above 10A from A level of the traditional FPC, and the current transmission capability of the vehicle-mounted medium-load working load is realized.

In the invention, the base layer and the protective film need to meet the same performance requirements of the vehicle-scale wire insulating layer, and specifically, materials such as polyvinyl chloride (PVC), polyethylene, cross-linked polyethylene (XLPE), polypropylene and the like are selected according to the requirements of vehicle parts and electrical performance used by SFH. The PVC is still widely applied to low-voltage cables due to the advantages of convenient process, good comprehensive mechanical and electrical properties, good flame retardant property, low cost and the like, and can be applied to the arrangement position of a trunk area in a vehicle; polyethylene is widely applied to cable insulation and outdoor cable sheaths due to excellent electrical property, moisture resistance, cold resistance and moderate mechanical property, and can be applied to a part far away from a hot area outside a vehicle; the cross-linked polyethylene is widely applied to the insulation of medium and high voltage cables due to the excellent electrical property and mechanical property, and can be applied to the large current outside the vehicle and the parts needing bending vibration; polypropylene is commonly used for insulation of communication cables and oil well cables and is also the first choice insulating material for telephone and computer flexible ropes due to its excellent electrical properties, good high temperature and oil resistance.

According to the invention, the reinforcing layer is used for reinforcing the SFH, and simultaneously provides a fixing structure to realize clamping and fixing with a vehicle metal plate or a vehicle plastic part, so that the assembling diversity of the SFH in a vehicle environment is improved, and the different material reinforcing of an SFH main body and a connector assembly area is realized. On the premise of not influencing the welding strength of the contact point position of the end part, the hardness of the main body is higher as much as possible, and meanwhile, the end part of the reinforcing layer has proper flexibility and deflection for absorbing the stress under the vehicle vibration environment.

In the invention, the adhesive layer can be doped with metal fine particles and is used for eliminating EMC influence between the upper and lower layer conductors and the left and right conductors on the same layer;

compared with the traditional FPC conductor, the copper foil layer is wider in thickness and width, and higher requirements are provided for the fixing strength of the copper foil layer in the whole flexible wire harness, so that the material of the adhesion layer needs to be high-temperature-resistant, higher in adhesion strength and better in flexibility.

The electromagnetic signal isolation layer (protective film) is added between the layers, so that the signals can be prevented from being transmitted between the layers without electromagnetic mutual interference.

In the invention, under the condition that the multi-path conductor concurrent connection is required to be realized, the conductors are led out to the same position together through the arrangement design of the conductors, and the concurrent connection is realized by using a lathe-gauge grade Pack connector welding process. Therefore, the wire harness is in accordance with the traditional wire harness design, and the problem is conveniently checked and maintained.

The SFH is a novel automobile conductor which takes FPC as a carrier and takes an automobile and a traditional wiring harness process flow as a combined body, and can be regarded as an automobile FPC wiring harness which is simplified and meets the requirements of automobile current and signal transmission. Compared with the traditional FPC, the arrangement of wires fully considers the rationality of DFM and production efficiency, eliminates the punching and copper plating process of connecting each layer of conductor of the traditional multilayer FPC, and avoids the conduction design between layers.

In the invention, the combination of the multi-piece SFH (marked as MSFH) is adopted, the lamination can be realized by the double-sided adhesive tape with good high and low temperature resistance, the lamination of the multi-piece SFH realizes the modular manufacturing concept of the traditional wire harness KSK, and the combination of different SFHs can be selectively realized with the vehicle configuration state, thereby realizing the modular manufacturing and lean production. The MSFH can be realized with the fixed mode that uses the double faced adhesive tape equally with the assembly and the fixed of vehicle interface, also can use bottom SFH edge to punch, is fixed in automobile body metal panel beating or interior trim part through push pin buckle.

In the case of vehicles with simultaneous presence of multiple transmission media, such as ethernet cables, LVDS cables, Fakra cables. The invention can coexist with the special cables, is bound and fixed by using the adhesive tape, and considers the traditional automobile buckle fixing or wire groove fixing scheme.

The SFH is connected with a vehicle gauge connector by adopting two realization modes:

(1) the PIN needle is welded with the SFH flexible conductor under the supporting structure, so that automatic production can be realized; designing a plastic clamp on the terminal support structure to fix an external reinforcing layer of the flexible wire harness and ensure the connection rigidity between the SFH and the terminal support structure, as shown in FIG. 6; the conductor layer and the terminal of the SFH adopt a laser welding technology to ensure the mechanical strength and the electrical stability; after laser welding, the PIN needle part of the connector and the welding part of the SFH are integrally molded by using a plastic molding (please note Chinese character) process, so that sealing and strength maintaining are realized; (a plastic shell can be designed to cover the molding part in the area without waterproof requirement, so that the maintainability is improved);

(2) the traditional turning gauge male PIN is connected with an SFH conductor under a switching structure of a PCB, a laser welding technology is used between the SFH conductor and the PCB, and a plastic clamping structure is designed at the front end of a laser welding part on the PCB and used for fixing an external reinforcing layer of the SFH so as to ensure the connection rigidity between the SFH and the PCB; after the integral assembly, the PIN needle part of the connector and the welding part of the SFH are integrally molded by using a molding process, so that sealing and strength maintaining are realized; (in the area without waterproof requirement, the plastic shell can be designed to cover the molding part, so as to improve the maintainability).

The flexible intelligent automobile wire harness (SFH) designed by the invention applies the concept of FPC to the electrical environment of an intelligent automobile, combines the traditional wire harness and the structural characteristics of the electric appliance of the whole automobile, and provides the concept of 'super flexible automobile wire harness' (1) the super flexible wire harness adopts a fixing mode of combining Push Pin and viscose; under the condition that an Ethernet line or a high-speed signal line coexists in some path designs, a portable wire harness bracket is designed to be coated and fixed; (2) the super-flexible wire harness adopts a sectional type production and assembly concept and combines a wire harness concept of KSK to realize modular configuration, optional assembly, lean production and intelligent detection; (3) the ultra-flexible wire harness can be designed with 1-4 conductor layers, depends on the Pinout requirement of an electrical appliance interface of a vehicle-mounted domain controller, and simultaneously considers the EMC and heat dissipation factors of the ultra-flexible conductor; (4) each layer of the super flexible conductor consists of a base layer, an adhesive layer and a protective film, and metal fine particles are doped in the adhesive layer to eliminate the EMC influence between an upper layer conductor and a lower layer conductor and a left conductor and a right conductor on the same layer; (5) the ultra-flexible lead wire needs to meet the requirements of vehicle specification grade flexibility, strength, conductivity, high and low temperature, EMC and the like, and meets the requirement of vehicle durability; (6) the connector of the ultra-flexible wiring harness SFH is realized by side-by-side automatic welding of SFH conductors and the traditional automobile wiring harness connector, and is integrally formed outside a welding area by using a molding process.

The technical scheme of the invention has the following beneficial technical effects:

the SFH realizes the automation, standardization and intellectualization of manufacturing, and accords with the national development route of intelligent manufacturing of industrial 4.0. The application of the MSFH in the automobile wire harness industry reduces the weight of an automobile wire harness system, improves the efficiency of vehicle assembly, and is beneficial to energy conservation and endurance increase of new energy automobiles and energy conservation and emission reduction of traditional automobiles. The development of the SFH series products can realize customized pre-production and multi-manufacturer spread production, and the wire harness manufacturer only needs to realize the modular assembly and test of the MSFH according to the OEM model selection, thereby greatly reducing the human input and the complex process links, and further reducing the whole vehicle cost and the vehicle purchasing cost. The MSFH realizes the end-to-end connection, is matched with the scheme of defining a domain controller under a novel framework of an automobile by SOA software, essentially changes the transition of an automobile connection technology from the traditional lead time to the integrated circuit time, conforms to the development trend of the automobile industry and changes the whole automobile wire harness industry.

The production and manufacturing process of the SFH flexible conductor part of the ultra-flexible automobile wire harness is different from the traditional FPC production process and technology. The traditional FPC production process has various flows, and the core process is the processes of developing, etching and stripping. As shown in fig. 7, the process steps of double-sided plating the FPC are exemplified. Different production stations of the traditional FPC do not form a production line and are distributed in independent rooms or different floors. The linking efficiency between the stations is low, and the stations are difficult to balance to achieve the highest production efficiency. The SFH of the ultra-soft automobile wire harness adopts a simplified FPC core production process and is implanted into the traditional automobile production flow, and the TS-16949 systematic management is realized. The process of d.e.s (development, etching and stripping) uses the finishing process of FPC. The rest production processes are all streamlined, and material transfer and accurate tracing between stations are realized by automatic equipment in follow-up consideration. The production process flow of SFH is shown in FIG. 8.

Drawings

Fig. 1 is a conceptual layout diagram of the present invention within a vehicle.

Fig. 2 is a partially enlarged 3D state diagram of fig. 1 according to the present invention.

Fig. 3 is a partially enlarged 2D schematic view of fig. 1 according to the present invention.

FIG. 4 is a schematic diagram of the single-layer conductor of FIG. 1 according to the present invention.

FIG. 5 is a schematic view of the dual layer conductor of FIG. 1 according to the present invention.

FIG. 6 is a partial schematic view of the connector of FIG. 1 of the present invention.

Fig. 7 is a process flow of the conventional FPC production.

FIG. 8 is a schematic view of the production process of a vehicle-scale SFH designed by the present invention.

Reference numerals in the figures; 1 is a first layer conductor; 2 is a second layer conductor; 3 is a third layer conductor; 4 is a fourth layer conductor; 5 is SFH outer layer clip; 6 is the welding part of the SFH conductor and the connector terminal; 7 is a connector terminal fixing support frame; and 8 is a connector body.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings in conjunction with the following detailed description. It should be understood that the description is intended to be exemplary only, and is not intended to limit the scope of the present invention. Moreover, in the following description, descriptions of well-known structures and techniques are omitted so as to not unnecessarily obscure the concepts of the present invention.

As shown in fig. 1-3, a concept of a new automotive wiring harness is illustrated, transitioning from traditional labor intensive wiring harness manufacturing to automated manufacturing. The form of the wiring harness has evolved into a consumer-like connection and is arranged in a segmented fashion (see fig. 1) in the vehicle environment to provide end-to-end connections to the electrical devices. The SFH wire harness and the assembly mode of the vehicle body environment are currently considered to be fixed by using high and low temperature resistant double faced adhesive tapes, and meanwhile, the wire grooves similar to the traditional wire harness can be adopted to realize the fixed protection.

As shown in fig. 4-5, the SFH interface layout of a single-layer conductor and a double-layer conductor is exemplified, and as can be seen from the layer-to-layer relationship, the SFH production process will be completely different from the conventional wire harness, which can be understood as a push-type production that replaces a complex process flow with a hierarchical parallel automatic production. The process between layers refers to the production process of FPC, the base material and the process flow of each layer are improved on the premise of meeting the requirements of SFH vehicle-scale test, and the specific implementation form can be gradually realized in the implementation process of the invention.

As shown in fig. 6, the SFH connector realizes connection with the SFH, and the reinforcing and fixing structures 5 and 7 are fixed to the connector to form a whole, so that the PIN of the connector is firmly connected with the conductor layers 1, 2, 3 and 4 of the SFH. Direct Molding or cladding fixation using a plastic housing is considered at the periphery of the entire assembly to achieve a highly robust connection of the connector, terminals, flexible conductors and SFH.

Claims

1. A super-flexible automotive wiring harness, comprising: the unit sheet layer comprises a base layer, a conductor layer and a protective film; an adhesive layer is arranged between the base layer and the conductor layer to bond the base layer and the conductor layer together; a protective film over the conductor layer; an adhesive layer is arranged between the upper unit sheet layer and the lower unit sheet layer and adheres the upper unit sheet layer and the lower unit sheet layer together; the reinforcing layer is arranged on the top of the N unit layers, and the reinforcing layer is adhered to the top unit layer by the adhesive layer;

in each unit sheet layer, a plurality of conductors are arranged in parallel on the conductor layer, and a proper gap is formed between every two adjacent conductors.

2. The automotive wiring harness of claim 1, wherein the conductive layer is a copper foil layer, the thickness of the copper layer of the circuit is 100-200 μm, and the line width is 2mm or more.

3. The automotive super-flexible harness as claimed in claim 1, wherein the base layer and the protective film are made of a material with good insulating property, and are selected from polyvinyl chloride, polyethylene, cross-linked polyethylene and polypropylene.

4. The ultra-flexible automotive wire harness of claim 1, wherein the reinforcement layer, while used to reinforce the SFH, provides a securing structure to enable snap-fit securement with a vehicle sheet metal or plastic part; at the same time, there is suitable flexibility and deflection at the ends of the reinforcement layer for absorbing stresses in the shock environment of the vehicle.

5. The ultra-flexible automotive wire harness of claim 1, wherein the adhesive layer is doped with fine particles of a metallic material.

6. The ultra-flexible automotive wiring harness of claim 1, wherein when a plurality of paths of conductors need to be connected in a common point, the conductors are led out to the same position together through the arrangement design of the conductors, and the common point connection is realized by using a connector welding process.

7. The ultra-flexible automotive wiring harness of claim 1, wherein the assembly and fixation with the vehicle interface is fixed by a double-sided adhesive tape, or is fixed to a metal sheet or an interior trim part of an automotive body by a push pin buckle through punching holes on the edge of a base layer.

8. The ultra-flexible automotive wiring harness of claim 1, wherein two implementation modes are adopted in connection with a gauge-level connector:

(1) the PIN is realized in a mode of welding with a flexible conductor of the SFH under the supporting structure; specifically, a plastic clamp is designed on a terminal supporting structure and used for fixing an external reinforcing layer of a flexible wiring harness, so that the connection rigidity between the SFH and the terminal supporting structure is ensured; the conductor layer and the terminal of the SFH adopt a laser welding technology to ensure the mechanical strength and the electrical stability; after laser welding, the PIN needle part of the connector and the welding part of the SFH are integrally molded by using a plastic molding process, so that sealing and strength maintaining are realized;

(2) the traditional turning gauge male PIN is connected with an SFH conductor under a switching structure of a PCB, a laser welding technology is used between the SFH conductor and the PCB, a plastic clamping structure is designed at the front end of a laser welding part on the PCB and used for fixing an external reinforcing layer of the SFH, and the connection rigidity between the SFH and the PCB is ensured; and after the integral assembly, the PIN needle part of the connector and the welding part of the SFH are integrally molded by using a molding process, so that sealing and strength maintaining are realized.