WO2021204054A1 - 一种注塑成型的线束及成型方法 - Google Patents

一种注塑成型的线束及成型方法 Download PDF

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Publication number
WO2021204054A1
WO2021204054A1 PCT/CN2021/084898 CN2021084898W WO2021204054A1 WO 2021204054 A1 WO2021204054 A1 WO 2021204054A1 CN 2021084898 W CN2021084898 W CN 2021084898W WO 2021204054 A1 WO2021204054 A1 WO 2021204054A1
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WIPO (PCT)
Prior art keywords
wire harness
injection
conductor
molded
terminal
Prior art date
Application number
PCT/CN2021/084898
Other languages
English (en)
French (fr)
Inventor
王超
Original Assignee
长春捷翼汽车零部件有限公司
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Filing date
Publication date
Application filed by 长春捷翼汽车零部件有限公司 filed Critical 长春捷翼汽车零部件有限公司
Priority to BR112022020340A priority Critical patent/BR112022020340A2/pt
Priority to JP2022560354A priority patent/JP7462067B2/ja
Priority to KR1020227038072A priority patent/KR20220162164A/ko
Priority to US17/995,526 priority patent/US20230154650A1/en
Priority to EP21785050.2A priority patent/EP4135129A4/en
Priority to MX2022012675A priority patent/MX2022012675A/es
Priority to CA3173649A priority patent/CA3173649A1/en
Publication of WO2021204054A1 publication Critical patent/WO2021204054A1/zh
Priority to ZA2022/10902A priority patent/ZA202210902B/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/40—Insulated conductors or cables characterised by their form with arrangements for facilitating mounting or securing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/502—Bases; Cases composed of different pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14598—Coating tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14639—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles for obtaining an insulating effect, e.g. for electrical components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/0207—Wire harnesses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/0207—Wire harnesses
    • B60R16/0215—Protecting, fastening and routing means therefor
    • B60R16/0222—Grommets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/32—Filling or coating with impervious material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0009—Details relating to the conductive cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0045—Cable-harnesses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5205—Sealing means between cable and housing, e.g. grommet
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R31/00—Coupling parts supported only by co-operation with counterpart
    • H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/70—Insulation of connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/005—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
    • H01R43/24—Assembling by moulding on contact members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3462—Cables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2410/00—Constructional features of vehicle sub-units
    • B60Y2410/115—Electric wiring; Electric connectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles

Definitions

  • the present invention relates to the technical field of wire harnesses, in particular to an injection-molded wire harness and a molding method.
  • wiring harnesses serve as bridges for electrical circuit connections, connecting power supplies and electrical appliances, as well as electrical appliances for data exchange. They are essential components in automobiles, airplanes, ships, various household appliances and equipment.
  • the way and material of the wire harness are very different, but the main structure is composed of cables, terminals, sheaths, fixing devices, waterproof devices, etc.
  • the cables are composed of conductors and insulating layers covering the conductors.
  • the processing technology of wire harness is relatively complicated, including cutting, stripping, crimping, welding, pipe threading, plugging blind plugging, plugging terminal, plugging sheath, sub-assembly, wiring, encapsulation, branch fixing, installation positioning device, installation parts, Conduction, visual inspection, packaging and other processes.
  • the various parts of the traditional wiring harness are not tightly integrated, including the cable and the protective sleeve on it, the cable is connected to the sheath through the terminal, the positioning device is fixed by tape or cable tie, and the waterproof device is through the elasticity of the rubber part. Attached to the wiring harness, etc., in the long-term use, the connection of various parts will gradually fail, causing the cable and the protective sleeve to wear, the cable and the sheath are separated, the positioning device is inaccurate or falling off, and the waterproof device is damaged or falling off. The function of each part is lost, which leads to the failure of the wiring harness and, in severe cases, an accident.
  • the current wire harness industry urgently needs a new method that can simplify the wire harness assembly production process, which can reduce manual operations, improve product consistency, and reduce product production costs.
  • Chinese invention patent application CN 104149770 A discloses an injection-molded anti-lock brake system sensor wiring harness.
  • injection-molded positioning parts are added, but this invention is only for the transmission of anti-lock brake systems.
  • the sense wire harness has limitations in its use.
  • This invention still needs to purchase finished cables and then process them into the main body of the wire harness, which cannot save the cost of the wire harness.
  • This invention does not protect the cable. After being installed and used in a vehicle, the cable insulation will be damaged due to vibration and friction at the installation part. In severe cases, it will cause a short circuit and cause a combustion accident.
  • the injection molded parts added by this invention have a single function and cannot meet other complicated requirements on the wiring harness.
  • the technical problem solved by the present invention is to provide a new injection molding wire harness and molding method, which can greatly reduce the wire harness processing flow, reduce manual operations, and improve The consistency of the product increases the waterproof level and reduces the production cost of the product. It can realize one-time processing and shaping of complex shaped wire harnesses, improve production efficiency, and make wire harnesses more widely applicable.
  • the wiring harness with sealing requirements can be formed at one time, which increases the sealing performance of the wiring harness, reduces the use of cement, sealant and other materials, extends the service life of the waterproof area, and greatly improves the safety performance.
  • the present invention is an injection molded wire harness.
  • the wire harness includes a terminal and at least one conductor. One end of the terminal is connected to an electrical circuit of an electrical device, and the other end of the terminal is connected to the conductor.
  • the wire harness of the present invention is different from the traditional wire harness.
  • a cable with an insulating layer can be used, or a conductor can be directly used for injection molding.
  • the processing forms of conductors can also be varied, such as coiled conductor cutting, copper foil cutting, conductor printing, 3D printing, and so on. It can be selected and optimized according to different wiring harness usage environments, saving raw materials to a greater extent, reducing processing man-hours, and improving product quality.
  • each part is heated and melted, and then cooled and formed to be connected together. It can be said to be an integrated structure, there is no mutual wear between the parts, the relative positioning size is also accurate, and the service life is similar. Compared with the traditional wiring harness, it is greatly improved, and the safety can also be guaranteed.
  • an insulating layer is further provided outside the conductor, and the protective layer is injection-molded outside the insulating layer.
  • the positioning device includes a first fixing device connected to the wire harness and an assembly device matingly connected to the mounting end of the wire harness, and the assembly device is connected to the first fixing device.
  • the positioning device when the general wire harness is installed, if the length exceeds a certain length, the positioning device will be used to connect to the installation end to ensure that the wire harness can be fixed on the installation end, such as the engine, sheet metal frame or other pipelines. If there is no positioning device, the wiring harness will move on the installation end, increasing the wear of the wiring harness. In addition, the movement of the wiring harness will also produce abnormal noise, which will affect the experience of using cars, airplanes, ships or various household appliances.
  • the first fixing device is a cylindrical structure, and the inner wall of the cylindrical structure is matched with the outer surface of the protective layer and is wrapped around the outer surface of the protective layer.
  • the cylindrical structure is to strengthen the strength of the fixing device and prevent the positioning device from falling off the wire harness under force.
  • the assembling device is a columnar structure, and the outer periphery of the columnar structure has an inverted tooth structure.
  • the inverted tooth structure is for preventing the columnar structure from falling out of the mounting hole when the columnar structure matches the mounting hole of the mounting end.
  • the assembling device has a clip-like structure.
  • the clip-like structure has a groove, and barbs are provided on two side walls in the groove.
  • the barbs are arranged in the grooves to prevent the clip-like structure from falling off the sheet metal edge when the clip-like structure matches the sheet metal edge of the mounting end.
  • the assembling device has a circular ring structure or a C-ring structure.
  • the circular ring structure or the C-ring structure is to prevent the assembling device from falling off the pipeline when the assembling device is matched with other pipelines at the mounting end.
  • the positioning device is a plastic part processed by injection molding. Since the positioning devices are all rigidly connected to the mounting end, if rubber parts are used and the amount of deformation is large, the connection will be weak. Therefore, plastic parts with good hardness and elasticity will be used.
  • the sealing device includes a second fixing device and a waterproof device connected to the wire harness, and one end of the waterproof device is connected to the second fixing device.
  • the second fixing device is a cylindrical structure, and the inner wall of the cylindrical structure is matched with the outer surface of the protective layer, and is wrapped on the outer surface of the protective layer.
  • the cylindrical structure is to strengthen the strength of the fixing device and prevent the sealing device from falling off the wire harness under force.
  • the sealing device is a rubber part processed by injection molding. Since the sealing device needs to seal the sealed end of the wire harness, the sealed end of the wire harness is injection-sealed using elastic materials such as rubber parts to prevent water in the external environment from entering the wire harness, causing corrosion of the wire harness conductors, and seriously reducing the wire harness The service life of the battery may cause safety accidents in severe cases.
  • the sealed end of the wire harness refers to the general wire harness that will pass through the through holes on the partition plate of some dry and wet areas during installation.
  • the waterproof device on the wire harness needs to be matched and tightly connected with the through hole on the partition plate.
  • a sealing device is required to seal and wrap the exposed conductors and terminals to prevent water in the external environment from corroding the conductors and terminals.
  • a sealing device is required to seal the holes of the sheath.
  • the wire harness is further provided with at least one sheath that is mated with the electrical device, and the terminal is assembled in the corresponding hole of the sheath.
  • the sheath is integrally molded onto at least the terminal.
  • the conductor is connected to the sheath through the connected terminal.
  • the conductor and the sheath can be fixed with the protective layer when the protective layer is injection molded Together, thereby extending the service life of the wiring harness.
  • the conductor is a solid conductor, a flat conductor or a conductor of a multi-strand wire. According to the different use environment of the wire harness, the conductor can choose different structures.
  • the terminal is connected to a conductor of a solid conductor, a flat conductor or a multi-stranded wire by crimping or welding.
  • a crimping method is adopted.
  • a welding method is adopted.
  • the cross-section of the conductive part of the conductor is circular, elliptical, polygonal, wavy or special-shaped structure.
  • conductive parts with different cross-sectional areas can be selected to form a conductive loop.
  • the conductors on the non-terminal side are connected to the conductor connection points according to the requirements of the circuit by means of crimping or welding.
  • the conductor connection point is packaged and sealed by an integral injection molding.
  • the conductor connection point can greatly save the use of conductor materials, so that the current is shunted by different conductors at a suitable position. Due to the use of crimping or welding, the conductor stress on both sides of the conductor connection point is relatively concentrated, and subsequent use will cause the conductor connection point to break due to force, causing the wiring harness to lose its function. Therefore, it is necessary to use the overall injection molding method to connect the conductor to the conductor connection point. Carry out package protection.
  • the integral injection molding of the conductor connection points in the wet area can also play a role of sealing and waterproofing.
  • the method for preparing the wire harness of the present invention includes the following steps:
  • the terminal is connected to the conductor using a crimping or welding device; and the protective layer or positioning device or sealing device is injected according to step B to step C.
  • the terminal is connected to the conductor using a crimping or welding device; according to steps B to C, the protective layer is injected first, and the multiple conductors are isolated Open, and then inject the positioning device or the sealing device.
  • the conductors are connected to the conductor connection points according to the requirements of the circuit by crimping or welding; according to steps B to C. Inject the harness protection device first, then inject the protective layer, and finally inject the positioning device or sealing device.
  • the terminal of the connecting conductor is inserted into the corresponding hole of the sheath before injection molding; or the semi-finished wire harness is injection molded first, and then the connecting conductor The terminal is inserted into the corresponding hole of the sheath.
  • the semi-finished wire harness is put into an injection mold, and the sheath is integrally injection molded onto at least the terminal.
  • the present invention has the following beneficial effects:
  • the traditional design concept of wiring harness is to purchase, process, and assemble various raw materials such as cables, terminals, sheaths, fixing devices, waterproof devices, tapes, and support trunking into finished wiring harnesses.
  • This approach can make The raw material manufacturer and the wiring harness factory cooperate with each other to perform their own duties.
  • the process flow of such production is particularly cumbersome, the processing procedures are many, the defective rate of the production process is high, and the size and performance of the finished wire harness are difficult to guarantee.
  • the inventor of the present application found that in addition to conductors and terminals, the wiring harnesses are basically plastic parts and rubber parts.
  • the current production process of plastic parts and rubber parts is mostly injection molding. Therefore, the injection molding method of the present invention is used to process the wire harness protective layer.
  • the positioning device and the waterproof device can reduce the cost of the wiring harness, improve the production efficiency, reduce the product defect rate and extend the service life of the wiring harness.
  • the wire harness of the present invention uses conductors for direct injection molding, and the processing forms of the conductors can also be varied, and can be selected and optimized according to different wire harness usage environments, which saves wire harness raw materials to a greater extent, reduces processing man-hours, and improves wire harness product quality. It also provides wire harness designers with more diverse design options, optimizes wire harness costs, and improves wire harness product stability.
  • the injection molding protective layer of the present invention replaces the manual operation of the casing and the rubberized cloth in the traditional wiring harness, and can realize automatic production. The more branches of the wiring harness, the more man-hours are saved.
  • the protective layer made by the injection molding process avoids the shortcomings of inaccurate size and insufficient protection of the joints in the manual coating operation, which can better ensure the quality of the wiring harness and extend the service life of the wiring harness.
  • the wire harness of the present invention adopts an integral injection molding process.
  • the protective layer, positioning device and sealing device can be tightly integrated with other parts of the wire harness.
  • the waterproof effect of the wire harness can reach IP67 level.
  • the wire harness has undergone salt spray experiment, high and low temperature experiment, and vibration. After the experiment and the aging experiment, the mechanical properties and electrical properties between the wire harness conductor and the terminal are minimally affected, which can better ensure the quality of the wire harness product and extend the service life of the wire harness.
  • there are more kinds of injection molding materials there are more kinds of injection molding materials. Different injection materials can be selected according to different use environments to make the wire harness more flexible and have better anti-vibration effect. It can be used in environments with harsher vibration environments, significantly prolonging the service life of the wire harness and improving the efficiency of the wire harness. safety.
  • the wire harness of the present invention can also use a wire with an insulating layer.
  • the wire harness has fewer loops, or the length of the wire is longer, and the tightness requirement is not high, the wire with an insulating layer can be used to reduce the cost of the injection mold.
  • the assembly device adopts an injection molding processing method, and can be set to different styles according to the different shapes of the wire harness mounting ends, which is more convenient for the wire harness installation and significantly improves the wire harness installation efficiency.
  • the positioning device adopts plastic parts, which makes the injection molding process more convenient. When assembling with the wiring harness installation end, the elasticity of the plastic parts can be better installed and matched, and the installation efficiency of the positioning device is significantly improved. At the same time, the plastic parts are highly resistant to corrosion. The earth extends the service life of the wiring harness.
  • the sealing device is not easy to be damaged, and it is more closely integrated with the wiring harness protective layer.
  • the sealing device will not have size deviation or even break away from the wiring harness and cause the wiring harness sealing function to fail, which can significantly extend the wiring harness.
  • Service life can also be arranged between the terminal and the conductor, between the sheath and the protective layer, to better seal the conductor, prevent water in the external environment from corroding the conductor, and significantly extend the service life of the wire harness.
  • the sealing device adopts rubber parts, which have better fit with other parts. At the same time, the elasticity of the rubber parts makes the sealing performance of the wire harness better and significantly improves the service life of the wire harness.
  • the wiring harness of the present invention uses a separate sheath or an integrally injection molded sheath, which can be more quickly matched and installed with electrical devices, improve installation efficiency, and can quickly replace damaged wiring harnesses, improve wiring harness maintenance efficiency, and reduce labor cost.
  • the integrated injection-molded sheath can be processed more quickly, and it is more closely attached to the terminal, protective layer or insulating layer, which significantly improves the sealing level of the wiring harness.
  • the conductors are solid conductors, flat conductors, multi-stranded conductors, and various cross-sections of conductive parts of the conductors. Corresponding conductor structures can be adopted according to the actual use environment of the wire harness, which saves wire harness costs and improves wire harness installation efficiency . At the same time, different conductor structures and cross-sections of conductive parts of the conductor can be adapted to terminals of different connection methods, which facilitates the wire harness designer to choose the terminals and conductors used by the wire harness, optimizes the cost of the wire harness, and improves the stability of the wire harness product.
  • the non-terminal side conductors are connected to the conductor connection points according to the requirements of the circuit by crimping or welding.
  • the conductor connection points are integrally molded and sealed, which can ensure that the conductor connection points will not be damaged during wire harness installation and use. In a harsh vibration environment, the conductor connection points that are integrally molded and sealed will not be broken by vibration. And the integral injection molding package sealing can prevent the external environment water from corroding the conductor connection points, and significantly extend the service life of the wire harness.
  • the present invention also provides a method for preparing an integrated injection molding wire harness. According to different wire harness structures, different process flows are adopted, which can significantly improve the production efficiency of the wire harness and reduce the cost of the wire harness.
  • Figure 1 is a schematic diagram of a wire harness with a single conductor, no sheath, and a positioning device and a sealing device according to the present invention.
  • Fig. 2 is a schematic diagram of a wiring harness with multiple conductors of the present invention, with a sheath, a protective layer, a positioning device, and a sealing device.
  • 3A is a schematic cross-sectional view of a wire harness of a single conductor with a protective layer according to the present invention.
  • Fig. 3B is a schematic cross-sectional view of a wiring harness in which a plurality of conductors with protective layers are arranged side by side according to the present invention.
  • 3C is a schematic cross-sectional view of a wire harness in which a plurality of conductors with a protective layer are arranged in a ring shape according to the present invention.
  • Fig. 3D is a schematic cross-sectional view of a wire harness of multiple conductors with insulating layers and protective layers according to the present invention.
  • Fig. 4 is a schematic diagram of a wiring harness with multiple conductors and conductor connection points according to the present invention.
  • Fig. 5 is a schematic diagram of the structure of the positioning device of the present invention.
  • Figure 6 is a schematic diagram of the assembly device of the inverted tooth structure.
  • Fig. 7 is a schematic diagram of an assembling device with a clip-like structure.
  • Fig. 8 is a schematic diagram of the assembly device of the C-ring structure.
  • 9A is a schematic structural diagram of the wiring harness of the present invention with a sealing device that cooperates with the through hole on the partition plate.
  • Fig. 9B is a partial cross-sectional view of the structure of Fig. 9A.
  • Fig. 10 is a schematic diagram of the structure of the sealing device of the conductor, the terminal and the protective layer of the present invention.
  • Fig. 11 is a schematic diagram of the structure of the sealing device of the sheath of the present invention.
  • Fig. 12 is a schematic diagram of the structure of the integral injection-molded sheath of the present invention.
  • the reference signs are: 1, terminal, 2, conductor, 3, insulating layer, 4, sealing device, 5, positioning device, 6, sheath, 7, protective layer, 8, wiring harness protection device, 9, waterproof Device, 10, second fixing device, 11, assembling device, 12, first fixing device, 13, waterproof cover, 14, card slot.
  • the wire harness is composed of a single conductor, and both ends of the conductor 2 are connected to the terminal 1 respectively.
  • the terminal 1 is a copper terminal, and the copper terminal is made of a copper alloy with a copper content of 60%, which can ensure that the copper terminal has good conductivity and workability.
  • the surface of the terminal 1 is plated with nickel, and can also be plated with one of cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, silver or gold. The plating layer can slow down the corrosion of the terminal and prolong the service life of the terminal .
  • One end of the terminal 1 is connected to the conductor 2.
  • the other end of the terminal 1 is used to connect an electrical circuit of an electrical device.
  • the conductor 2 is composed of a multi-core wire, and the cross-section of the multi-core wire is circular.
  • the conductor 2 may also be a solid conductor or a flat conductor.
  • the cross section of the conductive part of the conductor 2 may also be elliptical, polygonal, wavy or irregular.
  • the wire harness is provided with an injection-molded protective layer 7 covering the outside of the conductor 2.
  • the protective layer 7 is made of plastic or rubber.
  • the material of the protective layer 7 is PVC; and at least one positioning device 5 for fixing the position of the wire harness or/and a sealing device 4 for waterproofing by injection molding.
  • the conductor 2 can be a purchased wire with an insulating layer 3, and the protective layer 7 is injection molded on the insulating layer 3; or the protective layer 7 can be directly injection molded on the conductor 2. As shown in FIG. 3A, the single conductor 2 is arranged in the middle, and the protective layer 7 is injection molded on the periphery.
  • the two ends of the conductor 2 are respectively connected to the terminal 1 by means of crimping or welding. Then the semi-finished product is put into an injection mold, and the protective layer 7, the positioning device 5 and the sealing device 4 are injected according to the determined size.
  • the specific injection molding method is as follows:
  • the material of the positioning device 5 is PA66.
  • the positioning device 5 is a plastic part processed by injection molding.
  • the positioning device 5 includes a first fixing device 12 connected to the wire harness and an assembly device 11 matingly connected to the wire harness installation end, and the assembly device 11 is connected to the first fixing device 12 On;
  • the first fixing device 12 is a cylindrical structure, the inner wall of the cylindrical structure is matched with the outer surface of the protective layer 7, and is wrapped on the outer surface of the protective layer 7.
  • the specific structure of the assembling device 11 may be an inverted tooth structure that is inserted into the mounting hole, that is, the assembling device is a columnar structure, and the outer periphery of the columnar structure is provided with an inverted tooth structure that is opposite to the insertion position of the hole to be installed (as shown in Figure 6). (Shown);
  • the assembly device may also be a clip-like structure with a mating connection with the plate (as shown in Figure 7), specifically with a groove, the two side walls of the groove are provided The barbs that are locked in place with the sheet; can also be a circular or C-shaped ring structure assembled with a tubular or columnar structure (as shown in Figure 8).
  • the material of the sealing device 4 is EPDM.
  • the sealing device 4 is a rubber part processed by injection molding.
  • the sealing device in this example 4 Including a second fixing device 10 connected to the wire harness and a waterproof device 9, the waterproof device 9 is connected to the second fixing device 10; the second fixing device 10 has a cylindrical structure, a cylindrical structure The inner wall is matched with the outer surface of the protective layer 7, and is wrapped around the outer surface of the protective layer 7.
  • the structure of the waterproof device 9 includes a waterproof cover 13 connected to the second fixing device 10 at one end and connected to the other end of the waterproof cover 13 , Play the card slot 14 with the waterproof hole assembly.
  • a sealing device is set between the protective layer 7, conductor 2 and terminal 1 of the wire harness, and the protective layer 7, conductor 2 and terminal 1 are sealed and wrapped, as shown in Figure 10, the sealing device 4Injection on the conductor 2 and the junction between the terminal 1 and the conductor 2 and outside the protective layer.
  • the part corresponding to the conductor 2 and the terminal 1 is the waterproof device 9, and the part corresponding to the protective layer 7 is the second fixing device 10.
  • the wire harness is composed of more than one conductor 2.
  • Each of the conductors 2 is connected to the terminal 1 at both ends.
  • the surface of the terminal 1 is galvanized or can be plated One of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, copper, silver or gold.
  • the conductor 2 and the terminal 1 are the same as the embodiment 1, and will not be repeated here.
  • the difference from Embodiment 1 is that the wiring harness is also provided with at least one sheath 6 that is mated with the electrical device. After the conductor 2 is connected to the terminal 1, the terminal 1 is assembled in the sheath 6.
  • the terminal 1 corresponds to the different holes of the sheath 6 according to the design requirements, so as to play a role in connection with different circuits, and at the same time, it can protect the terminal 1 from damage.
  • the sheath 6 is integrally injection molded onto at least the terminal 1.
  • the two ends are respectively connected to the terminal 1 by crimping or welding. Then put the semi-finished product into the injection mold, according to the determined size, the protective layer 7 and the positioning device 5, and the sealing device 4 are injected. First, the wire harness protective layer 7, then the wire harness protective device 8, and then the positioning device 5 Or sealing device 4.
  • a sealing device 4 is set between the protective layer 7, conductor 2 and terminal 1 of the wire harness to seal the protective layer 7, conductor 2 and terminal 1, as shown in Figure 10.
  • the device 4 is injection molded on the conductor 2, where the terminal 1 and the conductor are connected and outside the protective layer 7, the part corresponding to the conductor 2 and the terminal 1 is the waterproof device 9, and the part corresponding to the protective layer 7 is the second fixing device 10.
  • the specific injection molding method is as follows:
  • the parameters of injection molding include heating temperature, cooling temperature, injection pressure, injection time, etc., operating according to existing injection molding equipment, which is a conventional operation method.
  • the finished injection molded product must not have defects such as impurities, pits, flashes, and pores.
  • the plurality of conductors 2 are arranged in the middle, and a protective layer 7 is injection molded on the periphery.
  • the multiple conductors 2 are insulated and protected to prevent the multiple conductors 2 from short-circuiting each other and being damaged by external forces such as scraping and abrasion after the wiring harness is installed.
  • the conductor 2 is a solid conductor or a flat conductor, and the cross-section of the conductive part of the conductor 2 is a special-shaped structure, which may also be an ellipse or a wave shape.
  • the material of the protective layer 7 is PVC.
  • the positioning device 5 and the sealing device 4 are the same as those in Embodiment 1, and will not be described in detail.
  • the wire harness is composed of more than one conductor 2.
  • a part of the conductor 2 end is connected to the terminal 1, and the other part of the conductor 2 end is connected by crimping or welding according to the requirements of the loop.
  • Conductor connection point The surface of the terminal 1 is plated with silver, and can also be plated with one of nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc or gold.
  • the terminal 1 is assembled into a sheath 6 that is mated with an electrical device, and differently, the terminal 1 corresponds to different holes of the sheath 6 according to design requirements.
  • the conductor connection point is sealed as a wire harness protection device 8 as a whole; the wire harness protection device 8 is a rubber or plastic part processed by injection molding.
  • the conductor 2 is provided with an insulating layer 3, and a protective layer 7 is injection molded on the insulating layer 3.
  • the terminal 1 and the sheath 6 are the same as those in the embodiment 1, and will not be repeated.
  • the plurality of conductors 2 are cut to a fixed length respectively, according to design requirements, some of the conductors 2 are respectively connected to the terminal 1 by means of crimping or welding.
  • the non-terminal side conductors are connected to the conductor connection points according to the requirements of the circuit by crimping or welding. Then put the semi-finished product into the injection mold, according to the determined size, according to the injection steps described in Example 2, firstly, the protective layer 7 is injected, then the harness protection device 8, and finally the positioning device 5 and/or the sealing device 4 are injected .
  • the conductor 2 is a multi-stranded wire, and the cross section of the conductive part of the conductor 2 is a polygonal structure.
  • the material of the wire harness protection device 8 is plastic. In other applications, the material of the wire harness protection device 8 may also be rubber.
  • the protective layer 7, the positioning device 5, and the sealing device 4 are the same as those in the second embodiment, and will not be repeated here.
  • the terminal 1 of the connecting conductor 2 is inserted into the corresponding hole of the sheath 6, and then injection molding is performed; or the wire harness is first The semi-finished product is injection molded, and then the terminal 1 of the connecting conductor 2 is inserted into the corresponding hole of the sheath 6.
  • a sealing device 4 is provided to seal the holes of the sheath 6, and the sheath 6 and the conductor 2
  • the waterproof device 9 is injected into the connection gap to seal the sheath 6 for waterproofing, and the second fixing device 10 is connected to the ends of the waterproof device 9 and the sheath 6.
  • the waterproof device 9 is formed by injection molding, and the second fixing device 10 is a sleeve structure that cooperates with the outer protective layer 7 of the conductor 2.
  • the sheath 6 described in this example can also be integrally injection molded, the semi-finished wire harness is placed in an injection mold, and the sheath 6 is integrally injection-molded onto at least the terminal 1.
  • the sheath 6 may also be integrally injection-molded onto the terminal 1 and the conductor 2, or the sheath 6 may be integrally injection-molded onto the terminal 1, the conductor 2 and the protective layer 7.
  • the specific experiment process is as follows: simulate the actual use environment of the wiring harness, but increase the test conditions to a level that is far more stringent than the ordinary environment, and in a short time, the test results that can be achieved for a long time under the actual use environment can be obtained.
  • the series of experiments include: 1) the initial pull-out force and voltage drop test of the terminal 1 and conductor 2 of the two wire harnesses to obtain the initial mechanical and electrical properties of the wire harness; 2) 1000 hours of salt spray experiment, using a salt spray test box , Spraying salt water on the two wiring harnesses can replace the ten-year salt spray resistance test in the ordinary coastal environment; 3) 200 hours of high and low temperature experiments, so that the two wiring harnesses are respectively at the highest and lowest temperature of the use environment for one hour, The temperature switching time is less than 5 seconds, and 100 cycles are performed, which can replace the 10-year high and low temperature resistance test in the external cold and heat alternate environment; 4) 120-hour vibration test, fix the two wiring harnesses on the vibration test bench, and select the vibration according to the use environment Amplitude, the vibration of the two wiring harnesses in three directions can replace the 10-year vibration test under the normal vibration environment; 5) 6000-hour aging test, put the two wiring harnesses into the aging test box to simulate the exceeding rated use conditions The environment
  • Table 1-1 The influence of traditional wiring harness and integrated injection molding wiring harness on the pull-out force and voltage drop of terminals and conductors (before the experiment and after the 1000-hour salt spray experiment)
  • Table 1-2 The influence of traditional wiring harness and integrated injection molding wiring harness on the pull-out force and voltage drop of terminals and conductors (200 hours of high and low temperature test and 120 hours of vibration test)
  • Table 1-3 The influence of traditional wiring harness and integrated injection molding wiring harness on the pull-out force and voltage drop of terminals and conductors (6000-hour aging test)
  • the integrated injection molded wiring harness, the terminal 1 and conductor 2 pulling force values after the experiment are much higher than the traditional The drawing force values of terminal 1 and conductor 2 after the experiment of the processed wire harness are also relatively close to the initial drawing force values.
  • the pulling force value of the terminal 1 and the conductor 2 after the experiment is significantly lower, and the mechanical properties are unstable, which may cause the terminal 1 and the conductor 2 of the wire harness to separate, resulting in a short circuit of the wire harness, and minor function failure. In severe cases, it can lead to a burning accident.
  • the voltage drop between the terminal 1 and the conductor 2 after the experiment is basically close to the initial voltage drop between the terminal 1 and the conductor 2 of the harness processed by the traditional method.
  • the voltage drop value of terminal 1 and conductor 2 is also significantly reduced after the experiment, and the electrical performance is unstable.
  • the contact resistance between terminal 1 and conductor 2 of the wire harness increases, which will cause the terminal 1 and conductor 2 of the wire harness to conduct electricity. Fever and redness. In severe cases, it will burn due to high temperature and cause serious accidents.
  • the mechanical and electrical properties of the terminal 1 and the conductor 2 after the experiment of the integrated injection harness are much better than those processed by the traditional method, which can reduce the product defect rate and prolong the service life of the harness.
  • Table 2 The effect of vibration test on the performance of the fixture (120-hour vibration test) for traditional wiring harness and integrated injection molding wiring harness
  • the traditional wire harness uses a cable tie to fix the positioning device.
  • the size deviation of the positioning device 5 accounts for 52% of the total number of wire harnesses, and the number of wire harness detachment accounts for 11% of the total number of wire harnesses.
  • the defect rate is very high; traditional The wire harness uses tape to fix the positioning device 5, the size of the positioning device 5 accounts for 69% of the total number of wire harnesses, and the number of wire harnesses detached accounts for 24% of the total number of wire harnesses.
  • the defect rate is very high, which seriously affects the installation and function realization of the wire harness. , In severe cases, the wiring harness function will fail.
  • the integrated injection molding wire harness, the positioning device 5 and the wire harness are more firmly combined, the positioning device 5 is not easy to fall off, the positioning effect is better, and in the environment with a harsh vibration environment, the positioning device 5 rarely has a size deviation or even separates from the wire harness, resulting in the wire harness positioning Function failure can significantly extend the service life of the wiring harness.
  • the sealing device 4 is protected against the erosion of external dust and water.
  • the performance of the sealing device 4 is tested for the protection level. The results are shown in the following table:
  • the protection level pass rate is only 89%, 92% and 88%; in the IP67 protection level test, the protection level pass rate Only 68%, 75% and 71%, the pass rate of the protection level is very low, the sealing performance of the wire harness cannot be guaranteed, and the conductor 2 cannot be prevented from being corroded by dust and water in the external environment, resulting in the failure of the wire harness function.
  • the three sealing devices 4 of one-piece injection-molded wiring harness in the IP54 protection level test, the protection level pass rate is 100%; in the IP67 protection level test, the protection level pass rate is 99%, 100% and 100%, It can fully meet the sealing performance of the wiring harness, make the wiring harness better, prevent the corrosion of the conductor by dust and water in the external environment, and significantly improve the service life of the wiring harness.
  • the conductor connection points are wrapped by different protection methods.
  • 100 each of the two kinds of wiring harnesses are selected .
  • the injection-wrapped conductor connection point of the integrated injection-molded wire harness has a breaking ratio of 0%, which can fully meet the conduction performance of the wire harness in a harsh vibration environment, and significantly improve the service life of the wire harness.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Connector Housings Or Holding Contact Members (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Insulated Conductors (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Processing Of Terminals (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Abstract

一种注塑成型的线束及成型方法，所述线束包括端子(1)和至少一根导体(2)，所述端子(1)的一端连接用电装置的电气回路，所述端子(1)的另一端与所述导体(2)连接，所述线束上设置有注塑成型的、包覆在所述导体(2)外部的保护层(7)，以及注塑成型的至少一个用于固定线束位置的定位装置(5)或/和用于防水的密封装置(4)。本方法能够减少人工操作，提高线束产品的一致性，降低线束产品的生产成本，延长线束使用寿命。

Description

一种注塑成型的线束及成型方法
相关申请
本申请要求申请号为202010283020.X，申请日为2020年04月10日，发明名称为“一种注塑成型的线束及成型方法”的中国发明专利的优先权。
技术领域
本发明涉及线束技术领域，尤其涉及一种注塑成型的线束及成型方法。
背景技术
在电气连接领域，线束作为电气回路连接的桥梁，连通电源与用电器，以及各个数据交换的电器之间，是汽车、飞机、船舶、各种家用电器和设备中必备的重要部件。
线束构成的方式和材料千差万别，但是主要的结构是由线缆、端子、护套、固定装置、防水装置等组成，其中线缆是由导体和包覆在所述导体周围的绝缘层组成。目前线束的加工工艺比较复杂，包含切线、剥皮、压端子、焊接、穿管、插盲堵、插端子、插护套、分装、布线、包胶、分支固定、安装定位装置、安装部件、导通、外观检查、包装等工序，其中，分装、布线、包胶、分支固定、安装定位装置和安装部件是占用线束生产的主要工时，而且目前没有自动化生产设备，全部是由人工进行操作，不合格率高，生产成本大，产品一致性无法保证，已经成为限制线束行业发展的瓶颈。传统线束加工工艺中，线束的定位装置的安装方式有两种，分别是使用胶布固定和使用扎带固定，但这两种方法都有安装尺寸不准确，定位装置易脱落等缺点。且在传统线束加工工艺中，线束的密封装置是由橡胶制成，安装时需要事先撑开以保证能够穿过线缆并固定，为保证密封性，还要在密封装置和线缆之间添加胶泥和密封胶，工艺复杂，且容易导致密封装置破损，使密封功能失效。
另外、传统线束上的各个部分，都不是紧密结合，包括线缆和其上的保护套管、线缆通过端子与护套连接、定位装置通过胶布或扎带固定、防水装置通过橡胶件的弹性贴附线束上等，在长时间的使用中，各个零件连接会逐步失效，导致线缆和保护套管磨损、线缆与护套脱离、定位装置位置不准确或脱落以及防水装置破损或脱落，丧失了各个零件的功能，从而导致线束失效，严重时会造成事故。
因此，目前线束行业急需一种能够简化线束组装生产工艺的新方法，能够减少人工 操作，提高产品的一致性，降低产品的生产成本。
为此，中国发明专利申请CN 104149770 A公开了一种注塑型防抱死刹车系统传感器线束，在原有的信号传输线缆上，增加了注塑定位件，但是此发明只针对防抱死刹车系统传感线线束，使用上有局限性。此发明还是需要采购成品的线缆，然后加工成为线束主体，无法节约线束成本。此发明对于线缆并没有进行保护，在装车使用后，线缆绝缘皮会因为振动，摩擦安装部位导致破损，严重时会导致短路，引发燃烧事故。另外此发明所增加的注塑件，功能单一，无法满足线束上其他繁杂的需求。
因此，线束技术领域，急需一种生产工艺简单，线束尺寸精度高，使用寿命长的线束及成型方法，能够降低线束成本、增加防水等级，提高生产效率、降低产品不良率和延长线束使用寿命。
发明内容
针对上述存在的技术问题，为了克服现有技术的不足，本发明所解决的技术问题是提供一种全新的注塑成型的线束及成型方法，能够极大的减少线束加工流程，减少人工操作，提高产品的一致性，增加防水等级，降低产品的生产成本。能够对复杂成型的线束实现一次加工成型，提高生产效率，使线束的适用面更加广泛。并且能够对有密封要求的线束进行一次成型，增加了线束的密封性，减少了胶泥、密封胶等材料的使用，并且延长防水区域的使用寿命，大大提高使用安全性能。
本发明的目的是通过以下技术方案来实现的：
本发明一种注塑成型的线束，所述线束包括端子和至少一根导体，所述端子的一端连接用电装置的电气回路，所述端子的另一端与所述导体连接，所述线束上设置有注塑成型的、包覆在所述导体外部的保护层，以及注塑成型的至少一个用于固定线束位置的定位装置或/和用于防水的密封装置。需要说明的是，本发明的线束与传统线束不同，可以使用带有绝缘层的线缆，也可以直接使用导体注塑成型。其中，导体的加工形式也可以多种多样，例如成卷导体裁切、铜箔裁剪、导体印刷、3D打印等方式。可以根据不同的线束使用环境进行挑选优化，更大程度上节省原材料、降低加工工时，提高产品质量。
本发明的一种注塑成型的线束，各个零件是通过加热熔融，然后再冷却成型连接在一起，可以说是一体的结构，不存在零件之间的相互磨损，相对定位尺寸也准确，使用寿命相比传统线束极大地提高，安全性也能保证。
优选地，所述导体外部还设置有绝缘层，保护层注塑在所述绝缘层外。
优选地，所述定位装置包括与所述线束连接的第一固定装置和与所述线束的安装端相配合连接的装配装置，所述装配装置连接在所述第一固定装置上。
需要说明的是，一般线束在安装时，超过一定的长度，都会使用定位装置与安装端相连接，保证线束能够固定在安装端上，例如发动机、钣金架或其他管路上。如果没有定位装置，线束会在安装端上相互移动，增加线束的磨损，另外线束的移动，也会产生异响，影响汽车、飞机、船舶或各种家用电器的使用感受。
优选地，所述第一固定装置为筒状结构，筒状结构的内壁与所述保护层的外表面配合，并包裹在所述保护层的外表面。
所述筒状结构，是为了加强固定装置的强度，避免定位装置受力从线束上脱落。
优选地，所述装配装置为柱状结构，所述柱状结构外周具有倒牙结构。
所述倒牙结构，是为了所述柱状结构与安装端的安装孔匹配时，能够防止所述柱状结构从所述安装孔中脱落。
优选地，所述装配装置具有夹子状结构。
优选地，所述夹子状结构带有凹槽，凹槽内两侧壁上设置倒刺。所述凹槽内设置倒刺，是为了所述夹子状结构与安装端的钣金边缘匹配时，能够卡住钣金边缘，防止所述夹子状结构从所述钣金边缘上脱落。
优选地，所述装配装置具有圆环形结构或者C型环结构。所述圆环形结构或者C型环结构，是为了所述装配装置与安装端的其他管路匹配时，能够防止所述装配装置从所述管路上脱落。
优选地，所述定位装置为使用注塑方式加工的塑料件。由于所述定位装置都是与安装端硬性连接，如果使用橡胶件，变形量大，则会出现连接不牢固的情况，因此会使用硬度和弹性都较好的塑料件。
优选地，所述密封装置包括与线束连接的第二固定装置和防水装置，所述防水装置一端连接在所述第二固定装置上。
优选地，所述第二固定装置为筒状结构，筒状结构的内壁与所述保护层的外表面配合，包裹在所述保护层的外表面。所述筒状结构，是为了加强固定装置的强度，避免密封装置受力从线束上脱落。
优选地，所述密封装置为使用注塑方式加工的橡胶件。由于所述密封装置需要密封所述线束的密封端，所以采用橡胶件等弹性材料将所述线束的密封端进行注塑密封，防 止外界环境的水进入线束内部，造成线束导体腐蚀，严重的降低线束的使用寿命，严重时或造成安全事故。
需要说明的是，所述线束的密封端，是指一般线束在安装时，会穿过一些干燥区域和潮湿区域的分隔板上的过孔，为了防止潮湿区域的水进入到干燥区域内，需要有线束上的防水装置与所述分隔板上的过孔配合密封连接。再有，线束处在潮湿区域的时候，线束的保护层和端子之间会有导体露出，需要有密封装置将露出的导体和端子进行密封包裹，防止外界环境的水将导体和端子腐蚀。另外，所述护套在潮湿区域时，为了防止水进入到护套内造成端子和导体腐蚀，需要有密封装置将护套的孔位进行密封。
优选地，所述线束还设置至少一个与用电装置对插的护套，所述端子装配在所述护套对应孔位中。
优选地，所述护套为一体注塑到至少所述端子上。
所述导体，通过连接的端子与所述护套相连接，为了保证导体与护套之间的连接牢固，在注塑所述保护层时，可以将所述导体和所述护套用保护层固定在一起，从而延长线束的使用寿命。
优选地，所述导体为实心导体、扁平导体或多股导线的导体。根据线束不同的使用环境，导体可以选用不同的结构。
优选地，所述端子通过压接或焊接的方式，连接到实心导体、扁平导体或多股导线的导体上。
一般情况下，所述导体与所述端子为同种材料或相近材料时，采用压接的方式。所述导体与所述端子为差异较大的材料时，采用焊接的方式。
优选地，所述导体的导电部分的横截面为圆形、椭圆形、多边形、波浪形或异形结构。
根据导体在线束中的结构，可以选用不同截面积的导电部分，构成导电回路。
优选地，当所述导体多于两根并属于同一回路时，采用压接或焊接的方式，将非所述端子侧的导体按照回路要求连接成为导体连接点。
优选地，所述导体连接点被整体注塑包裹密封。
所述导体连接点，可以极大的节省导体材料的使用，使电流在合适的位置，被不同的导体分流。由于采用了压接或焊接的方式，导体连接点两侧的导体应力比较集中，后续使用中会受力导致导体连接点断裂，造成线束失去功能，因此需要使用整体注塑的方式，对导体连接点进行包裹保护。在潮湿区域的导体连接点整体注塑，还能起到密封防 水的作用。
本发明制备所述线束的方法，包括如下步骤：
A、制备线束半成品；
B、将所需原材料放入注塑设备中，并烘干，再将步骤A中制备的线束半成品放入到注塑模具中；或者将步骤A中制备的线束半成品放入到注塑模具中，再将所需原材料放入注塑设备中，并烘干；
C、启动注塑设备将原材料加热熔融，注入注塑模具中成型。
优选地，所述制备线束半成品为单根导体时，将所述端子使用压接或焊接设备连接到所述导体上；按照步骤B～步骤C注塑保护层或定位装置或密封装置。
优选地，所述制备线束半成品为多于一根导体时，将所述端子使用压接或焊接设备连接到所述导体上；按照步骤B～步骤C先注塑保护层，并使多根导体隔离开，然后注塑定位装置或密封装置。
优选地，所述制备线束半成品为带有多于两根所述导体并属于同一回路时，采用压接或焊接的方式，将所述导体按照回路要求连接成为导体连接点；按照步骤B～步骤C先注塑线束保护装置，然后注塑保护层，最后注塑定位装置或密封装置。
优选地，所述线束半成品设有护套时，将所述连接导体的端子插入所述护套的相应孔位后，再进行注塑；或者先对线束半成品进行注塑，再将所述连接导体的端子插入所述护套的相应孔位。
所述线束半成品放入到注塑模具中，所述护套一体注塑成型到至少所述端子上。
与现有技术相比，本发明的有益效果在于：
1.线束的传统设计观念，就是将线缆、端子、护套、固定装置、防水装置、胶带、支撑线槽等各种原材料，分别采购，加工，然后组装成为线束成品，这种做法可以使原材料厂家和线束厂分工协作，各司其职。但是，这样生产的工艺流程特别繁琐，加工工序多，生产过程不良率高，线束成品的尺寸和性能都很难保证。本申请的发明人发现，线束上除了导体和端子，其他基本为塑料件和橡胶件，而目前塑料件和橡胶件的生产工艺方法大多为注塑，因此使用本发明注塑的方法，加工线束保护层、定位装置和防水装置，能够降低线束成本、提高生产效率、降低产品不良率和延长线束使用寿命。
2.本发明线束使用导体直接注塑成型，导体的加工形式也可以多种多样，可以根据不同的线束使用环境进行挑选优化，更大程度上节省线束原材料、降低加工工时，提高线束产品质量。也为线束设计者提供了更多种多样的设计选择，更加优化线束成本， 提高线束产品稳定性。本发明的注塑保护层取代了传统线束中套管和包胶布的人工操作，并且能够实现自动化生产，线束的分支越多，节省的工时越多。另外，注塑工艺制作的保护层，避免了人工包胶布作业的尺寸不准，连接处保护不足的缺点，能够更好的保证线束产品质量，延长线束的使用寿命。
3.本发明线束采用整体注塑的加工方式，保护层、定位装置和密封装置和线束其他部件都能紧密结合，线束的防水效果能够达到IP67等级，在线束经过盐雾实验、高低温实验、振动实验和老化实验后，线束导体和端子之间的力学性能和电学性能受到极小的影响，能够更好的保证线束产品质量，延长线束的使用寿命。同时注塑材料更多样，可以根据使用环境不同选择不同的注塑材料，使线束更加柔软，抗振动效果更佳，可以使用在振动环境比较恶劣的环境，显著的延长线束的使用寿命，提高线束的安全性。
4.本发明线束也可以采用带有绝缘层的导线，当线束回路较少，或者导线长度较长，密封性要求不高时，采用带有绝缘层的导线，能够减少注塑模具的成本。
5.使用本发明注塑的方式加工定位装置，替代使用胶布固定和使用扎带固定定位装置，定位装置的位置尺寸由模具保证精度，尺寸准确并且一致性好，能够更好的保证线束产品质量。同时由于定位装置是一体注塑在线束上，结合更牢固，定位装置不易脱落，定位效果更好，并且在振动环境比较恶劣的环境，定位装置极少出现尺寸偏差甚至脱离线束导致线束定位功能失效，能够显著的延长线束的使用寿命。所述装配装置采用注塑的加工方式，可以根据所述线束安装端的不同形状，设定为不同的样式，更加方便线束安装，显著的提高线束安装效率。所述定位装置采用塑料件，注塑加工更加方便，在和线束安装端装配时，塑料件的弹性能够更好的进行安装匹配，显著提高定位装置安装效率，同时由于塑料件耐腐蚀性高，极大地延长线束使用寿命。
6.使用本发明注塑的方式加工密封装置，在线束的使用环境中，潮湿区域和干燥区域使用密封装置进行密封，防止潮湿区域的水进入到干燥区域，或者进入到电气回路中，损坏干燥区域的电气线路，造成电器功能失效，严重时会造成安全事故。使用本发明的注塑工艺一体将密封装置注塑，不需要像一般线束加工那样将密封装置预先撑开再穿入线束，即能保证密封装置的位置尺寸准确，并且能够使密封装置与保护层结合更紧密，不需要使用胶泥和密封胶，节省材料费用与安装工时。由于是一次定型，密封装置不易损坏，与线束保护层的结合更加紧密，并且在振动环境比较恶劣的环境，密封装置不会出现尺寸偏差甚至脱离线束导致线束密封功能失效，能够显著的延长线束的使用寿命。同时，密封装置还可以设置在端子与导体之间，护套和保护层之间，能够将导体更 好的密封，防止外界环境的水对导体的腐蚀，显著的延长所述线束的使用寿命。所述密封装置采用橡胶件，与其他零件贴合性更好，同时橡胶件的弹性，使线束的密封性更好，显著的提高线束的使用寿命。
7.本发明的线束使用单独的护套，或者一体注塑的护套，能够更加快捷的和用电装置进行匹配安装，提高安装效率，并且能够快速更换损坏的线束，提高线束维修效率，减少人工成本。一体注塑的护套，加工更加快捷，与端子、保护层或绝缘层贴合更加紧密，显著提高线束的密封等级。
8.所述导体为实心导体、扁平导体、多股导线的导体，以及多样的导体导电部分的横截面，可以根据线束的实际使用环境，采用对应的导体结构，节省线束成本，提高线束安装效率。同时不同的导体结构和导体导电部分的横截面，可以适应不同连接方式的端子，方便线束设计者对线束使用的端子和导体进行选择，更加优化线束成本，提高线束产品稳定性。
9.本发明的线束，所述导体多于两根并属于同一回路时，采用压接或焊接的方式，将所述非端子侧导体按照回路要求连接成为导体连接点，能够在设计线束时，减少导体的使用量，显著的降低线束的成本。同时所述导体连接点被整体注塑包裹密封，能够保证导体连接点不会在线束安装和使用中被破坏，在恶劣的振动环境中，被整体注塑包裹密封的导体连接点不会被振动断裂，并且整体注塑包裹密封能够防止外界环境的水对导体连接点的腐蚀，显著的延长线束的使用寿命。
10.本发明还提供制备一体注塑线束的方法，按照不同的线束结构，采用不同的工艺流程，能够显著的提升线束的生产效率，降低线束成本。
上述说明仅是本发明技术方案的概述，为了能够更清楚了解本发明的技术手段，而可依照说明书的内容予以实施，并且为了让本发明的上述和其他目的、特征和优点能够更明显易懂，以下特举较佳实施例，并配合附图，详细说明如下。
附图说明
图1为本发明单根导体，无护套，带有定位装置、密封装置的线束示意图。
图2为本发明多根导体，带有护套、保护层、定位装置、密封装置的线束示意图。
图3A为本发明带保护层的单根导体的线束横截面示意图。
图3B为本发明带保护层的多根导体并列设置的线束横截面示意图。
图3C为本发明带保护层的多根导体呈环形设置的线束横截面示意图。
图3D为本发明带绝缘层和保护层的多根导体的线束横截面示意图。
图4为本发明多根导体、带有导体连接点的线束示意图。
图5为本发明定位装置的结构示意图。
图6为倒牙结构的装配装置示意图。
图7为夹子状结构的装配装置示意图。
图8为C环型结构的装配装置示意图。
图9A为本发明线束带有与分隔板上的过孔配合的密封装置的结构示意图。
图9B为图9A的局部剖视结构示意图。
图10为本发明导体、端子和保护层的密封装置的结构示意图。
图11为本发明护套的密封装置的结构示意图。
图12为本发明一体注塑护套的结构示意图。
其中，各附图标记为：1、端子，2、导体，3、绝缘层，4、密封装置，5、定位装置，6、护套，7、保护层，8、线束保护装置，9、防水装置，10、第二固定装置，11、装配装置，12、第一固定装置，13、防水套，14、卡槽。
具体实施方式
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效，以下结合附图及较佳实施例，对依据本发明的具体实施方式、结构、特征及其功效，详细说明如下：
实施例1
如图1、图3A所示，所述线束是由单根导体构成的，所述导体2两端分别连接端子1。所述端子1为铜端子，所述铜端子是由铜含量为60％的铜合金制成，能够保证铜端子有良好的导电性和可加工性。所述端子1表面镀镍，也可以镀镉、锆、铬、钴、锰、铝、锡、钛、锌、铜、银或金中的一种，镀层能够减缓端子腐蚀，延长端子的使用寿命。所述端子1的一端与所述导体2连接，在使用时，端子1的另一端用于连接用电装置的电气回路。本实施例中，所述导体2是由多芯线组成，所述多芯线的横截面为圆形。在其他实施例中，所述导体2还可以是实心导体和扁平导体。所述导体2的导电部分的横截面还可以是椭圆形、多边形、波浪形或异形。所述线束上设置有注塑成型的、包覆在所述导体2外部的保护层7，所述保护层7是由塑料或橡胶制成，在本实施例中，所述保护层7的材质为PVC；以及注塑成型的至少一个用于固定线束位置的定位装置5或/和用于防水的密封装置4。
其中所述的导体2可以是外购的带有绝缘层3的电线，在其绝缘层3外注塑保护层7；也可以是在导体2外直接注塑保护层7。如图3A所示，所述单根导体2在中间排布，外围注塑保护层7。
所述导体2在经过定长切断后，两端分别使用压接或焊接的方式，与所述端子1连接。然后将半成品放入到注塑模具中，按照确定的尺寸，进行保护层7、定位装置5和密封装置4的注塑，具体注塑成型方法如下：
A、制备线束半成品；
B、将所需原材料放入注塑设备中，并烘干，再将步骤A中制备的线束半成品放入到注塑模具中；或者将步骤A中制备的线束半成品放入到注塑模具中，再将所需原材料放入注塑设备中，并烘干；
C、启动注塑设备将原材料加热熔融，注入注塑模具中成型。
所述定位装置5材质为PA66，在其他实施例中，所述定位装置5为使用注塑方式加工的塑料件。如图5所示，所述定位装置5包括和线束连接的第一固定装置12和与所述线束安装端相配合连接的装配装置11，所述装配装置11连接在所述第一固定装置12上；所述第一固定装置12为筒状结构，筒状结构的内壁与所述保护层7的外表面配合，包裹在所述保护层7的外表面。装配装置11具体结构可以是与安装孔对插的倒牙结构，即：所述装配装置为柱状结构，所述柱状结构外周带有与待安装孔对插卡位的倒牙结构(如图6所示)；在其他实施例中，所述装配装置也可以是带有与板材配合连接的夹子状结构(如图7所示)，具体是带有凹槽，凹槽内两侧壁上设置与所述板材卡位的倒刺；还可以是带有与管状或者柱状结构装配的圆环形或者C型环结构(如图8所示)。
需要说明的是，所述密封装置4的材质为EPDM，在其他实施例中，所述密封装置4为使用注塑方式加工的橡胶件。一般线束在安装时，会穿过一些干燥区域和潮湿区域的分隔板上的过孔，为了防止潮湿区域的水进入到干燥区域，如图9A和图9B所示，本例所述密封装置4包括和线束连接的第二固定装置10和与防水装置9，所述防水装置9连接在所述第二固定装置10上；所述第二固定装置10结构为筒状结构，筒状结构的内壁与所述保护层7的外表面配合，包裹在所述保护层7的外表面，防水装置9结构包括一端与第二固定装置10连接的防水套13，以及与防水套13的另一端连接，起到与防水孔装配的卡槽14。
本例线束处在潮湿区域的时候，在线束的保护层7、导体2及端子1之间设置密封装置，将保护层7、导体2及端子1进行密封包裹，如图10所示，密封装置4注塑在导 体2、端子1与导体2连接处及保护层外，对应导体2和端子1部位为防水装置9，对应保护层7部位为第二固定装置10。
实施例2
如图2、图3B、图3C所示，所述线束是由多于一根导体2组成的，每一根所述导体2，两端分别连接端子1，端子1表面镀锌，也可以镀镍、镉、锆、铬、钴、锰、铝、锡、钛、铜、银或金中的一种。所述导体2和所述端子1与实施例1相同，不多赘述。与实施例1不同的是：所述线束还设置至少一个与用电装置对插的护套6，所述导体2连接端子1后，所述端子1装配于所述护套6中，不同所述端子1按设计要求对应到所述护套6不同的孔位中，以起到连同不同回路的作用，同时也能保护端子1不受损伤。所述护套6为一体注塑成型到至少所述端子1上。
所述多根导体2在经过分别定长切断后，两端分别使用压接或焊接的方式，与所述端子1连接。然后将半成品放入到注塑模具中，按照确定的尺寸，进行保护层7和定位装置5、密封装置4的注塑，先注塑线束保护层7，然后是线束保护装置8，再后是定位装置5或密封装置4。
本例线束处在潮湿区域的时候，在线束的保护层7、导体2及端子1之间设置密封装置4，将保护层7、导体2及端子1进行密封包裹，如图10所示，密封装置4注塑在导体2、端子1与导体连接处及保护层7外，对应导体2和端子1部位为防水装置9，对应保护层7部位为第二固定装置10。
具体注塑成型方法如下：
A、制备线束半成品；
B、将所需原材料放入注塑设备中，并烘干，再将步骤A中制备的线束半成品放入到注塑模具中；或者将步骤A中制备的线束半成品放入到注塑模具中，再将所需原材料放入注塑设备中，并烘干；
C、启动注塑设备将原材料加热熔融，注入注塑模具中成型。
其中：注塑的参数包括加热温度、冷却温度、注塑压力、注塑时间等，按照现有注塑设备操作，为常规操作方法。要求：注塑完成品不能有杂质、凹坑、飞边、气孔等缺陷。
如图3B、图3C所示，所述多根导体2在中间排布，外围注塑保护层7，一是将所述多根导体2束缚在一起，防止在线束安装时导体2散开，二是将所述多根导体2进行 绝缘隔离保护，防止在线束安装后，所述多根导体2相互短路以及受刮磨等外力导致的破损。在本实施例中，所述导体2为实心导体或扁平导体，所述导体2的导电部分的横截面为异形结构，也可以是椭圆形或波浪形。所述保护层7材质为PVC。所述定位装置5和所述密封装置4与实施例1相同，不多赘述。
实施例3
如图4所示，所述线束是由多于一根导体2组成的，一部分的所述导体2末端连接端子1，另一部分导体2末端，采用压接或焊接的方式，按照回路要求连接成为导体连接点。端子1表面镀银，也可以镀镍、镉、锆、铬、钴、锰、铝、锡、钛、锌或金中的一种。所述导体2连接端子1后，所述端子1装配到一个与用电装置对插的护套6中，不同所述端子1按设计要求对应到所述护套6不同的孔位中。制备时，所述导体连接点整体被密封为线束保护装置8；所述线束保护装置8为使用注塑方式加工的橡胶件或塑料件。如图3D所示，所述导体2外设置绝缘层3，在绝缘层3外注塑保护层7，所述端子1和所述护套6与实施例1相同，不多赘述。
所述多根导体2在经过分别定长切断后，按照设计要求，部分导体2分别使用压接或焊接的方式，与所述端子1连接。另一部分所述导体2多于两根并属于同一回路时，采用压接或焊接的方式，将所述非端子侧导体按照回路要求连接成为导体连接点。然后将半成品放入到注塑模具中，按照确定的尺寸，按照实施例2所述注塑步骤，先进行保护层7的注塑，然后注塑线束保护装置8，最后注塑定位装置5和/或密封装置4。在本实施例中，所述导体2是由多股导线，所述导体2的导电部分的横截面为多边形结构。所述线束保护装置8的材质为塑料，在其他应用中，所述线束保护装置8的材质还可以为橡胶。所述保护层7、定位装置5、密封装置4与实施例2相同，不多赘述。
在注塑成型的线束制备方法中，当所述线束半成品设有护套6时，将所述连接导体2的端子1插入所述护套6的相应孔位后，再进行注塑；或者先对线束半成品进行注塑，再将所述连接导体2的端子1插入所述护套6的相应孔位。
如图11所示，当所述护套6在潮湿区域时，为了防止水进入到护套6内，设置密封装置4将护套6的孔位进行密封，所述护套6与导体2间的连接缝隙中注塑防水装置9，以密封护套6，用以防水，在防水装置9和护套6端部连接第二固定装置10。所述在防水装置9注塑形成，第二固定装置10为与导体2外保护层7配合的套筒结构。
如图12所示，本例所述的护套6也可以是一体注塑成型，所述线束半成品放入到 注塑模具中，所述护套6一体注塑成型到至少所述端子1上，在其他实施例中，所述护套6还可以一体注塑成型到所述端子1和导体2上，或者，所述护套6可以一体注塑成型到所述端子1、导体2和保护层7上。
为了论证传统方法加工的线束和本发明实施例1～3所述一体注塑成型的线束对所述线束的端子与导体的力学性能和电学性能的影响，本申请的发明人对上述两种不同方法加工的线束进行了一系列的力学性能、电学性能和寿命的实验。
具体实验过程如下：模拟线束实际的使用环境，但将测试条件增加到远远严苛于普通环境的程度，能在短时间内，获得与实际的使用环境下很长时间能达到的测试效果。系列实验中包括：1)初始两种线束的端子1与导体2的拉拔力和电压降测试，以获得线束的初始力学和电学性能；2)1000小时的盐雾实验，使用盐雾实验箱，在两种线束上喷淋盐水，可以代替普通沿海环境下十年的耐盐雾测试；3)200小时的高低温实验，使两种线束分别处于使用环境最高和最低的温度各一个小时，温度切换时间小于5秒，进行100个循环，可以替代外界冷热交替环境10年的耐高低温测试；4)120小时振动实验，将两种线束固定在振动实验台上，按照使用环境选择振动幅度，在三个方向进行两种线束的振动，可以代替普通使用振动环境下10年的振动测试；5)6000小时的老化实验，将两种线束放入老化实验箱中，模拟超过额定使用条件的环境，可以替代20年普通使用环境下的老化测试。在每一个实验之后，都要测试两种线束的端子1与导体2的电压降值和拉拔力值。实验结果参见表1-1、表1-2和表1-3。
表1-1：传统线束和一体注塑成型线束对端子与导体的拉拔力和电压降的影响(实验前与1000小时盐雾实验后)
Figure PCTCN2021084898-appb-000001
Figure PCTCN2021084898-appb-000002
表1-2：传统线束和一体注塑成型线束对端子与导体的拉拔力和电压降的影响(200小时的高低温实验及120小时振动实验)
Figure PCTCN2021084898-appb-000003
表1-3：传统线束和一体注塑成型线束对端子与导体的拉拔力和电压降的影响(6000小时老化实验)
Figure PCTCN2021084898-appb-000004
Figure PCTCN2021084898-appb-000005
从上述表1-1、表1-2和表1-3的结果可以看出：传统方法加工的线束和一体注塑成型的线束，端子1与导体2的初始拉拔力数值和电压降数值比较接近。
在分别经过1000小时盐雾试验、200小时的高低温实验、120小时振动实验和6000小时的老化实验之后，一体注塑成型的线束，实验后的端子1与导体2拉拔力值远高于传统方法加工的线束实验后的端子1与导体2拉拔力值，与初始的拉拔力数值也比较接近。
而传统方法加工的线束，实验后的端子1与导体2拉拔力值明显较低，力学性能不稳定，有可能造成线束的端子1与导体2脱离，从而导致线束短路，轻则功能失效，重则导致燃烧事故。
一体注塑成型的线束，实验后的端子1与导体2的电压降与传统方法加工的线束的端子1与导体2的初始电压降基本接近。
而传统方法加工的线束，实验后端子1与导体2的电压降值也明显降低，电学性能不稳定，线束的端子1与导体2接触电阻升高，导电时会引起线束的端子1与导体2发热发红，严重时会因温度过高而燃烧，造成严重的事故。
因此，一体注塑的线束，在实验后端子1与导体2的力学性能和电学性能要远优于传统方法加工的线束，能够降低产品不良率和延长线束使用寿命。
为了论证传统方法加工的线束和本发明实施例1～3所述一体注塑成型的线束，固定装置在振动环境下的定位效果，选取各100根所述两种线束，对线束的固定装置的性能 进行振动试验测试。结果如下表所示：
表2：传统线束和一体注塑成型线束，振动试验对固定装置的性能的影响(120小时振动实验)
Figure PCTCN2021084898-appb-000006
从上表可以看出，传统线束使用扎带固定定位装置，定位装置5尺寸偏移的数量占线束总数量的52％，线束脱离的数量占线束总数量的11％，不良率非常高；传统线束使用胶布固定定位装置5，定位装置5尺寸偏移的数量占线束总数量的69％，线束脱离的数量的占线束总数量的24％，不良率非常高，严重影响线束的安装和功能实现，严重时会使线束功能失效。
而一体注塑成型线束的三种定位装置5，尺寸偏移的数量占线束总数量只有0％，1％和1％，线束脱离的数量占线束总数量全部为0％。因此，一体注塑成型线束，定位装置5和线束结合更牢固，定位装置5不易脱落，定位效果更好，并且在振动环境比较恶劣的环境，定位装置5极少出现尺寸偏差甚至脱离线束导致线束定位功能失效，能够显著的延长线束的使用寿命。
为了论证传统方法加工的线束和本发明实施例1～3所述一体注塑成型的线束，密封装置4在外界灰尘和水的侵蚀下的防护等级，选取各100根所述两种线束，对线束的密封装置4的性能进行防护等级的测试。结果如下表所示：
表3：传统线束和一体注塑成型线束，密封装置的防护等级通过率
Figure PCTCN2021084898-appb-000007
从上表可以看出，传统线束的三种密封装置4，在IP54的防护等级测试中，防护等级通过率只有89％、92％和88％；在IP67的防护等级测试中，防护等级通过率只有68％、75％和71％，防护等级通过率很低，无法保证线束的密封性能，无法防止外界环境的灰尘和水对导体2的腐蚀，从而导致线束功能失效。
一体注塑成型线束的三种密封装置4，在IP54的防护等级测试中，防护等级通过率都为100％；在IP67的防护等级测试中，防护等级通过率为99％、100％和100％，完全能够满足线束的密封性能，使线束的密封性更好，防止外界环境的灰尘和水对导体的腐蚀，显著的提高线束的使用寿命。
为了论证传统方法加工的线束和本发明实施例1～3所述一体注塑成型的线束，导体连接点被不同的保护方式包裹，对导体连接点断裂的风险，选取各100根所述两种线束，对线束进行120小时振动试验测试后，测量导体连接点的断裂比率。结果如下表所示：
表4：传统线束和一体注塑成型线束，导体连接点的断裂比率
Figure PCTCN2021084898-appb-000008
从上表可以看出，传统线束的两种导体连接点包裹方式，在线束进行120小时振动试验测试后，导体连接点用胶布包裹，导体连接点的断裂比率为26％，导体连接点用热缩管包裹，导体连接点的断裂比率为18％。导体连接点的断裂比率很高，无法保证线束在恶劣振动环境中的导通性能，从而存在极大的线束功能失效的风险。
一体注塑成型线束的注塑包裹导体连接点，导体连接点的断裂比率为0％，完全能够满足线束在恶劣振动环境中的导通性能，显著的提高线束的使用寿命。
上述实施方式仅为本发明的优选实施方式，不能以此来限定本发明保护的范围，本领域的技术人员在本发明的基础上所做的任何非实质性的变化及替换均属于本发明所要求保护的范围。

Claims (25)

  1. 一种注塑成型的线束，其中：所述线束包括端子和至少一根导体，所述端子的一端连接用电装置的电气回路，所述端子的另一端与所述导体连接，所述线束上设置有注塑成型的、包覆在所述导体外部的保护层，以及注塑成型的至少一个用于固定线束位置的定位装置或/和用于防水的密封装置。
  2. 根据权利要求1所述的注塑成型的线束，其中：所述导体外部还设置有绝缘层，所述保护层注塑在所述绝缘层外。
  3. 根据权利要求1所述的注塑成型的线束，其中：所述定位装置包括与所述线束连接的第一固定装置和与所述线束的安装端相配合连接的装配装置，所述装配装置连接在所述第一固定装置上。
  4. 根据权利要求3所述的注塑成型的线束，其中：所述第一固定装置为筒状结构，所述筒状结构的内壁与所述保护层的外表面配合，并包裹在所述保护层的外表面。
  5. 根据权利要求3所述的注塑成型的线束，其中：所述装配装置为柱状结构，所述柱状结构外周具有倒牙结构。
  6. 根据权利要求3所述的注塑成型的线束，其中：所述装配装置具有夹子状结构。
  7. 根据权利要求6所述的注塑成型的线束，其中，所述夹子状结构带有凹槽，所述凹槽内两侧壁上设置倒刺。
  8. 根据权利要求3所述的注塑成型的线束，其中：所述装配装置具有圆环形结构或者C型环结构。
  9. 根据权利要求3所述的注塑成型的线束，其中：所述定位装置为使用注塑方式加工的塑料件。
  10. 根据权利要求1所述的注塑成型的线束，其中：所述密封装置包括与线束连接的第二固定装置和防水装置，所述防水装置的一端连接在所述第二固定装置上。
  11. 根据权利要求10所述的注塑成型的线束，其中：所述第二固定装置为筒状结构，所述筒状结构的内壁与所述保护层的外表面配合，并包裹在所述保护层的外表面。
  12. 根据权利要求10所述的注塑成型的线束，其中：所述密封装置为使用注塑方式加工的橡胶件。
  13. 根据权利要求1所述的注塑成型的线束，其中：所述线束还设置至少一个与用电装置对插的护套，所述端子装配在所述护套对应孔位中。
  14. 根据权利要求13所述的注塑成型的线束，其中：所述护套为一体注塑到至少 所述端子上。
  15. 根据权利要求1所述的注塑成型的线束，其中：所述导体为实心导体、扁平导体或多股导线的导体。
  16. 根据权利要求1所述的注塑成型的线束，其中：所述端子通过压接或焊接的方式，连接到实心导体、扁平导体或多股导线的导体上。
  17. 根据权利要求1所述的注塑成型的线束，其中：所述导体的导电部分的横截面为圆形或椭圆形、多边形、波浪形或异形。
  18. 根据权利要求1所述的注塑成型的线束，其中：当所述导体多于两根并属于同一回路时，采用压接或焊接的方式，将非所述端子侧的所述导体按照回路要求连接成为导体连接点。
  19. 根据权利要求18所述的注塑成型的线束，其特征在于：所述导体连接点被整体注塑包裹密封。
  20. 一种制备权利要求1～19中任意一项所述线束的方法，其中：
    A、制备线束半成品；
    B、将所需原材料放入注塑设备中，并烘干，再将步骤A中制备的线束半成品放入到注塑模具中；或者将步骤A中制备的线束半成品放入到注塑模具中，再将所需原材料放入注塑设备中，并烘干；
    C、启动注塑设备将原材料加热熔融，注入注塑模具中成型。
  21. 如权利要求20所述的方法，其中：所述制备线束半成品为单根导体时，将所述端子使用压接或焊接设备连接到所述导体上；按照步骤B～步骤C注塑保护层或定位装置或密封装置。
  22. 如权利要求20所述的方法，其中：所述制备线束半成品为多于一根导体时，将所述端子使用压接或焊接设备连接到所述导体上；按照步骤B～步骤C注塑保护层，并使多根导体隔离开，并注塑定位装置或密封装置。
  23. 如权利要求20所述的方法，其中：所述制备线束半成品为带有多于两根所述导体并属于同一回路时，采用压接或焊接的方式，将所述导体按照回路要求连接成为导体连接点；按照步骤B～步骤C先注塑线束保护装置，然后注塑保护层，最后注塑定位装置或密封装置。
  24. 如权利要求20～23中任一项所述的方法，其中：所述线束半成品设有护套时，将所述连接导体的端子插入所述护套的相应孔位后，再进行注塑；或者先对线束半成品 进行注塑，再将所述连接导体的端子插入所述护套的相应孔位。
  25. 如权利要求20～23中任一项所述的方法，其中：所述线束半成品放入到注塑模具中，护套一体注塑成型到至少所述端子上。
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