WO2023005690A1 - 线束的生产方法及线束 - Google Patents
线束的生产方法及线束 Download PDFInfo
- Publication number
- WO2023005690A1 WO2023005690A1 PCT/CN2022/105973 CN2022105973W WO2023005690A1 WO 2023005690 A1 WO2023005690 A1 WO 2023005690A1 CN 2022105973 W CN2022105973 W CN 2022105973W WO 2023005690 A1 WO2023005690 A1 WO 2023005690A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- wire harness
- insulator
- conductor
- conductors
- production method
- Prior art date
Links
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- 239000004020 conductor Substances 0.000 claims abstract description 131
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- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 2
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- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims 1
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Images
Classifications
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- 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
-
- 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
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the invention relates to the technical field of electronic components, in particular to a production method of a wire harness and the wire harness.
- wire harnesses The electrical connection needs to be realized by using wire harnesses.
- the main components of wire harnesses are wires used as conductors. Wires need to be produced through processes such as conductor wire drawing, stranding, annealing, and extruding insulation layers. The production process is relatively complicated and the processing cost is high. In addition, in the production process of using wires to produce harnesses, it is necessary to cut the wires to a fixed length and strip off the insulation layer, and then lay and fix the wires one by one according to the circuit requirements.
- the object of the present invention is to provide a method for producing a wire harness and the wire harness, so as to alleviate the technical problems of relatively complicated production process and high processing cost of the wire harness.
- the present invention provides a production method of a wire harness.
- the production method includes: step S10, arranging a plurality of wire harness conductors; step S20, forming an insulator by additive material; gaps are provided between the wire harness conductors, and the insulator wraps the wire harness conductor and fill the gap.
- the present invention provides a wire harness, wherein the above wire harness production method is used to produce, the wire harness includes wire harness conductors and insulators, gaps are provided between the wire harness conductors, and the insulator wraps the wire harness conductors and fills the wire harness conductors. gap.
- a plurality of wire harness conductors are firstly arranged according to the electrical connection function to be realized, and then an insulator is added to form an insulator to realize insulation and fixing.
- the conductive loop can be connected with external electrical devices to realize the electrical connection function of the wiring harness.
- the produced wiring harness is easy to install and connect with external electrical components, reducing installation man-hours and saving space;
- the profiling molding shell can be used, the shape of the molding shell is suitable for the installation environment, which increases the application environment of the produced wire harness, can adapt to different product structures, and is easy to use in complex installation environments on electrical devices;
- the molded housing can be a component part of an electrical device, which can realize the integrated production of parts and wire harnesses, and realize the rapid installation and disassembly of the wire harnesses.
- Fig. 1 is the structural representation of the production method of wire harness provided by the present invention
- Fig. 2 is the working schematic diagram of the production method of wire harness provided by the present invention.
- Fig. 3 is a structural schematic diagram of a molded shell and a supporting sheet in the production method of the wire harness provided by the present invention
- Figure 4 and Figure 5 are partial schematic diagrams of wire harness conductors and insulators
- Fig. 6 is a schematic diagram of the wire feeding mechanism in the production method of the wire harness provided by the present invention.
- the present invention provides a production method of a wire harness.
- the production method of the wire harness includes: step S10, arranging a plurality of wire harness conductors 10; step S20, additively molding insulators 20; In the gap 11 , the insulator 20 wraps the harness conductor 10 and fills the gap 11 .
- a plurality of wire harness conductors 10 are arranged according to the electrical connection function to be realized, and then the insulator 20 is additively formed to realize insulation and fixing.
- the conductive loop can be connected with external electrical devices to realize the electrical connection function of the wiring harness.
- the production method of the wire harness has the following advantages: (1) the step of extruding the insulating layer of the wire is omitted, the processing time of the wire harness is reduced, the cost of raw materials is reduced, and the cost of wire harness wire production is reduced; (2) it can be adapted to Large-volume, automated production methods improve production efficiency and achieve rapid production; (3) uniformly arrange insulators 20 around the pre-arranged wire harness conductors 10 to achieve uniform insulation, and the insulators 20 can be conveniently and quickly provided; (4) the produced The advanced wiring harness is convenient for installation and connection with external electrical components, reducing installation man-hours and saving space.
- step S10 and step S20 may be sequentially and alternately implemented multiple times, that is, the wiring harness conductor 10 and the molded insulator 20 are arranged in multiple times.
- all wire harness wires are arranged at one time, and then the insulator 20 is reshaped, which improves the production efficiency.
- the terminals of the wire harness conductor 10 can be connected with gold fingers, crimp terminals, welding terminals or welding wires, so as to facilitate connection with other electrical circuits.
- FIG. 4 is a partial schematic view of the wire harness produced by the wire harness production method.
- the wire harness conductor 10 is a single-core structure, that is, the wire harness conductor 10 is a wire.
- FIG. 5, which is a partial schematic diagram of the wire harness produced by the wire harness production method.
- the wire harness conductor 10 is a multi-core structure, that is, the wire harness conductor 10 includes a plurality of wires.
- the wire harness is soft wire.
- the production method of the wire harness includes step S01 implemented before step S10, step S01: preparing a molded shell 30, the molded shell 30 is provided with a mold cavity 31; in step S10, arranging the wire harness conductor 10 in the mold In the cavity 31; in step S20, molding the insulator 20 in the cavity 31.
- step S01 preparing a molded shell 30, the molded shell 30 is provided with a mold cavity 31; in step S10, arranging the wire harness conductor 10 in the mold In the cavity 31; in step S20, molding the insulator 20 in the cavity 31.
- the shape and size of the insulator 20 are limited by the molded shell 30 , and the molded shell 30 conforming to the direction of the wire harness conductor 10 is prepared according to the requirements of the wire harness to be produced.
- the wire harness conductor 10 , the insulator 20 and the molded housing 30 form an integral structure, that is, the molded housing 30 serves as a part of the produced wire harness.
- the production method of the wire harness includes step S30 implemented after step S20, step S30: taking the insulator 20 and the wrapped wire harness conductor 10 out of the mold cavity 31, forming the housing 30 and its mold cavity 31 as the tooling of the production harness.
- the molding shell 30 can adopt a profiling structure, and the shape of the molding shell 30 is suitable for the installation environment.
- the insulator 20 of the formed wire harness can be a profiling structure, increasing the The application environment of the produced wire harness can be adapted to different product structures, and it is convenient to use on electrical devices with complex installation environments; in the case that the molded housing 30 is used as a part of the produced wire harness, the molded housing 30 can be used with the application Adapt to the environment, which increases the application environment of the produced wiring harness, can adapt to different product structures, and is easy to use on electrical devices with complex installation environments
- the molded housing 30 is a part of the wire harness produced, and the molded housing 30 is a component part of the electrical device, which realizes the integrated production of the parts and the wire harness, and facilitates the rapid installation and disassembly of the wire harness.
- step S10 the plurality of wire harness conductors 10 are disconnected, and each wire harness conductor 10 transmits current independently.
- at least two wiring harness conductors 10 are electrically connected by one or more of crimping, welding, 3D printing connection, laser sintering connection, and connection point printing. Multiple wire harness conductors 10 can realize relatively complex circuit functions.
- the wire harness conductor 10 may extend along a straight line or along a curve. As shown in FIG. 2 , a plurality of wire harness conductors 10 are distributed along the same plane.
- step S10 the multiple wire harness conductors 10 are distributed and extended in space, for example, the wire harness extends along a space curve.
- step S10 adopts one or more of 3D printing process, laser powder sintering process, metal injection molding process, laser subtractive process, conductive ink printing process or printed circuit board process.
- the 3D printing process and the laser powder sintering process belong to the additive process, using metal powder or conductive material for fusion printing, and the molding shell 30 can be used for carrying and forming.
- the metal injection molding process uses a mold in which the metal can be molded and then put into the cavity 31 .
- the laser subtractive process is to cut the unnecessary part after forming the sheet or foil metal material, leaving the wire harness conductor 10 part.
- the conductive ink printing process is to print the conductive ink on the substrate to form a conductive circuit, and the conductive circuit and the substrate together serve as the wire harness conductor 10 .
- the printed circuit board process is to use the way of corroding the copper plate to obtain the conductive loop, and the conductive loop is used as the wire harness conductor 10 .
- step S10 the wire harness conductor 10 is arranged in a laying manner.
- Wires can be selected as the wire harness conductor 10, and the selected wires can save the insulating skin and insulating varnish.
- manual laying can be used, and laying can also be done by equipment.
- the production method of the wire harness uses the wire feeding mechanism 40; in step S10, the wire harness conductor 10 is delivered to the mold cavity 31 through the wire feeding mechanism 40, and the wire feeding mechanism 40 is beneficial to ensure the accuracy of the position of the wire harness conductor 10.
- the wire feeding mechanism 40 can perform spatial arrangement of the wire harness conductors 10 on the mold cavity 31 and the supporting sheet 32 .
- the wire feeding mechanism 40 includes a roller mechanism 41, and the roller mechanism 41 includes at least two rollers 42 arranged at intervals. As shown in FIG. 6, the wire harness conductor 10 passes between the two rollers 42. The frictional force drives the wire harness conductor 10 to translate into the mold cavity 31 to complete the arrangement of the wire harness conductor 10 .
- the mold cavity 31 is provided with a supporting sheet 32 for supporting the wire harness conductor 10, and the supporting sheet 32 can support the wire harness conductor 10 so that the insulator 20 surrounds the wire harness conductor 10; the supporting sheet 32 also supports the wire harness conductor 10 play a positioning role.
- a plurality of supporting pieces 32 may be arranged in the mold cavity 31 .
- the insulator 20 may form an integral structure with a support sheet 32 as part of the wire harness being produced.
- the supporting sheet 32 is preferably made of an insulating material. More preferably, the supporting sheet 32 and the insulator 20 are made of the same material.
- the insulator 20 is overmolded outside the wire harness conductor 10, and the supporting sheet 32 is integrated with the insulating layer, preferably To ensure the insulation performance of the wiring harness.
- step S20 adopts 3D printing process, injection molding process, spraying process or dipping process to form the insulator 20 , and the insulator 20 is formed around the wire harness conductor 10 .
- the 3D printing process is to melt the insulating material and then print it into the mold cavity 31 .
- the injection molding process is to use the injection mold as the molding shell 30, and integrally inject the insulating material into the injection mold.
- the spraying process is to spray the insulating material onto the conductor to form an insulating layer.
- the dipping process is to immerse the mold cavity 31 and the conductor into the insulating material, so that the insulating material can be attached to the conductor.
- the insulator 20 is molded with a molded shell 30 . In some cases, such as the case where the insulator 20 adopts a molding process, the molded casing 30 may be omitted.
- the present invention provides a wire harness, which is produced by the above wire harness production method.
- the wire harness includes a wire harness conductor 10 and an insulator 20 .
- a gap 11 is provided between the wire harness conductors 10 .
- the insulator 20 wraps the wire harness conductor 10 and fills the gap 11 .
- the wire harness conductor 10, the insulator 20 and the molding shell 30 form an integrated structure.
- Some wire harnesses have complex shapes, and the material of the insulator 20 is filled in a uniform insulation method, which can eliminate multiple steps in the existing wire harness processing technology and save Processing time is improved, productivity is increased, and wiring harness costs are reduced.
- the material of the insulator 20 has a certain degree of adhesion, it is difficult to remove the molded housing. Therefore, when designing the wire harness, the molded housing 30 can be directly set as a part of the wire harness to form an integrated structure, and there is no need to mold the molded housing 30. The housing 30 is removed from the insulator 20 .
- the molding shell 30 can adopt a profiling structure, and the shape of the molding shell 30 is suitable for the installation environment.
- the insulator 20 of the formed wire harness can be a profiling structure, increasing the The application environment of the produced wire harness can be adapted to different product structures, and it is convenient to use on electrical devices with complex installation environments; in the case that the molded housing 30 is used as a part of the produced wire harness, the molded housing 30 can be used with the application Adapt to the environment, which increases the application environment of the produced wiring harness, can adapt to different product structures, and is easy to use on electrical devices with complex installation environments
- the molded housing 30 is a part of the wire harness produced, and the molded housing 30 is a component part of the electrical device, which realizes the integrated production of the parts and the wire harness, and facilitates the rapid installation and disassembly of the wire harness.
- multiple wire harness conductors are disconnected, and each wire harness conductor 10 transmits current independently.
- the wire harness conductors extend along a straight line or along a curve. As shown in FIG. 2 , multiple wire harness conductors 10 are distributed along the same plane. For electrical devices, the conductors of the harness will extend along the route of the assembly.
- the multiple wire harness conductors are distributed along the same plane, or the multiple wire harness conductors are distributed and extended in space.
- the complex wiring harness has multiple branch structures, which will be used to connect many different electrical devices. At present, the electrical devices will have a larger planar structure or curved surface structure, and the complex wiring harness can be directly arranged on the electrical device, which can also facilitate Pouring of insulator 20 .
- the insulator is provided with a support piece 32 , the support piece 32 includes a side surface and a peripheral surface, the side surface and at least the peripheral surface are connected to the insulator 20 , and the wire harness conductor 10 passes through the side surface or contacts the peripheral surface.
- some wire harness conductors 10 are longer in length and lower in hardness, which will cause the wire harness conductors 10 in the middle to sag and contact the molding shell 30.
- the casing 30 is isolated, causing the wire harness conductors 10 to be short-circuited, causing damage to the wire harness and even causing a safety accident.
- step S02 implemented before step S10, a supporting sheet for supporting the wire harness conductor 10 is provided in the mold cavity to ensure that the filled insulator 20 can isolate the wire harness conductor 10 from the molding housing 30.
- the insulator 20 can fully isolate the plurality of wire harness conductors 10 to ensure the accuracy of the wire harness loop.
- the support piece 32 also plays a positioning role for the wire harness conductor 10 .
- a plurality of supporting pieces 32 may be arranged in the mold cavity 31 .
- the insulator 20 may form an integral structure with a support sheet 32 as part of the wire harness being produced.
- the supporting sheet 32 is preferably made of an insulating material. More preferably, the supporting sheet 32 and the insulator 20 are made of the same material.
- the insulator 20 is overmolded outside the wire harness conductor 10, and the supporting sheet 32 is integrated with the insulating layer, preferably To ensure the insulation performance of the wiring harness.
- the material forming the insulator 20 is one of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, polyethylene or Various combinations.
- the wire harness conductor 10 is made of a metal material, and the metal material is nickel or its alloys, cadmium or its alloys, zirconium or its alloys, chromium or its alloys, cobalt or its alloys, manganese or its alloys, aluminum or One or more of its alloys, tin or its alloys, titanium or its alloys, zinc or its alloys, copper or its alloys, silver or its alloys, and gold or its alloys.
- the most commonly used metal material for conductors is copper or copper alloy, because copper has the best conductivity among metals, and copper is not a precious metal, so it is easy to process and has good ductility.
- the material of the wire harness conductor 10 includes non-metallic materials, and the non-metallic materials are one or more combinations of conductive ceramics, carbon-containing conductors, solid electrolytes, mixed conductors, and conductive polymer materials.
- the carbon-containing conductor is one or a combination of graphite powder, carbon nanotube material, and graphene material.
- the cross-sectional area of the harness conductor 10 is 0.1 mm 2 -260 mm 2 .
- the cross-sectional area of the wire harness conductor 10 determines the current that the wire harness conductor 10 can conduct.
- the wire harness conductor 10 that realizes signal conduction has a small current, and the cross-sectional area of the wire harness conductor 10 is also small, such as an automobile wire harness.
- the minimum cross-sectional area of the wire harness conductor 10 of the signal line can reach 0.1mm 2 , while the wire harness conductor 10 that realizes power conduction has a large current, and the cross-sectional area of the wire harness conductor 10 is also relatively large, such as a car battery wire harness, the maximum cross-sectional area of the wire harness conductor 10 reaches 260mm 2 .
- the wiring harness conductor 10 can be laid by a wire feeding mechanism.
- 3D printing can be used Conductor 2 laying method.
- the material of the insulator 20 is one or more of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene and polyethylene .
- the breakdown strength of the insulator 20 is 0.3KV/mm-35KV/mm. Breakdown strength is also called dielectric breakdown strength. Indicates the highest electric field strength that a material can withstand under the action of an electric field to avoid being destroyed (breakdown). When the breakdown strength of the insulator 20 is lower than 0.3KV/mm, some thinner insulators 20 may be broken down under normal voltage, resulting in ineffective insulation. When the breakdown strength of the insulator 20 is higher than 35KV/mm, since the high voltage higher than 35KV will not appear in the general vehicle environment, choosing a material with too high breakdown strength will increase the cost of the integrated wiring harness assembly, resulting in design waste.
- the thickness of the insulator 20 is 0.03mm-5mm.
- the thickness of the insulator 20 is less than 0.03 mm, which not only cannot ensure that the breakdown voltage of the insulator 20 is higher than the working voltage, but also cannot guarantee the wear resistance of the insulator 20. After repeated scraping and grinding, the insulator 20 will be damaged and the wire harness conductor will be exposed. 10. It will lead to leakage or short circuit, resulting in line damage and function failure.
- the thickness of the insulator 20 is equal to 5 mm, the breakdown voltage, insulation resistance and wear resistance of the insulator 20 can meet the requirements, but when the thickness is greater than 5 mm, the thickness of the insulator 20 is relatively large, and problems such as pores and collapse may occur during processing. The performance of the insulator 20 is reduced. In addition, the material of the insulating layer is wasted, and the processing steps and time are increased. Therefore, the inventor chooses the thickness of the insulator 20 to be 0.03mm-5mm.
- the wiring harness can be adapted to large-volume, automated production methods, improve production efficiency, and realize rapid production; and realize uniform insulation, and can conveniently and quickly set the insulator 20; the wiring harness is convenient for installation and connection with external electrical devices, reducing installation hours and saving space, saves the step of extruding the insulating layer of the wire, reduces the processing time of the wire harness, and reduces the cost of raw materials and wire harness production.
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- Injection Moulding Of Plastics Or The Like (AREA)
- Insulated Conductors (AREA)
Abstract
本发明提供了一种线束的生产方法及线束，该线束的生产方法包括：步骤S10，布置多根线束导体；步骤S20，增材成型绝缘体；所述线束导体之间设有间隙，所述绝缘体包裹所述线束导体且填充于所述间隙。通过本发明，缓解了线束的生产工艺比较复杂、加工成本较高的技术问题。
Description
相关申请
本申请要求专利申请号为CN202110875931.6、申请日为2021年07月30日、发明名称为“线束的生产方法及线束”的中国发明专利的优先权。
本发明涉及电子元器件的技术领域，尤其是一种线束的生产方法及线束。
电气连接需使用线束来实现，线束的主要组成是作为导体的电线，电线需要经过导体拉丝、绞合、退火、挤塑绝缘层等工序来生产，生产工艺比较复杂，加工成本较高。另外，利用电线来生产线束的生产过程中，还需要将电线定长切断、以及剥除绝缘层，再将电线按照回路要求进行一根根地铺设和固定。
发明内容
本发明的目的是提供一种线束的生产方法及线束，以缓解线束的生产工艺比较复杂、加工成本较高的技术问题。
本发明的上述目的可采用下列技术方案来实现：
本发明提供一种线束的生产方法，所述生产方法包括：步骤S10，布置多根线束导体；步骤S20，增材成型绝缘体；所述线束导体之间设有间隙，所述绝缘体包裹所述线束导体且填充于所述间隙。
本发明提供一种线束，其中，采用上述的线束的生产方法生产，所述线束包括线束导体和绝缘体，所述线束导体之间设有间隙，所述绝缘体包裹所述线束导体且填充于所述间隙。
本发明的特点及优点是：
该线束的生产方法中，先将多根线束导体按照所要实现的电气连接功能布置好，然后增材成型绝缘体，实现绝缘和固定。导电回路可以与外部的电器件连接，实现线束的电气连接功能。该线束的生产方法具有以下优点：
(1)省去了对电线的挤塑绝缘层的步骤，缩减了线束加工时间，并且降低了原材料成本，减少了线束电线生产的成本；
(2)可以适应大批量，自动化的生产方式，提高生产效率，实现快速生产；
(3)在预先布置的线束导体的周围统一设置绝缘体，实现统一绝缘，能够方便快捷的设置绝缘体；
(4)所生产的线束便于与外部的电器件安装与连接，减少安装工时，节省空间；
(5)可以采用仿形的成型壳体，成型壳体的形状与安装环境下相适配，增大了所生产的线束的应用环境，可以适应不同的产品结构，便于使用在安装环境复杂的电器件上；
(6)成型壳体可以是电器件的组成零部件，可以实现零部件和线束一体生产，实现线束的快速安装和拆卸。
以下附图仅旨在于对本发明做示意性说明和解释，并不限定本发明的范围。其中：
图1为本发明提供的线束的生产方法的结构示意图；
图2为本发明提供的线束的生产方法的工作示意图；
图3为本发明提供的线束的生产方法中成型壳体与支撑片的结构示意图；
图4和图5为线束导体与绝缘体的局部示意图；
图6为本发明提供的线束的生产方法中送丝机构的示意图。
为了对本发明的技术特征、目的和效果有更加清楚的理解，现对照附图说明本发明的具体实施方式。在本发明的描述中，除非另有说明，“多个”的含义是两个或两个以上。
实施例一
本发明提供了一种线束的生产方法，如图1所示，该线束的生产方法包括：步骤S10，布置多根线束导体10；步骤S20，增材成型绝缘体20；线束导体10之间设有间隙11，绝缘体20包裹线束导体10且填充于间隙11。
该线束的生产方法中，先将多根线束导体10按照所要实现的电气连接功能布置好，然后增材成型绝缘体20，实现绝缘和固定。导电回路可以与外部的电器件连接，实现线 束的电气连接功能。该线束的生产方法具有以下优点：(1)省去了对电线的挤塑绝缘层的步骤，缩减了线束加工时间，并且降低了原材料成本，减少了线束电线生产的成本；(2)可以适应大批量，自动化的生产方式，提高生产效率，实现快速生产；(3)在预先布置的线束导体10的周围统一设置绝缘体20，实现统一绝缘，能够方便快捷的设置绝缘体20；(4)所生产的线束便于与外部的电器件安装与连接，减少安装工时，节省空间。
在一实施方式中，步骤S10和步骤S20可以依次地交替实施多次，即分多次布置线束导体10，和成型绝缘体20。在另一实施方式中，一次性把线束导线都布置好，再成型绝缘体20，提高了生产效率。
线束导体10的终端可以连接金手指、压接端子、焊接端子或焊接电线，以便于与其他电器回路进行连接。
该线束的生产方法中，线束导体10外可以省去绝缘皮和绝缘漆，通过步骤S20，形成统一的绝缘体20。在一些实施方式中，请参照图4，图4为该线束的生产方法所生产的线束的局部示意图，线束导体10为独芯结构，即线束导体10为一根导线。在一些实施方式中，请参照图5，图5为该线束的生产方法所生产的线束的局部示意图，线束导体10为多芯结构，即线束导体10包括多根导线，优选地，导线为柔软导线。
在一实施方式中，线束的生产方法包括在步骤S10之前实施的步骤S01，步骤S01：制备成型壳体30，成型壳体30设有模腔31；步骤S10中，将线束导体10布置于模腔31中；步骤S20中，在模腔31中成型绝缘体20。如图2和图3所示，成型壳体30对绝缘体20的形状和尺寸进行限定，根据所生产的线束的要求，制备符合线束导体10走向的成型壳体30。
在一实施方式中，线束导体10、绝缘体20和成型壳体30形成一体结构，即成型壳体30作为所生产的线束的一部分。
在另一实施方式中，该线束的生产方法包括在步骤S20之后实施的步骤S30，步骤S30：将绝缘体20和包裹的线束导体10，从模腔31中取出，成型壳体30及其模腔31作为生产线束的工装。
成型壳体30可以采用仿形结构，成型壳体30的形状与安装环境相适配，在成型壳体30作为工装的情况下，可以使所成型的线束的绝缘体20为仿形结构，增大了所生产的线束的应用环境，可以适应不同的产品结构，便于使用在安装环境复杂的电器件上；在成型壳体30作为所生产的线束的一部分的情况下，成型壳体30可以与应用环境相适 配，增大了所生产的线束的应用环境，可以适应不同的产品结构，便于使用在安装环境复杂的电器件上
进一步地，成型壳体30作为所生产的线束的一部分，并且成型壳体30是电器件的组成零部件，实现了零部件和线束一体生产，有利于线束的快速安装和拆卸。
在一实施方式中，步骤S10中，多根线束导体10之间相断开，各根线束导体10独立地传输电流。在另一实施方式中，步骤S10中，使用压接、焊接、3D打印连接、激光烧结连接、连接点印刷方式的一种或几种，将至少两根线束导体10进行电连接，线束内的多根线束导体10可以实现比较复杂的电路功能。
在一实施方式中，步骤S10中，线束导体10可以沿直线延伸或者沿曲线延伸。如图2所示，多根线束导体10沿同一平面分布。
在另一些实施方式中，步骤S10中，多根线束导体10在空间内分布和延伸，例如，线束沿空间曲线延伸。
在一实施方式中，步骤S10采用3D打印工艺、激光粉末烧结工艺、金属注射成型工艺、激光减材工艺、导电油墨印刷工艺或印刷线路板工艺的一种或几种。
具体地，3D打印工艺、激光粉末烧结工艺都属于增材工艺，采用金属粉末或导电材料，进行熔融打印，可以使用成型壳体30来承载成型。金属注射成型工艺是采用模具，使金属能在模具中成型，然后再放入到模腔31内。激光减材工艺，是将片状或箔状的金属材料成型后，将不需要的部分进行裁切，留下线束导体10部分。导电油墨印刷工艺是将导电油墨印刷到基板上，形成导电回路，导电回路与基板一起作为线束导体10。印刷线路板工艺是使用腐蚀铜板的方式，获得导电回路，导电回路作为线束导体10。
在另一实施方式中，步骤S10中，线束导体10采用铺设的方式来布置。可以选用导线作为线束导体10，所选用的导线可以省去绝缘皮和绝缘漆。具体地，可以使用手工铺设，也可以通过设备进行铺设。
该线束的生产方法应用送丝机构40；步骤S10中，通过送丝机构40将线束导体10递送至模腔31中，送丝机构40有利于保障线束导体10的到位位置的准确性。送丝机构40可以在模腔31和支撑片32上进行线束导体10的空间布置。
进一步地，送丝机构40包括滚筒机构41，滚筒机构41包括至少两个间隔设置的滚筒42，如图6所示，线束导体10从两个滚筒42之间穿过，滚筒42自转时，依靠摩擦力驱动线束导体10向模腔31中平移，完成线束导体10的布置。
在一实施方式中，模腔31中设有用于支撑线束导体10的支撑片32，支撑片32能 将线束导体10撑起，以便使绝缘体20包围线束导体10；支撑片32还对线束导体10起到定位作用。模腔31内可以设置多个支撑片32。绝缘体20可以与支撑片32形成一体结构，支撑片32作为所生产的线束的一部分。支撑片32优选为绝缘材质，更优选地，支撑片32与绝缘体20采用同种材料，步骤S20中，绝缘体20在线束导体10外包覆成型，并且支撑片32与绝缘层形成一体，更好地保障线束的绝缘性能。
在一实施方式中，步骤S20采用3D打印工艺、注塑工艺成型、喷涂工艺或浸塑工艺成型绝缘体20，绝缘体20成型于线束导体10周围。具体地，3D打印工艺是将绝缘材料进行熔融，然后打印到模腔31内。注塑工艺成型，是将注塑模具作为成型壳体30，将绝缘材料一体注塑到注塑模具内。喷涂工艺是将绝缘材料喷涂到导体上，形成绝缘层。浸塑工艺是将模腔31和导体浸入绝缘材料中，使绝缘材料能够附着在导体上。优选地，利用成型壳体30来成型绝缘体20。一些情况下，例如绝缘体20采用浸塑工艺的情况下，可以省去成型壳体30。
实施例二
本发明提供了一种线束，采用上述的线束的生产方法生产，线束包括线束导体10和绝缘体20，线束导体10之间设有间隙11，绝缘体20包裹线束导体10且填充于间隙11。
在一实施方式中，线束导体10、绝缘体20和成型壳体30形成一体结构，有些线束形状复杂，采用统一绝缘的方式填充绝缘体20材料，可以去除现有线束加工工艺的多个步骤，能够节省加工时间，提高生产效率，降低线束成本。由于绝缘体20的材料有一定的粘连性，因此成型壳体的去除较困难，因此在设计线束的时候，可以将成型壳体30直接设置为线束的一部分，形成一体结构，也就不需要将成型壳体30从绝缘体20上拆除。
成型壳体30可以采用仿形结构，成型壳体30的形状与安装环境相适配，在成型壳体30作为工装的情况下，可以使所成型的线束的绝缘体20为仿形结构，增大了所生产的线束的应用环境，可以适应不同的产品结构，便于使用在安装环境复杂的电器件上；在成型壳体30作为所生产的线束的一部分的情况下，成型壳体30可以与应用环境相适配，增大了所生产的线束的应用环境，可以适应不同的产品结构，便于使用在安装环境复杂的电器件上
进一步地，成型壳体30作为所生产的线束的一部分，并且成型壳体30是电器件的组成零部件，实现了零部件和线束一体生产，有利于线束的快速安装和拆卸。
在一实施方式中，多根线束导体之间相断开，各根线束导体10独立地传输电流。或者，使用压接、焊接、3D打印连接、激光烧结连接、连接点印刷方式的一种或几种，将至少两根线束导体进行电连接，线束内的多根线束导体10可以实现比较复杂的电路功能。
在一实施方式中，线束导体沿直线延伸或者沿曲线延伸，如图2所示，多根线束导体10沿同一平面分布，当线束连接的用电装置较少时，线束的两端连接不同的用电装置，线束导体会依照装配的路线延伸。
在一实施方式中，多根线束导体沿同一平面分布，或者，多根线束导体在空间内分布和延伸。复杂线束有多个分支结构，会用来连接很多不同的用电装置，目前用电装置都会有较大的平面结构或曲面结构，可以将复杂线束直接布置在用电装置上，也能方便对绝缘体20的灌注。
在一实施方式中，绝缘体中设有支撑片32，支撑片32包括侧面和周面，侧面和至少周面与绝缘体20连接，线束导体10穿过侧面或与周面接触。在线束导体10布置过程中，有部分线束导体10长度较长，硬度较低，会使中间的线束导体10下垂并接触到成型壳体30，填充绝缘体20时也不会使线束导体10与成型壳体30隔离，导致线束导体10短路，造成线束损坏甚至会造成安全事故。因此在步骤S10之前实施的步骤S02，模腔中设有用于支撑线束导体10的支撑片，保证填充的绝缘体20可以将线束导体10与成型壳体30隔离，另外，当线束导体10为多根时，使用支撑片32将多根线束导体10，可以是使绝缘体20充分隔离开多根线束导体10，保证线束回路准确。
支撑片32还对线束导体10起到定位作用。模腔31内可以设置多个支撑片32。绝缘体20可以与支撑片32形成一体结构，支撑片32作为所生产的线束的一部分。支撑片32优选为绝缘材质，更优选地，支撑片32与绝缘体20采用同种材料，步骤S20中，绝缘体20在线束导体10外包覆成型，并且支撑片32与绝缘层形成一体，更好地保障线束的绝缘性能。
在一实施方式中，形成绝缘体20的材质为聚氯乙烯、聚氨酯、尼龙、聚丙烯、硅橡胶、交联聚烯烃、合成橡胶、聚氨酯弹性体、交联聚乙烯、聚乙烯中的一种或多种的组合。
在一实施方式中，线束导体10的材质包括金属材料，金属材料为镍或其合金、镉或其合金、锆或其合金、铬或其合金、钴或其合金、锰或其合金、铝或其合金、锡或其合金、钛或其合金、锌或其合金、铜或其合金、银或其合金和金或其合金中的一种或多 种。导体最常用的金属材料为铜或铜合金，因为铜的导电率在金属中属于较好的，而且铜不属于贵重金属，加工比较方便，延展率好。但是，随着铜价日益上涨，使用铜材作为导体的材料成本会越来越高。为此，人们开始寻找金属铜的替代品来降低成本。金属铝在地壳中的含量约为7.73％，提炼技术优化后，价格相对较低，并且相对于铜，铝的重量较轻，导电率仅次于铜，铝或铝合金在电气连接领域可以替代部分铜或铜合金。
在一实施方式中，线束导体10的材质包括非金属材料，非金属材料为导电陶瓷、含碳导体、固体电解质、混合导体、导电高分子材料中的一种或多种的组合。
在一实施方式中，含碳导体为石墨粉、碳纳米管材料、石墨烯材料的一种或几种的组合。
在一实施方式中，线束导体10的截面积为0.1mm
2-260mm
2。在线束中，线束导体10的截面积决定线束导体10所能导通的电流，一般情况下，实现信号导通的线束导体10，电流较小，线束导体10截面积也较小，例如汽车线束的信号线线束导体10最小截面积可达到0.1mm
2，而实现电源导通的线束导体10，电流较大，线束导体10截面积也较大，例如汽车蓄电池线束，线束导体10最大截面积达到260mm
2。对于线束导体10的截面积较小的，可以采用送丝机构进行铺设的方式进行线束导体10的布置，对于线束导体10的截面积较大的，可以采用3D打印线束导体10或者直接将成型的导体2进行铺设的方法。
在一实施方式中，绝缘体20的材质聚氯乙烯、聚氨酯、尼龙、聚丙烯、硅橡胶、交联聚烯烃、合成橡胶、聚氨酯弹性体、交联聚乙烯和聚乙烯中的一种或多种。
在一实施方式中，绝缘体20的击穿强度为0.3KV/mm-35KV/mm。击穿强度又称介电击穿强度。表示材料在电场作用下，避免被破坏(击穿)所能承受最高的电场强度。当绝缘体20的击穿强度低于0.3KV/mm，有部分较薄绝缘体20在正常电压下就有可能被击穿，从而导致绝缘无效。当绝缘体20的击穿强度高于35KV/mm，由于在一般的车载环境中不会出现高于35KV的高压，选用过高击穿强度的材料会提高集成线束组件的成本，造成设计浪费。
在一实施方式中，绝缘体20的厚度为0.03mm-5mm。绝缘体20的厚度低于0.03mm，不仅不能够保证绝缘体20的击穿电压高于工作电压，也不能保证绝缘体20的耐磨性能，在多次刮磨后，会使绝缘体20破损，露出线束导体10，会导致漏电或短路的情况，造成线路损坏，功能失效。绝缘体20厚度等于5mm时，绝缘体20的击穿电压、绝缘电阻和耐磨性能都能满足要求，但是厚度大于5mm时，绝缘体20厚度较大，在加工过程 中或出现气孔、塌陷等问题点，降低了绝缘体20的性能，另外，也浪费绝缘层材料，并且增加了加工的工序和时间，因此，发明人选用绝缘体20的厚度为0.03mm-5mm。
该线束可以适应大批量，自动化的生产方式，提高生产效率，实现快速生产；并且实现统一绝缘，能够方便快捷的设置绝缘体20；该线束便于与外部的电器件安装与连接，减少安装工时，节省空间，省去了对电线的挤塑绝缘层的步骤，缩减了线束加工时间，减少了原材料及线束生产的成本。
以上所述仅为本发明示意性的具体实施方式，并非用以限定本发明的范围。任何本领域的技术人员，在不脱离本发明的构思和原则的前提下所作的等同变化与修改，均应属于本发明保护的范围。
Claims (24)
- 一种线束的生产方法，其中，所述生产方法包括：步骤S10，布置多根线束导体；步骤S20，增材成型绝缘体；所述线束导体之间设有间隙，所述绝缘体包裹所述线束导体且填充于所述间隙。
- 如权利要求1所述的线束的生产方法，其中，所述线束的生产方法包括在所述步骤S10之前实施的步骤S01；所述步骤S01，制备成型壳体，所述成型壳体设有模腔；所述步骤S10中，将所述线束导体布置于所述模腔中；所述步骤S20中，在所述模腔中成型所述绝缘体。
- 如权利要求2所述的线束的生产方法，其中，所述线束的生产方法包括在所述步骤S20之后实施的步骤S30，所述步骤S30：将所述绝缘体和包裹的线束导体，从所述模腔中取出。
- 如权利要求1所述的线束的生产方法，其中，所述步骤S10中，多根所述线束导体之间相断开，或者，使用压接、焊接、3D打印连接、激光烧结连接、连接点印刷方式的一种或几种，将至少两根所述线束导体进行电连接。
- 如权利要求1所述的线束的生产方法，其中，所述步骤S10中，所述线束导体沿直线延伸或者沿曲线延伸。
- 如权利要求1所述的线束的生产方法，其中，所述步骤S10中，多根所述线束导体沿同一平面分布，或者，多根所述线束导体在空间内分布和延伸。
- 如权利要求1所述的线束的生产方法，其中，所述步骤S10采用3D打印工艺、激光粉末烧结工艺、金属注射成型工艺、激光减材工艺、导电油墨印刷工艺或印刷线路板工艺的一种或几种。
- 如权利要求2所述的线束的生产方法，其中，所述线束的生产方法应用送丝机构；所述步骤S10中，通过所述送丝机构将线束导体递送至所述模腔中。
- 如权利要求2所述的线束的生产方法，其中，所述线束的生产方法包括在所述步骤S10之前实施的步骤S02，所述模腔中设有用于支撑所述线束导体的支撑片。
- 如权利要求1所述的线束的生产方法，其中，所述步骤S20采用3D打印工艺、注塑工艺成型、喷涂工艺或浸塑工艺成型所述绝缘体。
- 一种线束，其中，采用权利要求1-10中任一项所述的线束的生产方法生产，所 述线束包括线束导体和绝缘体，所述线束导体之间设有间隙，所述绝缘体包裹所述线束导体且填充于所述间隙。
- 如权利要求11所述的线束，其中，所述线束的生产方法包括在所述步骤S10之前实施的步骤S01；所述步骤S01，制备成型壳体，所述成型壳体设有模腔；所述步骤S10中，将所述线束导体布置于所述模腔中；所述步骤S20中，在所述模腔中成型所述绝缘体；所述线束导体、所述绝缘体和所述成型壳体形成一体结构。
- 如权利要求11所述的线束，其中，多根所述线束导体之间相断开，或者，至少两根所述线束导体进行电连接。
- 如权利要求11所述的线束，其中，所述线束导体沿直线延伸或者沿曲线延伸。
- 如权利要求11所述的线束，其中，多根所述线束导体沿同一平面分布，或者，多根所述线束导体在空间内分布和延伸。
- 如权利要求11所述的线束，其中，所述绝缘体中设有支撑片，所述支撑片包括侧面和周面，所述侧面和至少所述周面与所述绝缘体连接，所述线束导体穿过所述侧面或与所述周面接触。
- 如权利要求11所述的线束，其中，形成所述绝缘体的材质为聚氯乙烯、聚氨酯、尼龙、聚丙烯、硅橡胶、交联聚烯烃、合成橡胶、聚氨酯弹性体、交联聚乙烯、聚乙烯中的一种或多种的组合。
- 如权利要求11所述的线束，其中，所述线束导体的材质包括金属材料，所述金属材料为镍或其合金、镉或其合金、锆或其合金、铬或其合金、钴或其合金、锰或其合金、铝或其合金、锡或其合金、钛或其合金、锌或其合金、铜或其合金、银或其合金和金或其合金中的一种或多种。
- 如权利要求11所述的线束，其中，所述线束导体的材质包括非金属材料，所述非金属材料为导电陶瓷、含碳导体、固体电解质、混合导体、导电高分子材料中的一种或多种的组合。
- 如权利要求19所述的线束，其中，所述含碳导体为石墨粉、碳纳米管材料、石墨烯材料的一种或几种的组合。
- 如权利要求11所述的线束，其中，所述线束导体的截面积为0.1mm 2-260mm 2。
- 如权利要求11所述的线束，其中，所述绝缘体的材质聚氯乙烯、聚氨酯、尼龙、聚丙烯、硅橡胶、交联聚烯烃、合成橡胶、聚氨酯弹性体、交联聚乙烯和聚乙烯中的一 种或多种。
- 如权利要求22所述的线束，其中，所述绝缘体的击穿强度为0.3KV/mm-35KV/mm。
- 如权利要求11所述的线束，其中，所述绝缘体的厚度为0.03mm-5mm。
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