WO2023005691A1 - 线束的生产方法、喷嘴及线束 - Google Patents

线束的生产方法、喷嘴及线束 Download PDF

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Publication number
WO2023005691A1
WO2023005691A1 PCT/CN2022/105976 CN2022105976W WO2023005691A1 WO 2023005691 A1 WO2023005691 A1 WO 2023005691A1 CN 2022105976 W CN2022105976 W CN 2022105976W WO 2023005691 A1 WO2023005691 A1 WO 2023005691A1
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WIPO (PCT)
Prior art keywords
conductive
wire harness
production method
layer
spraying
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PCT/CN2022/105976
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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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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 EP22848296.4A priority Critical patent/EP4379748A1/en
Publication of WO2023005691A1 publication Critical patent/WO2023005691A1/zh

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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

Definitions

  • the invention relates to the technical field of electronic components, in particular to a production method of a wire harness, a nozzle and a wire harness.
  • the existing wiring harness is mainly composed of parts such as electric wires, terminals, sheaths, positioning parts and brackets, and the parts are numerous and the structure is relatively complicated.
  • the wires in the wiring harness need to be produced through processes such as conductor drawing, stranding, annealing, and extruding insulation layers. The production process is relatively complicated and the processing cost is relatively high.
  • Most of the existing wiring harness production methods adopt the mode of centralized batch production.
  • wire harness products with small batches and many types of products have high requirements for flexible production and cannot achieve mass production; such wire harnesses can only be produced by manual and temporary tooling, the processing cycle is relatively long, and the production cost is increased.
  • the purpose of the present invention is to provide a production method of a wire harness, a nozzle and a wire harness, so as to alleviate the technical problems of complicated production process and high processing cost of the wire harness for electrically connecting electrical devices.
  • the present invention provides a production method of a wire harness.
  • the production method of the wire harness includes: step S10, preparing a substrate; step S20, spraying a conductive paint onto the substrate to form a conductive circuit; step S30, forming a conductive circuit on the conductive circuit An insulating protective layer is formed around and on the surface.
  • the present invention provides a nozzle, which is applied to the above wire harness production method, and the outlet of the nozzle is square.
  • the present invention provides a wire harness, which is produced by the above wire harness production method.
  • the wire harness includes: a substrate, at least one conductive circuit and at least one insulating protective layer, and each of the conductive circuits is located between the substrate and the outermost layer. Between the insulating protective layers, the conductive loops are distributed alternately with the insulating protective layers.
  • the production method of the wire harness adopts the method of spraying to form a conductive loop on the substrate, and the conductive loop can be connected with external electrical devices to realize the electrical connection function of the wire harness; and the insulating protection layer is used for insulation protection, thereby realizing rapid prototyping of the wire harness loop.
  • the production method of the wire harness has the following advantages:
  • the wiring harness produced by spraying has a high degree of flexible production, fast and convenient processing, high efficiency, and the cost is much lower than the existing production mode of small batch wiring harness;
  • Multi-layer spraying can be used, and more conductive circuits can be prepared under the condition of a small substrate area to meet the requirements of more electrical circuits;
  • the method of punching and pouring conductive materials can be used to electrically connect the conductive circuits of different layers, and realize the design scheme of more complex electrical circuits, which can be applied to more complex wiring harnesses;
  • the cross-sectional area of the conductive circuit can be adjusted by adjusting the spraying parameters, which is suitable for circuit processing with multiple wire diameters, and is convenient for regulating the conductivity of the conductive circuit;
  • the trajectory of the nozzle is controlled by a servo mechanism or a manipulator, which facilitates the processing of wire harnesses with complex spatial structures; and ensures stable spraying and uniform size of the conductive circuit;
  • the material selection of the insulating protective layer is relatively diverse, and a variety of process methods can be used to achieve insulation protection and ensure the insulation protection effect;
  • the substrate can be a component part of an electrical device, which can realize the integrated production of parts and wiring harnesses, and realize the rapid installation and disassembly of wiring harnesses;
  • a profiling substrate can be used, and spraying can be performed on a non-planar substrate, which increases the application environment of the spraying wire harness;
  • a flexible substrate can be used, so that the sprayed wire harness can be applied to a variety of installation situations; the produced wire harness can be applied to electrical appliances with complex installation environments, and can also be used in environments with high vibration requirements to reduce the interference of vibration factors ;
  • the shielding layer is set outside the wiring harness, which can be placed in a position where the electromagnetic interference is relatively strong, so that the signal in the wiring harness can shield the electromagnetic interference and ensure the stability of the signal;
  • a heat sink is provided on the insulating protective layer, which can quickly dissipate the heat generated by the wire harness current into the air, which is beneficial to reduce the temperature of the wire harness and reduce the risk of the conductive circuit fusing.
  • Fig. 1 is the schematic diagram 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-Fig. 4 is the schematic structural view of the wire harness produced by the production method of the wire harness provided by the present invention.
  • Fig. 5-Fig. 6 is the structural representation of the nozzle in the production method of wire harness provided by the present invention.
  • Fig. 7 is a top view of an embodiment of the wire harness produced by the wire harness production method provided by the present invention.
  • Fig. 8 is a side sectional view of an embodiment of a wire harness produced by the wire harness production method provided by the present invention.
  • Fig. 9 is a top view of another embodiment of the wire harness produced by the wire harness production method provided by the present invention.
  • Fig. 10 is a side sectional view of another embodiment of the wire harness produced by the wire harness production method 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, preparing a substrate 10; step S20, spraying a conductive paint onto the substrate 10 to form a conductive circuit 21 ; Step S30 , forming an insulating protective layer 40 around and on the surface of the conductive circuit 21 .
  • the production method of the wiring harness adopts the method of spraying to form a conductive loop 21 on the substrate 10.
  • the conductive loop 21 can be connected with external electrical devices to realize the electrical connection function of the wiring harness; and the insulating protection layer 40 is used for insulation protection, thereby realizing the wiring harness.
  • the production method of the wire harness adopts a spraying method to produce the wire harness, which has a high degree of flexible production, fast and convenient processing, high efficiency, and reduces production costs, and is suitable for the production of small batches of wire harnesses.
  • the production method of the wire harness includes step S40 implemented after step S30, step S40: spraying conductive paint onto the insulating protective layer 40 to form a conductive loop 21; and, step S40 and step S30 alternate in sequence performed one or more times.
  • Step S20 forms a conductive layer 30 on the substrate 10 ;
  • step S40 is performed once, and another conductive layer 30 can be formed on the formed conductive loop 21 and insulating protection layer 40 .
  • step S40 and step S30 a plurality of conductive layers 30 are constructed on the substrate 10 to form a multilayer structure. Multi-layer spraying is adopted to form a plurality of conductive layers 30 to realize the preparation of more conductive circuits 21 under the condition of a smaller area of the substrate 10 to meet the requirements of more electrical circuits.
  • a conductive layer 30 may include a plurality of conductive loops 21; in a multi-layer structure wire harness, the number and structure of the conductive loops 21 in each conductive layer 30 may be the same or different.
  • the production method of the wire harness includes step S50, step S50: punching holes in the insulating protection layer 40 and/or the conductive loop 21, and pouring conductive material to form a communication loop 22 electrically connecting at least two layers of the conductive loop 21.
  • punching holes and pouring conductive materials the conductive loops 21 of different layers can be electrically connected to realize a relatively complicated design of the electrical loop, and can be applied to more complicated wiring harnesses.
  • the wire harness produced by the wire harness production method includes a plurality of conductive layers 30, and the insulating protective layer 40 between two adjacent conductive layers 30 is punched, and the conductive material is poured to form a communication loop 22 , the connection loop 22 connects the conductive loops 21 of two adjacent conductive layers 30 .
  • the wire harness produced by the wire harness production method includes at least three conductive layers 30, and the at least three conductive layers 30 include an upper conductive layer 31, a middle conductive layer 32 and a lower conductive layer 33; 32, and the communication loop 22 communicates with the upper conductive layer 31 and the lower conductive layer 33 respectively.
  • the connection loop 22 passes through the conductive loop 21 of the middle conductive layer 32 and communicates with the conductive loop 21 , thereby connecting the upper conductive layer 31 , the middle conductive layer 32 and the lower conductive layer 33 simultaneously.
  • connection loop 22 passes through the middle conductive layer 32 through the region where the conductive loop 21 is not provided, and the connection loop 22 connects the upper conductive layer 31 and the lower conductive layer 33, and avoids the conduction of the middle conductive layer 32. Loop 21, avoid communicating with it.
  • the conductive loop 21 in the middle conductive layer 30 can be improved, for example, the conductive loop 21 extends along a curve or a broken line, so as to avoid the position where the connecting loop 22 is provided by punching.
  • the communication loop 22 can also be set to extend along a folded line or a curve, so as to avoid one or more conductive layers 30 in the middle.
  • each conductive layer 30 is formed, then punch holes and pour conductive materials; it is also possible to punch holes and pour conductive materials while forming the conductive layer 30 and the insulating protective layer 40, for example, after molding a conductive layer 30 or After one layer of insulating protection layer 40 , the layer is punched and filled with conductive material to form a connection circuit 22 , and then the next conductive layer 30 or insulating protection layer 40 is formed.
  • the conductive loops 21 in the middle conductive layer 30 are relatively dense, and it is difficult to make the connecting loops 22 avoid the conductive loops 21 in the middle conductive layer 30 by improving the conductive loops 21 . For this reason, the inventor made further improvements to the production method of the wire harness and the wire harness produced.
  • the wiring harness includes an upper conductive layer 31, a middle conductive layer 32 and a lower conductive layer 33, and the conductive circuits 21 in the upper conductive layer 31 are respectively connected with conductive protruding parts 23, and the conductive protruding parts 23 Deviated from the conductive loop 21 in the middle conductive layer 32, the communication loop 22 communicates with the conductive raised portion 23 in the upper conductive layer 31 and the conductive raised portion 23 in the lower conductive layer 33 respectively, and avoids the conductive loop 23 in the middle conductive layer 32.
  • the wiring harness includes an upper conductive layer 31, a middle conductive layer 32, and a lower conductive layer 33, and the position of the punching hole in step S50 is directly opposite to the conductive circuit 21 of the upper conductive layer 31 and the conductive loop 21 of the lower conductive layer 33.
  • the conductive loop 21 of the loop 21 and the middle conductive layer 32, the hole punched runs through the conductive loop 21 of the middle conductive layer 32; an insulating sleeve 342 is arranged in the hole, and the insulating sleeve 342 is positioned at the middle conductive layer 32 and the middle conductive layer 32
  • the conductive loop 21 is separated; pouring conductive material into the hole and the insulating sleeve 342 can prevent the communication loop 22 from communicating with the middle conductive layer 32 .
  • the hole punched in step S50 is a stepped hole 341, and the inner diameter of the portion of the stepped hole 341 located in the lower conductive layer 33 is smaller to facilitate the installation of the insulating sleeve 342.
  • the stepped portion of the stepped hole 341 can be Play a supporting role for the insulating sleeve 342 .
  • Adjusting the cross-sectional area of the conductive loop 21 can realize the adjustment of the conduction current of the conductive loop 21 .
  • the cross-sectional area of the conductive loop 21 can be adjusted by adjusting the spraying parameters in step S20.
  • a suitable thickness or width of the conductive loop 21 is constructed.
  • the production method of the wire harness is suitable for loop processing of multiple wire diameters, and is convenient for regulating the conductivity of the conductive loop 21.
  • step S20 and step S40 use nozzles 50 respectively, and the conductive paint is sprayed out through the nozzles 50 .
  • nozzles 50 of different sizes or shapes, it is possible to adjust the width and thickness of the section of the conductive circuit 21 .
  • the discharge port 501 of the nozzle 50 is square, which is beneficial to make the width and thickness of the cross section of the conductive circuit 21 uniform, to ensure the stability of the cross section, and to avoid excessive discharge at the middle position of the cross section and discharge at both sides during spraying. There is less material, and finally the conductive loop 21 with a high middle section and low sides at the cross section is formed.
  • the size of the discharge port 501 of the nozzle 50 is adjustable, so as to adjust the width and thickness of the section of the conductive circuit 21 .
  • the nozzle 50 includes a nozzle body 51 and a movable side wall 52, the movable side wall 52 is connected to the nozzle body 51 through a hinge 53, and the movable side wall 52 is rotated around the center of the hinge 53 relative to the nozzle body 51 , adjust the installation angle of the movable side wall 52 to adjust the position of the lower end of the movable side wall 52 , so as to adjust the size of the discharge port 501 of the nozzle 50 .
  • the nozzle body 51 is connected with a motor 54, and the motor 54 shaft of the motor 54 is connected with a drive screw 55; a screw hole is set on the movable side wall 52, and the drive screw 55 cooperates with the screw hole.
  • the motor 54 drives the driving screw 55 to rotate, and the driving screw 55 drives the movable side wall 52 to rotate around the center of the hinge 53 to adjust the size of the discharge port 501 of the nozzle 50 .
  • the outlet 501 of the nozzle 50 is square, so that the size of the section of the conductive circuit 21 can be adjusted by adjusting the size of the outlet 501 .
  • Adjusting the spraying distance of the nozzle 50 can also adjust the width and thickness of the section of the conductive circuit 21 .
  • Adjusting the spraying speed that is, adjusting the moving speed of the nozzle 50 can also adjust the width and thickness of the section of the conductive loop 21 .
  • the spraying distance is 5 mm to 100 mm
  • the spraying speed is 0.1 mm/s to 100 mm/s, which can prevent the sprayed material from being too dispersed, and prevent the track of the conductive loop 21 from being broken, so as to ensure the electrical conductivity.
  • the nozzle 50 can be installed on the servo mechanism or the manipulator, and the servo mechanism or the manipulator drives the nozzle 50 to move in the space, spray the conductive circuit 21 along various angles, form a wire harness with a spatial structure, and facilitate processing to realize a wire harness with a complex spatial structure; and Ensure stable spraying and keep the size of the conductive loop 21 uniform. Further, the nozzle 50 is mounted on a three-axis servo mechanism or a six-axis manipulator.
  • a moving guide rail is provided in the X direction, Y direction, and Z direction of the three-axis servo mechanism, and the movement in each direction is respectively driven by the servo motor 54.
  • the three-dimensional machining trajectory is realized, and the conductive circuit forming the spatial trajectory is sprayed. twenty one.
  • the six-axis manipulator can drive the nozzle 50 to move more flexibly, and spray the conductive circuit 21 that forms a more complex spatial trajectory.
  • the conductive layer 30 formed in step S20 includes a plurality of conductive loops 21 to prepare more conductive loops 21 .
  • the multiple conductive loops 21 are disconnected or electrically connected. For example: all the conductive loops 21 in the conductive layer 30 of the same layer are disconnected; in the conductive layer 30 of the same layer, at least two conductive loops 21 are electrically connected. According to the electrical connection function to be realized, the conductive loops 21 in the conductive layers 30 of each layer are provided.
  • step S20 is to spray the conductive paint mixed with the adhesive onto the substrate 10 by means of high-pressure airless spraying, electrostatic spraying or air spraying.
  • the conductive paint and the binder form a paint, which is sprayed onto the molding surface, and the paint is cured to form a conductive circuit 21 .
  • air spraying compressed air is used to atomize the paint for spraying.
  • high-pressure airless spraying the paint is pressurized to a pressure of 9.8MPa-29.4MPa through a booster pump, and then sprayed out through 50 small holes of olive-shaped nozzles.
  • the high-pressure paint rushes out of the nozzle 50 and enters the atmosphere, it immediately bursts and expands and disintegrates into very fine mist, which is directly sprayed onto the surface of the substrate 10 or the formed insulating protection layer 40 .
  • the paint is pressurized to a high pressure by a high-pressure pump and does not mix with compressed air itself.
  • electrostatic spraying the principle of corona discharge is used to make the atomized paint negatively charged under the action of a high-voltage direct current electric field, and adsorbed on the surface of the positively charged substrate to discharge.
  • the electrostatic spraying equipment includes a spray gun, a spray cup, and an electrostatic spraying high-voltage power supply.
  • Conductive coatings can be one or more powders of copper, aluminum, gold, silver, graphite, etc.; binders include epoxy resins, polyester resins, acrylic resins, polyamide resins, modified phenolic resins, and cellulose At least one of the resin-like resins.
  • the conductive paint includes a metal material
  • step S20 is to spray the melted conductive paint onto the substrate 10 by means of thermal spraying, arc spraying or plasma spraying.
  • thermal spraying the paint is heated and melted, atomized into extremely fine particles by high-speed airflow, and sprayed onto the molding surface at a high speed, and the paint is cured to form a coating.
  • arc spraying the metal is melted by the arc burning between the continuously fed metal powder, the molten metal is atomized by high-speed airflow, and the atomized metal particles are accelerated to spray them to the forming surface to form a conductive coating. Loop 21.
  • a plasma arc driven by direct current is used as a heat source to heat the conductive coating to a molten or semi-molten state, and spray it to the molding surface at a relatively high speed to form a conductive loop 21 with firm adhesion.
  • Thermal spraying includes flame spraying and electric arc spraying, the difference is that the material is melted by flame or electric arc.
  • Plasma spraying is a kind of arc spraying, and the plasma arc can generate a higher temperature to heat the metal powder.
  • the conductive paint can be metal powder or wire.
  • the conductive paint is metal powder
  • the conductive paint includes 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 its alloys, tin or One or more of its alloys, titanium or its alloys, zinc or its alloys, copper or its alloys, silver or its alloys, and gold or its alloys.
  • the conductive coating is non-metallic powder
  • the conductive coating includes one or a combination of conductive ceramics, carbon-containing conductors, solid electrolytes, mixed conductors, and conductive polymer materials.
  • the carbon-containing conductor is one or more of graphite powder, carbon nanotube material, and graphene material.
  • Step S40 may use the same process method as step S20, which will not be repeated here.
  • the material forming the insulating protective layer 40 is one of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene.
  • a combination of one or more types; step S30 uses one or more of coating, printing, spraying, dipping, and injection molding processes to form the insulating protection layer 40, so as to ensure the insulation protection effect of the insulating protection layer 40 on the conductive layer 30.
  • Step S10 includes cleaning the surface of the substrate 10 .
  • the way to clean the substrate 10 may be one or more of solution cleaning, ultrasonic cleaning, and high-pressure cleaning to remove oil, impurities and dirt.
  • step S05 is further included before step S10: an insulating layer is provided on the surface of the substrate 10, and the conductive circuit 21 is formed on the surface of the insulating layer.
  • the substrate 10 can be made of conductive material, the insulation between the conductive loops 21 can be ensured by pre-setting an insulating layer on the substrate 10 .
  • the insulating layer can be formed by one or more of coating, printing, spraying, dipping, and injection molding processes. In the case where the substrate 10 itself is an insulating material, no insulating layer may be provided.
  • the base plate 10 can adopt a profiling structure, so that the produced wire harness can be adapted to the application environment; the base plate 10 can use a flexible base plate 10, so that the produced wire harness can be applied to various installation situations, and it is convenient to apply to electrical appliances with complex installation environments. It is beneficial to reduce the interference of vibration factors and ensure the stability of use in environments with high vibration requirements.
  • the substrate 10 can be a component part of an electrical device, which can realize integrated production of parts and wire harnesses, and realize quick installation and disassembly of the wire harnesses.
  • the substrate 10 is a vehicle body component or a vehicle electrical component, and the conductive circuit 21 is integrated with the substrate 10.
  • the wiring harness can be replaced, which not only saves maintenance man-hours, but also reduces maintenance costs.
  • the inner liner of the car door can be used as the base plate 10 of the door harness, and the inner liner can be directly replaced during maintenance.
  • the substrate 10 can also be a body in white, a bumper, a car roof, a car door inner panel, a seat frame or various components of on-board electrical appliances.
  • the spraying process has the characteristics of large coverage, uniform thickness and strong adhesion, and is generally used for surface coating such as anti-corrosion and wear-resisting.
  • the production method of the wire harness adopts a spraying process to manufacture the conductive loop 21, which realizes adjustable width and thickness, and has a small coverage.
  • the production method of the wire harness includes step S15 and step S60, step S15 is implemented before step S20, step S60 is implemented before step S30; step S15, spraying the lower shielding layer on the substrate; step S60, insulated An upper shielding layer is sprayed on the periphery of the protective layer, the upper shielding layer is electrically connected to the lower shielding layer and the conductive loop 21 is closed.
  • the upper shielding layer and the lower shielding layer are connected through the shielding layer located on the side wall of the wiring harness, and the upper shielding layer, the lower shielding layer and the shielding layer located on the side wall of the wiring harness form a box structure and surround the conductive loop 21 .
  • the shielding structure is set outside the wiring harness, which can be located in a place where electromagnetic interference is relatively strong, so that the signal in the wiring harness can shield electromagnetic interference and ensure the stability of the signal.
  • the upper shielding layer is disposed above the uppermost conductive layer, that is, step S80 is performed before the last step S50 is performed.
  • the insulating layer is provided on the surface of the substrate
  • the lower shielding layer is provided above the insulating layer.
  • the shielding layer located on the side wall of the wiring harness can be formed by spraying or printing, or aluminum foil can be used.
  • the production method of the wire harness further includes a step S70 after the step S30 : crimping or welding a connection terminal at the terminal of the conductive loop 21 .
  • the electrical connection between different wire harnesses or between wire harnesses and electrical appliances is realized through the mutual insertion of connecting terminals.
  • the terminal of the conductive loop 21 is provided with a connecting terminal 211
  • the connecting terminal 211 can be a golden finger or a pin terminal, and wires can also be welded to connect with other electrical circuits.
  • the production method of the wire harness further includes step S80 after step S70: providing a sheath at the terminal end of the conductive loop 21, and the connecting terminal is accommodated in the sheath.
  • the contact connection of the connection terminals 211 in the sheath is realized through the mating of the sheaths.
  • a plurality of connection terminals 211 are arranged in one sheath, and two matching sheaths are connected to ensure the firmness of the connection.
  • the electrical connection of the connecting terminal 211 can be made more reliable and stable.
  • the production method of the wire harness further includes step S90 implemented after step S30, step S90: disposing a heat sink on the insulating protective layer, disposing a heat sink on the insulating protective layer, passing through the heat sink, and dissipating the wire harness current
  • step S90 disposing a heat sink on the insulating protective layer, disposing a heat sink on the insulating protective layer, passing through the heat sink, and dissipating the wire harness current
  • the generated heat is quickly dissipated into the air, which is beneficial to lowering the temperature of the wiring harness and reducing the risk of the conductive loop 21 being blown.
  • the present invention provides a nozzle 50, which is applied to the above wire harness production method, and the conductive paint is sprayed out through the nozzle 50. Adjusting the size or shape of the outlet 501 of the nozzle 50 can adjust the width and thickness of the section of the spraying conductive circuit 21 . As shown in FIG. 5 and FIG. 6 , the outlet 501 of the nozzle 50 is square. The discharge port 501 of the nozzle 50 is square, which is conducive to making the width and thickness of the cross section of the conductive circuit 21 uniform, ensuring the stability of the cross section, and avoiding more discharge in the middle of the cross section and less discharge in both sides during spraying. In the end, a conductive loop 21 with a cross section that is high in the middle and low on both sides is formed.
  • the size of the discharge port 501 of the nozzle 50 is adjustable, so as to adjust the width and thickness of the section of the conductive circuit 21 .
  • the nozzle 50 includes a nozzle body 51 and a movable side wall 52, the movable side wall 52 is connected to the nozzle body 51 through a hinge 53, and the movable side wall 52 is rotated around the center of the hinge 53 relative to the nozzle body 51 , adjust the installation angle of the movable side wall 52 to adjust the position of the lower end of the movable side wall 52 , so as to adjust the size of the discharge port 501 of the nozzle 50 .
  • the nozzle body 51 is connected with a motor 54, and the motor 54 shaft of the motor 54 is connected with a driving screw 55; a threaded hole is provided on the movable side wall 52, and the driving screw 55 is matched with the threaded hole.
  • the motor 54 drives the driving screw 55 to rotate, and the driving screw 55 drives the movable side wall 52 to rotate around the center of the hinge 53 to adjust the size of the discharge port 501 of the nozzle 50 .
  • the outlet 501 of the nozzle 50 is square, so that the size of the section of the conductive circuit 21 can be adjusted by adjusting the size of the outlet 501 .
  • the present invention provides a wire harness, which is produced by the above wire harness production method.
  • the wire harness includes: a substrate 10, at least one conductive circuit 21 and at least one insulating protective layer 40, and each conductive circuit 21 is located between the substrate 10 and the outermost Between the insulating protection layers 40 of the layers, the conductive loops 21 and the insulating protection layers 40 are alternately distributed.
  • the wiring harness is suitable for flexible production and small batch production, and has fast and convenient processing, high efficiency and reduced production cost.
  • the section width of the conductive loop 21 is 0.1 mm-68 mm.
  • the cross-sectional area of the conductor determines the current that the conductor can conduct.
  • the conductor that realizes the signal conduction has a small current and a small cross-sectional area.
  • the minimum cross-sectional area of the signal line of the automobile wiring harness can reach 0.1mm 2
  • the conductor for power supply conduction has a large current and a large cross-sectional area.
  • the maximum cross-sectional area of a car battery wiring harness reaches 260mm 2 .
  • the width of the conductive loop 21 is less than 0.1mm, in order to obtain a conductor with a cross - sectional area of 0.1mm, it is necessary to spray a conductive loop 21 with a thickness of at least 1mm. The smaller the width, the greater the thickness. In order to obtain a thicker thickness , multiple sprayings are required, which wastes man-hours and reduces processing efficiency. In addition, because the conductive loop 21 is too narrow, the strength cannot meet the requirements, and the layout of the wiring harness is also limited, and the height of the wiring harness cannot be reduced.
  • the width of the conductive loop 21 is greater than 68mm, in order to obtain a conductor with a cross - sectional area of 260mm, it is necessary to spray a conductor with a thickness of at least 3.82mm.
  • the larger the width, the smaller the thickness, but the smaller the thickness, the sprayed conductive loop 21 The larger the area, the smaller the footprint of the harness cannot be reduced.
  • the inventor selected the cross-sectional width of the conductive loop to be 0.1mm-68mm, and obtained conductors with different cross-sectional areas by printing the conductive loop 21 with different thicknesses.
  • the cross-sectional width of the conductive loop is 0.5mm-58mm
  • the aspect ratio of the printed conductive loop 21 is within a reasonable range
  • the thickness range is suitable for printing, and the occupied area will not be wasted. Therefore, the inventors prefer that the cross-sectional width of the conductive loop is 0.5mm-58mm.
  • the conductive coating includes conductive fillers, binders, solvents and additives
  • the conductive fillers include one or more of metal powder, conductive ceramics, carbon-containing conductors, solid electrolytes, mixed conductors, and conductive polymer materials. combination of species.
  • the carbon-containing conductor is one or a combination of graphite powder, carbon nanotube material, and graphene material.
  • the metal powder can be 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 its alloys, tin or its alloys, One or more of titanium or its alloys, zinc or its alloys, copper or its alloys, silver or its alloys and gold or its alloys, preferably, the most commonly used metal material for conductors is copper or copper alloys, because copper The electrical conductivity is the best among metals, and copper is not a precious metal, so it is easy to process and has good ductility. However, as the price of copper increases day by day, the material cost of using copper as a conductor will become higher and higher.
  • the material of the insulating protective layer 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 breakdown strength of the insulating protective layer 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).
  • Breakdown strength of the insulating protective layer is lower than 0.3KV/mm, some thinner insulating protective layers may be broken down under normal voltage, resulting in ineffective insulation.
  • the breakdown strength of the insulating protective layer is higher than 35KV/mm, since the high voltage higher than 35KV will not appear in the general vehicle environment, the selection of materials with too high breakdown strength will increase the cost of the integrated wiring harness assembly, resulting in design waste.
  • the insulating protective layer has a thickness of 0.03mm-5mm.
  • the thickness of the insulating protective layer is less than 0.03mm, which not only cannot ensure that the breakdown voltage of the insulating protective layer is higher than the working voltage, but also cannot guarantee the wear resistance of the insulating protective layer. After repeated scraping, the insulating protective layer will be damaged , Exposing the conductor will lead to leakage or short circuit, resulting in damage to the line and failure of the function.
  • the thickness of the insulating protective layer is equal to 5mm, the breakdown voltage, insulation resistance and wear resistance of the insulating protective layer can meet the requirements, but when the thickness is greater than 5mm, the thickness of the insulating protective layer is relatively large, and pores, collapse, etc.
  • the inventor chooses the thickness of the insulating protective layer to be 0.03mm-5mm.
  • the base plate 10 can adopt a profiling structure, so that the produced wire harness can be adapted to the application environment; the base plate 10 can use a flexible base plate 10, so that the produced wire harness can be applied to various installation situations, and it is convenient to apply to electrical appliances with complex installation environments. It is beneficial to reduce the interference of vibration factors and ensure the stability of use in environments with high vibration requirements.
  • the substrate 10 can be a component part of an electrical device, which can realize integrated production of parts and wire harnesses, and realize quick installation and disassembly of the wire harnesses.
  • the substrate 10 is a vehicle body component or a vehicle electrical component, and the conductive circuit 21 is integrated with the substrate 10.
  • the wiring harness can be replaced, which not only saves maintenance man-hours, but also reduces maintenance costs.
  • the inner liner of the car door can be used as the base plate 10 of the door harness, and the inner liner can be directly replaced during maintenance.
  • the substrate 10 can also be a body in white, a bumper, a car roof, a car door inner panel, a seat frame or various components of on-board electrical appliances.
  • the usual printed circuit board mainly functions as a circuit board, which is used to install electrical components and realize specific electrical functions.
  • the wiring harness is different from the usual printed circuit board, the wiring harness is used to conduct current and transmit signals, the terminal of the conductive loop 21 is provided with a connecting terminal 211, and the connecting terminal 211 can be a golden finger, a pin terminal or a welding wire, etc. , the connecting terminal 211 electrically connects the conductive loop 21 to a power source or an electrical device.
  • the automotive wiring harness is usually produced separately for the wiring harness factory.
  • the wires, terminals, sheaths, positioning parts, seals, brackets, etc. are processed and assembled together to form a complete wiring harness, and then delivered to the automobile factory. Assembled on the vehicle body, installation is more difficult, wastes manpower.
  • the wiring harness can be directly installed on the body sheet metal, the instrument panel or the electrical device, without setting the wiring harness separately, the wiring harness is also installed after the auto parts are installed, saving the man-hours of the car assembly and reducing at least 60% of manual operations.

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Abstract

本发明提供了一种线束的生产方法、喷嘴及线束，该线束的生产方法包括：步骤S10，制备基板；步骤S20，将导电涂料喷涂至所述基板上，形成导电回路；步骤S30，在所述导电回路的周围及表面形成绝缘保护层。通过本发明，缓解了对电器件进行电气连接的线束，生产工艺比较复杂、加工成本较高的技术问题。

Description

线束的生产方法、喷嘴及线束
相关申请
本申请要求专利申请号为CN202110875947.7、申请日为2021年07月30日、发明名称为“线束的生产方法、喷嘴及线束”的中国发明专利的优先权。
技术领域
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、喷嘴及线束。
背景技术
电气连接需使用线束来实现。现有的线束主要由电线、端子、护套、定位件和支架等零件构成，零件繁多，结构比较复杂。线束中的电线，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。现有线束的生产方式大多采用集中批量生产的模式。
部分批量小、产品种类多的线束产品，柔性化生产要求较高，无法实现批量生产；这类线束，只能通过人工和临时工装来生产制作，加工周期比较长，并且提高了生产成本。
发明内容
本发明的目的是提供一种线束的生产方法、喷嘴及线束，以缓解对电器件进行电气连接的线束，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，所述线束的生产方法包括：步骤S10，制备基板；步骤S20，将导电涂料喷涂至所述基板上，形成导电回路；步骤S30，在所述导电回路的周围及表面形成绝缘保护层。
本发明提供一种喷嘴，所述喷嘴应用于上述的线束的生产方法，所述喷嘴的出料口为方形。
本发明提供一种线束，采用上述的线束的生产方法生产，所述线束包括：基板、至少一层导电回路和至少一层绝缘保护层，各个所述导电回路均位于所述基板与最外层的 所述绝缘保护层之间，所述导电回路与所述绝缘保护层交替分布。
本发明的特点及优点是：
该线束的生产方法采用喷涂的方式，在基板上形成导电回路，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；并通过绝缘保护层进行绝缘保护，从而实现线束回路快速成型。该线束的生产方法具有以下优点：
(1)采用喷涂方式生产的线束，柔性化生产程度高，加工快速方便，效率较高，成本远小于现有小批量线束的生产模式；
(2)可以采用多层喷涂，可以在基板面积较小的条件下，制备较多的导电回路，满足电气回路较多的要求；
(3)可以采用打孔和灌注导电材料的方式，可以使不同层的导电回路进行电气连接，实现比较复杂的电气回路的设计方案，能够适用于更加复杂的线束；
(4)导电回路的截面面积，可以通过调整喷涂参数进行调整，适用于多线径的回路加工，便于对导电回路的导电性能进行调控；
(5)采用伺服机构或机械手控制喷嘴的轨迹，便于加工实现空间结构复杂的线束；并且保障喷涂稳定，导电回路的尺寸均匀；
(6)绝缘保护层的材料选择比较多样，可以采用多种工艺方式实现绝缘保护，保障绝缘保护效果；
(7)基板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；
(8)可以采用仿形的基板，可以在不是平面的基板上进行喷涂，增大了喷涂线束的应用环境；
(9)可以使用柔性基板，使喷涂线束可以适用多种安装情况；所生产的线束可以应用于安装环境复杂的电器上，还可以使用在振动要求较高的环境中，减小振动因素的干扰；
(10)线束损坏时，可以直接更换损坏的基板，而不需要将整根线束拆除更换，既节省的维修工时，也减少了维修的成本；
(11)线束外设置屏蔽层，可以在电磁干扰比较强烈的位置，可以使线束内的信号能够屏蔽电磁干扰，保证信号的稳定；
(12)在绝缘保护层上设置散热片，能够将线束电流产生的热量快速散发到空气中，有利于降低线束的温度，降低导电回路熔断的风险。
附图说明
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-图4为本发明提供的线束的生产方法生产的线束的结构示意图；
图5-图6为本发明提供的线束的生产方法中的喷嘴的结构示意图；
图7为本发明提供的线束的生产方法生产的线束一种实施方式的俯视图；
图8为本发明提供的线束的生产方法生产的线束一种实施方式的侧向剖视图；
图9为本发明提供的线束的生产方法生产的线束另一种实施方式的俯视图；
图10为本发明提供的线束的生产方法生产的线束另一种实施方式的侧向剖视图。
具体实施方式
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和图2所示，该线束的生产方法包括：步骤S10，制备基板10；步骤S20，将导电涂料喷涂至基板10上，形成导电回路21；步骤S30，在导电回路21的周围及表面形成绝缘保护层40。
该线束的生产方法采用喷涂的方式，在基板10上形成导电回路21，导电回路21可以与外部的电器件连接，实现线束的电气连接功能；并通过绝缘保护层40进行绝缘保护，从而实现线束回路快速成型。该线束的生产方法采用喷涂方式来生产线束，柔性化生产程度高，加工快速方便，效率较高，降低了生产成本，适用于小批量线束的生产。
在一实施方式中，该线束的生产方法包括在步骤S30之后实施的步骤S40，步骤S40：将导电涂料喷涂至绝缘保护层40上，形成导电回路21；并且，步骤S40与步骤S30依次地交替实施一次或者多次。步骤S20在基板10上形成一个导电层30；步骤S40实施一次，可以在已成型的导电回路21和绝缘保护层40上再形成一个导电层30。通过步骤S40与步骤S30交替实施，在基板10之上构造出多个导电层30，形成多层结构。采用多层喷涂，形成多个导电层30，实现在基板10面积较小的条件下，制备较多的导电回 路21，满足电气回路较多的要求。
图3和图4为该线束的生产方法所生产的线束的示意图，图3所示的线束为单层结构，图4所示的线束为双层结构。一个导电层30可以包括多个导电回路21；多层结构的线束中，各个导电层30中的导电回路21的数量和结构可以相同，也可以不相同。
进一步地，该线束的生产方法包括步骤S50，步骤S50：对绝缘保护层40和/或导电回路21打孔，并灌注导电材料，形成对至少两层导电回路21进行电连接的连通回路22。采用打孔和灌注导电材料的方式，可以使不同层的导电回路21进行电气连接，实现比较复杂的电气回路的设计方案，能够适用于更加复杂的线束。
在一实施方式中，该线束的生产方法所生产的线束包括多个导电层30，对相邻两个导电层30之间的绝缘保护层40进行打孔，并灌注导电材料，形成连通回路22，该连通回路22将相邻两个导电层30的导电回路21连通。
在一实施方式中，该线束的生产方法所生产的线束包括至少三个导电层30，至少三个导电层30包括上导电层31、中导电层32和下导电层33；设置贯穿中导电层32的连通回路22，并且该连通回路22分别与上导电层31和下导电层33连通。在一些情况下，连通回路22穿过中导电层32的导电回路21且与该导电回路21连通，从将上导电层31、中导电层32和下导电层33同时连通。在另一些情况下，连通回路22经未设置导电回路21的区域穿过中导电层32，该连通回路22将上导电层31和下导电层33连通，且避开了中导电层32的导电回路21，避免与其连通。
在一些实施方式中，连通回路22连通的两个导电层30中间具有一个或者多个导电层30，且需避免与中间的一个或者多个导电层30连通。可以对中间的导电层30中的导电回路21进行改善，例如，导电回路21沿曲线或者折线延伸，以避开打孔设置连通回路22的位置。还可以将连通回路22设置为沿折线或者曲线延伸，以避开中间的一个或者多个导电层30。
可以在各个导电层30均成型之后，再进行打孔和灌注导电材料；也可以边成型导电层30和绝缘保护层40，边进行打孔和灌注导电材料，例如，成型完一个导电层30或一层绝缘保护层40后，即对该层进行打孔和灌注导电材料，形成连通回路22，然后继续成型下一个导电层30或绝缘保护层40。一些情况下，中间的导电层30中的导电回路21比较密集，难以通过改善导电回路21的方式，使连通回路22避开中间的导电层30中的导电回路21。为此，发明人对该线束的生产方法及其生产的线束，做了进一步的改进。
如图7和图8所示，该线束包括上导电层31、中导电层32和下导电层33，上导电层31中的导电回路21分别连接有导电凸起部23，导电凸起部23偏离中导电层32中的导电回路21，连通回路22分别与上导电层31中的导电凸起部23和下导电层33中的导电凸起部23连通，且避开了中导电层32中的导电回路21，从而实现将上导电层31与下导电层33连通且避免与中导电层32连通。
如图9和图10所示，该线束包括上导电层31、中导电层32和下导电层33，步骤S50的打孔位置正对上导电层31的导电回路21、下导电层33的导电回路21和中导电层32的导电回路21，所打的孔贯穿中导电层32的导电回路21；该孔中设置有绝缘套342，绝缘套342位于中导电层32且将中导电层32的导电回路21隔开；在该孔和绝缘套342中灌注导电材料，可以避免连通回路22与中导电层32连通。
进一步地，如图10所示，步骤S50所打的孔为阶梯孔341，该阶梯孔341位于下导电层33的部分内径较小，以方便设置绝缘套342，该阶梯孔341的阶梯部可以对绝缘套342起到支撑作用。
调整导电回路21的截面面积，例如调整导电回路21的厚度或宽度，可以实现对导电回路21的导通电流的大小进行调整。该线束的生产方法中，导电回路21的截面面积可以通过步骤S20中调整喷涂参数来进行调整。根据导电回路21要求的导通电流的大小，构造适合的导电回路21的厚度或宽度，该线束的生产方法，适用于多线径的回路加工，便于对导电回路21的导电性能进行调控。
在一实施方式中，步骤S20和步骤S40分别使用喷嘴50，导电涂料经喷嘴50向外喷出。通过使用尺寸或者形状不同的喷嘴50，可以调整喷导电回路21的截面的宽度和厚度。
进一步地，喷嘴50的出料口501为方形，有利于使导电回路21的截面的宽度、厚度均匀，保障截面的稳定，避免在喷涂时，出现截面的中间位置出料多、两侧位置出料少，最终形成截面的中间高、两侧低的导电回路21的情况。
在一实施方式中，喷嘴50的出料口501的大小为可调节的，以调整喷导电回路21的截面的宽度和厚度。如图5和图6所示，喷嘴50包括喷嘴本体51和活动侧壁52，活动侧壁52通过铰链53连接于喷嘴本体51，通过使活动侧壁52相对于喷嘴本体51绕铰链53中心转动，调整活动侧壁52的安装角度，以调整活动侧壁52的下端的位置，从而对喷嘴50的出料口501的大小实现调节。
具体地，喷嘴本体51连接有电机54，电机54的电机54轴与驱动螺杆55连接；活 动侧壁52上设置螺纹孔，驱动螺杆55与螺纹孔配合。电机54带动驱动螺杆55转动，驱动螺杆55带动活动侧壁52绕铰链53中心转动，以调整喷嘴50的出料口501的大小。喷嘴50的出料口501为方形，便于通过调节出料口501大小来调整导电回路21的截面大小。
调整喷嘴50的喷涂距离，例如调整喷嘴50到基板10的距离，也可以实现对导电回路21的截面的宽度和厚度进行调整。调整喷涂速度，即调整喷嘴50移动的速度，也可以实现对导电回路21的截面的宽度和厚度进行调整。优选地，喷涂距离为5mm～100mm，喷涂速度为0.1mm/s～100mm/s，可以避免喷涂材料过于分散，且避免导电回路21的轨迹断裂，保障导电性能。
喷嘴50可以安装到伺服机构上或机械手上，伺服机构或机械手带动喷嘴50在空间内运动，沿各个角度进行导电回路21的喷涂，形成空间结构的线束，便于加工实现空间结构复杂的线束；并且保障喷涂稳定，保持导电回路21的尺寸均匀。进一步地，喷嘴50安装于三轴伺服机构或者六轴机械手。
具体地，三轴伺服机构的X向、Y向、Z向各设置一个移动导轨，各个方向的移动分别由伺服电机54驱动，在程序控制下实现三维立体加工轨迹，喷涂形成空间轨迹的导电回路21。六轴机械手可以带动喷嘴50更加灵活地运动，喷涂形成更加复杂的空间轨迹的导电回路21。
在一实施方式中，步骤S20所形成的一层导电层30包括多根导电回路21，以制备较多的导电回路21。同一层的导电层30中，多根导电回路21之间相断开或者相电连接。例如：同一层的导电层30中的各根导电回路21均相断开；同一层的导电层30中，至少两根导电回路21相电连接。根据要实现的电气连接功能，对各层导电层30中的导电回路21进行设置。
在一实施方式中，步骤S20采用高压无气喷涂、静电喷涂或空气喷涂的方式，将与黏合剂混合的导电涂料喷涂至基板10上。导电涂料与黏合剂形成涂料，被喷涂至成型面，涂料固化形成导电回路21。具体地，采用空气喷涂的情况下，利用压缩空气将涂料雾化进行喷涂。采用高压无气喷涂的情况下，将涂料经加压泵加压至9.8MPa～29.4MPa的压力，然后通过橄榄形喷嘴50小孔喷出。高压的涂料冲出喷嘴50进入大气时，立即剧裂膨胀并碎裂为极细的雾状，直接喷射至基板10或已成型的绝缘保护层40的表面。高压无气喷涂中，涂料通过高压泵被增压至高压，本身并不与压缩空气混合。采用静电喷涂的情况下，利用电晕放电原理使雾化涂料在高压直流电场作用下荷负电，并吸附于 荷正电基底表面放电，静电喷涂设备包括喷枪、喷杯以及静电喷涂高压电源。优选地，涂料中还混合有溶剂及添加剂。导电涂料可以是铜、铝、金、银、石墨等粉末的一种或者多种；黏合剂包括环氧树脂、聚酯类树脂、丙烯酸类树脂、聚酰胺类树脂、改性酚醛树脂以及纤维素类树脂中的至少一种。
在一实施方式中，导电涂料包括金属材料，步骤S20采用热喷涂、电弧喷涂或等离子喷涂的方式，将熔融的导电涂料喷涂至基板10上。具体地，采用热喷涂的情况下，将涂料加热熔化，用高速气流将其雾化成极细的颗粒，并以很高的速度喷射到成型面，涂料固化形成涂层。采用电弧喷涂的情况下，利用燃烧于连续送料的金属粉末之间的电弧来熔化金属，用高速气流把熔化的金属雾化，并对雾化的金属粒子加速使它们喷向成型面，形成导电回路21。采用等离子喷涂的情况下，采用由直流电驱动的等离子电弧作为热源，将导电涂料加热到熔融或半熔融状态，并以较高速度喷向成型面，形成附着牢固的导电回路21。热喷涂包括火焰喷涂和电弧喷涂，区别是采用火焰还是电弧对材料进行熔化。等离子喷涂是电弧喷涂的一种，等离子弧可以产生较高的温度，来对金属粉末进行加热。导电涂料可以是金属粉末或者金属丝。
导电涂料为金属粉末的情况下，导电涂料包括有镍或其合金、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者多种的组合。导电涂料为非金属粉末的情况下，导电涂料包括导电陶瓷、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。其中，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。
步骤S40可以采用与步骤S20相同的工艺方法，在此不再赘述。
在一实施方式中，形成绝缘保护层40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；步骤S30采用涂覆、印刷、喷涂、浸镀、注塑工艺的一种或几种形成绝缘保护层40，以保障绝缘保护层40对导电层30的绝缘保护效果。
步骤S10包括对基板10的表面进行清洁。基板10清洁的方式，可以是溶液冲清洗、超声波清洗、高压冲洗方式的一种或几种，以去除油污、杂质和污垢。
在一实施方式中，还包括在步骤S10之前的步骤S05：基板10的表面设置绝缘层，导电回路21形成于绝缘层的表面。基板10可以为导电材质时，通过预先在基板10上设置绝缘层，可以保障导电回路21之间的绝缘。绝缘层可以采用涂覆、印刷、喷涂、 浸镀、注塑工艺的一种或几种来成型。在基板10本身为绝缘材料的情况下，可以不设置绝缘层。
基板10可以采用仿形结构，以便于生产的线束与应用环境相适配；基板10可以使用柔性基板10，使生产的线束可以适用多种安装情况，便于应用于安装环境复杂的电器上，有利于减小振动因素的干扰，保障在振动要求较高的环境中使用的稳定性。基板10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。例如，基板10为车身部件或车载电器的部件，导电回路21与基板10为一体结构，通过更换基板10，即可实现对线束进行更换，既节省的维修工时，也减少了维修的成本。例如，车门的内衬板可以作为门线束的基板10，维修时可以直接更换内衬板。基板10还可以是白车身、保险杠、车顶棚、车门内板，座椅骨架或者各种车载电器的部件。
通常情况下，喷涂工艺具有覆盖面大、厚度均匀、附着力强的特点，一般用于防腐、耐磨等表面涂覆。该线束的生产方法采用喷涂工艺来制作导电回路21，实现了宽度、厚度可调整，且覆盖面较小。
在一实施方式中，该线束的生产方法包括步骤S15和步骤S60，步骤S15在步骤S20之前实施，步骤S60在步骤S30之前实施；步骤S15，在基板上喷涂下屏蔽层；步骤S60，在绝缘保护层外围，喷涂上屏蔽层，上屏蔽层与下屏蔽层电性连接并将导电回路21封闭。
上屏蔽层与下屏蔽层通过位于线束的侧壁的屏蔽层连接，上屏蔽层、下屏蔽层与位于线束的侧壁的屏蔽层形成箱体结构，对导电回路21形成包围。线束外设置屏蔽结构，可以在电磁干扰比较强烈的位置，可以使线束内的信号能够屏蔽电磁干扰，保证信号的稳定。
在该线束包括多个导电层的情况下，上屏蔽层设于最上层的导电层的上方，即步骤S80在最后一次实施的步骤S50之前实施。在基板的表面设有绝缘层的情况下，下屏蔽层设于绝缘层的上方。位于线束的侧壁的屏蔽层，可以采用喷涂或者印刷的方式成型，也可以采用铝箔。
在一实施方式中，该线束的生产方法还包括在步骤S30之后的步骤S70：在导电回路21的终端压接或焊接连接端子。通过连接端子的互插，实现不同线束之间，或者线束与用电器之间的电气连接。
如图4所示，导电回路21的终端设置连接端子211，连接端子211可以为金手指或 插针端子，还可以焊接电线，以与其他电器回路进行连接。
进一步地，该线束的生产方法还包括在步骤S70之后的步骤S80：在导电回路21的终端设置护套，连接端子容纳在护套内。通过护套的对插，实现护套内连接端子211的接触连接，在一些情况下，一个护套内设置多个连接端子211，两个相配合的护套相连接，保障连接的牢固性，可以使连接端子211的电连接更加可靠稳定。
在一实施方式中，该线束的生产方法还包括在步骤S30之后实施的步骤S90，步骤S90：在绝缘保护层上设置散热片，在绝缘保护层上设置散热片，通过散热片，将线束电流产生的热量快速散发到空气中，有利于降低线束的温度，降低导电回路21熔断的风险。
实施例二
本发明提供了一种喷嘴50，应用于上述的线束的生产方法，导电涂料经喷嘴50向外喷出。调整喷嘴50的出料口501的尺寸或者形状，可以调整喷导电回路21的截面的宽度和厚度。如图5和图6所示，喷嘴50的出料口501为方形。喷嘴50的出料口501为方形，有利于使导电回路21的截面的宽度、厚度均匀，保障截面的稳定，避免在喷涂时，出现截面的中间位置出料多、两侧位置出料少，最终形成截面的中间高、两侧低的导电回路21的情况。
在一实施方式中，喷嘴50的出料口501的大小为可调节的，以调整喷导电回路21的截面的宽度和厚度。如图5和图6所示，喷嘴50包括喷嘴本体51和活动侧壁52，活动侧壁52通过铰链53连接于喷嘴本体51，通过使活动侧壁52相对于喷嘴本体51绕铰链53中心转动，调整活动侧壁52的安装角度，以调整活动侧壁52的下端的位置，从而对喷嘴50的出料口501的大小实现调节。
具体地，喷嘴本体51连接有电机54，电机54的电机54轴与驱动螺杆55连接；活动侧壁52上设置螺纹孔，驱动螺杆55与螺纹孔配合。电机54带动驱动螺杆55转动，驱动螺杆55带动活动侧壁52绕铰链53中心转动，以调整喷嘴50的出料口501的大小。喷嘴50的出料口501为方形，便于通过调节出料口501大小来调整导电回路21的截面大小。
实施例三
本发明提供了一种线束，采用上述的线束的生产方法生产，该线束包括：基板10、至少一层导电回路21和至少一层绝缘保护层40，各个导电回路21均位于基板10与最外层的绝缘保护层40之间，导电回路21与绝缘保护层40交替分布。该线束适应于柔 性化生产和小批量生产，加工快速方便，效率较高，降低了生产成本。
在一实施方式中，导电回路21的截面宽度为0.1mm-68mm。在线束中，导体的截面积决定导体所能导通的电流，一般情况下，实现信号导通的导体，电流较小，导体截面积也较小，例如汽车线束的信号线最小截面积可达到0.1mm 2，而实现电源导通的导体，电流较大，导体截面积也较大，例如汽车蓄电池线束，最大截面积达到260mm 2。
当导电回路21的宽度小于0.1mm时，为了能获得截面积为0.1mm 2的导体，就要喷涂出厚度至少为1mm的导电回路21，宽度越小，厚度越大，为了获得较厚的厚度，还需要进行多次喷涂，浪费工时，降低加工效率，另外，导电回路21由于太窄，强度不能满足要求，而且也使线束的布局受到限制，无法缩小线束的高度。
当导电回路21宽度大于68mm时，为了能获得截面积为260mm 2的导体，就要喷涂出厚度至少为3.82mm的导体，宽度越大，厚度越小，但是厚度越小，喷涂的导电回路21面积越大，无法缩小线束的占用面积。
因此，发明人选择导电回路的截面宽度为0.1mm-68mm，通过印刷不同厚度的导电回路21，从而获得不同截面积的导体。
经过发明人多次实验获得，当导电回路的截面宽度为0.5mm-58mm时，印刷的导电回路21的高宽比在比较合理的范围内，厚度范围适合印刷加工，占用面积也不会浪费，因此，发明人优选导电回路的截面宽度为0.5mm-58mm。
在一实施方式中，导电涂料包括导电性填料、黏合剂、溶剂和添加剂，导电性填料包括金属粉末、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，金属粉末可以采用镍或其合金、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，优选地，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，绝缘保护层的材质为聚氯乙烯、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，绝缘保护层的击穿强度为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。当绝缘保护层的击穿强度低于0.3KV/mm，有部分较薄绝缘保护层在正常电压下就有可能被击穿，从而导致绝缘无效。当绝缘保护层的击穿强度高于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，绝缘保护层的厚度为0.03mm-5mm。绝缘保护层的厚度低于0.03mm，不仅不能够保证绝缘保护层的击穿电压高于工作电压，也不能保证绝缘保护层的耐磨性能，在多次刮磨后，会使绝缘保护层破损，露出导体，会导致漏电或短路的情况，造成线路损坏，功能失效。绝缘保护层厚度等于5mm时，绝缘保护层的击穿电压、绝缘电阻和耐磨性能都能满足要求，但是厚度大于5mm时，绝缘保护层厚度较大，在加工过程中或出现气孔、塌陷等问题点，降低了绝缘保护层的性能，另外，也浪费绝缘保护层材料，并且增加了加工的工序和时间，因此，发明人选用绝缘保护层的厚度为0.03mm-5mm。
基板10可以采用仿形结构，以便于生产的线束与应用环境相适配；基板10可以使用柔性基板10，使生产的线束可以适用多种安装情况，便于应用于安装环境复杂的电器上，有利于减小振动因素的干扰，保障在振动要求较高的环境中使用的稳定性。基板10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。例如，基板10为车身部件或车载电器的部件，导电回路21与基板10为一体结构，通过更换基板10，即可实现对线束进行更换，既节省的维修工时，也减少了维修的成本。例如，车门的内衬板可以作为门线束的基板10，维修时可以直接更换内衬板。基板10还可以是白车身、保险杠、车顶棚、车门内板，座椅骨架或者各种车载电器的部件。
通常的印刷电路板主要起到电路板的作用，用来安装电气元件，实现特定的电气功能。该线束不同于通常的印刷电路板，该线束是起到导通电流和传递信号的作用，导电回路21的终端设置有连接端子211，连接端子211可以为金手指、插针端子或焊接电线等，连接端子211将导电回路21电与电源或用电装置连接起来。
目前，汽车线束通常为为线束厂单独生产，将电线、端子、护套、定位件、密封件、 支架等加工并组装在一起，形成完整线束，再交付给汽车厂，在汽车总装时分工位装配到车身上，安装比较困难，浪费人工。
该线束可以直接设置在车身钣金上、仪表盘上或用电装置上，不用单独设置线束，汽车零件安装完成，线束也就安装完成，节省汽车总装工时，减少至少60％的人工操作。
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)

  1. 一种线束的生产方法，其中，所述线束的生产方法包括：
    步骤S10，制备基板；
    步骤S20，将导电涂料喷涂至所述基板上，形成导电回路；
    步骤S30，在所述导电回路的周围及表面形成绝缘保护层。
  2. 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S30之后实施的步骤S40，所述步骤S40：将导电涂料喷涂至所述绝缘保护层上，形成导电回路；
    并且，所述步骤S40与所述步骤S30依次地交替实施一次或者多次。
  3. 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：
    步骤S50，对所述绝缘保护层和/或所述导电回路打孔，并灌注导电材料，形成对至少两层所述导电回路进行电连接的连通回路。
  4. 如权利要求1或2所述的线束的生产方法，其中，所述线束的生产方法包括：
    步骤S15，在所述基板上喷涂下屏蔽层；
    步骤S60，在所述绝缘保护层外围，喷涂上屏蔽层，所述上屏蔽层与所述下屏蔽层电性连接并将所述导电回路封闭；
    所述步骤S15在所述步骤S20之前实施，所述步骤S60在所述步骤S30之前实施。
  5. 如权利要求1所述的线束的生产方法，其中，所述步骤S20使用喷嘴，所述喷嘴的出料口为方形。
  6. 如权利要求5所述的线束的生产方法，其中，所述喷嘴安装于三轴伺服机构或者六轴机械手。
  7. 如权利要求1所述的线束的生产方法，其中，所述步骤S20采用高压无气喷涂、静电喷涂或空气喷涂的方式，将与黏合剂混合的导电涂料喷涂至所述基板上。
  8. 如权利要求1所述的线束的生产方法，其中，所述导电涂料包括金属材料，所述步骤S20采用热喷涂、电弧喷涂或等离子喷涂的方式，将熔融的导电涂料喷涂至所述基板上。
  9. 如权利要求1所述的线束的生产方法，其中，所述步骤S20所形成的一层导电层包括多根所述导电回路；同一层的所述导电层中，多根所述导电回路之间相断开或者相电连接。
  10. 如权利要求1所述的线束的生产方法，其中，还包括在步骤S10之前的步骤S05： 所述基板的表面设置绝缘层，所述导电回路形成于所述绝缘层的表面。
  11. 如权利要求1所述的线束的生产方法，其中，还包括在步骤S30之后的步骤S70：在所述导电回路的终端压接或焊接连接端子。
  12. 如权利要求11所述的线束的生产方法，其中，还包括在步骤S70之后的步骤S80：在所述导电回路的终端设置护套，所述连接端子容纳在所述护套内。
  13. 如权利要求1或2所述的线束的生产方法，其中，还包括在步骤S30之后的步骤S90：在所述绝缘保护层上设置散热片。
  14. 如权利要求1所述的线束的生产方法，其中，所述步骤S30采用涂覆、印刷、喷涂、浸镀、注塑工艺的一种或几种形成所述绝缘保护层。
  15. 一种喷嘴，其中，所述喷嘴应用于权利要求1-14中任一项所述的线束的生产方法，所述喷嘴的出料口为方形。
  16. 一种线束，其中，采用权利要求1-14中任一项所述的线束的生产方法生产，所述线束包括：基板、至少一层导电回路和至少一层绝缘保护层，各个所述导电回路均位于所述基板与最外层的所述绝缘保护层之间，所述导电回路与所述绝缘保护层交替分布。
  17. 如权利要求16所述的线束，其中，所述导电回路的截面宽度为0.1mm-68mm。
  18. 如权利要求16所述的线束，其中，所述导电回路的截面宽度为0.5mm-58mm。
  19. 如权利要求16所述的线束，其中，所述导电涂料包括导电性填料、黏合剂、溶剂和添加剂，所述导电性填料包括金属粉末、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。
  20. 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。
  21. 如权利要求19所述的线束，其中，所述金属粉末采用镍或其合金、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。
  22. 如权利要求16所述的线束，其中，所述绝缘保护层的材质为聚氯乙烯、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。
  23. 如权利要求16所述的线束，其中，所述绝缘保护层的击穿强度为0.3KV/mm-35KV/mm。
  24. 如权利要求16所述的线束，其中，所述绝缘保护层的厚度为0.03mm-5mm。
PCT/CN2022/105976 2021-07-30 2022-07-15 线束的生产方法、喷嘴及线束 WO2023005691A1 (zh)

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