WO2023006078A1 - 制造线束的方法及线束 - Google Patents
制造线束的方法及线束 Download PDFInfo
- Publication number
- WO2023006078A1 WO2023006078A1 PCT/CN2022/108998 CN2022108998W WO2023006078A1 WO 2023006078 A1 WO2023006078 A1 WO 2023006078A1 CN 2022108998 W CN2022108998 W CN 2022108998W WO 2023006078 A1 WO2023006078 A1 WO 2023006078A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- wire harness
- manufacturing
- metal sheet
- insulating layer
- conductors
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 103
- 239000004020 conductor Substances 0.000 claims abstract description 131
- 229910052751 metal Inorganic materials 0.000 claims abstract description 112
- 239000002184 metal Substances 0.000 claims abstract description 112
- 238000000034 method Methods 0.000 claims abstract description 80
- 239000000463 material Substances 0.000 claims abstract description 23
- 229910045601 alloy Inorganic materials 0.000 claims description 40
- 239000000956 alloy Substances 0.000 claims description 40
- 238000001035 drying Methods 0.000 claims description 16
- 230000008569 process Effects 0.000 claims description 16
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 14
- 239000010949 copper Substances 0.000 claims description 12
- 229910052802 copper Inorganic materials 0.000 claims description 12
- 230000015556 catabolic process Effects 0.000 claims description 11
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 10
- 238000001816 cooling Methods 0.000 claims description 10
- 238000005452 bending Methods 0.000 claims description 8
- 238000005266 casting Methods 0.000 claims description 8
- 238000005242 forging Methods 0.000 claims description 8
- 238000009413 insulation Methods 0.000 claims description 8
- -1 polypropylene Polymers 0.000 claims description 8
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 6
- 238000001125 extrusion Methods 0.000 claims description 6
- 238000005096 rolling process Methods 0.000 claims description 6
- 238000007598 dipping method Methods 0.000 claims description 5
- 239000011261 inert gas Substances 0.000 claims description 5
- 229910052757 nitrogen Inorganic materials 0.000 claims description 5
- 238000003466 welding Methods 0.000 claims description 5
- 239000004677 Nylon Substances 0.000 claims description 4
- 239000004698 Polyethylene Substances 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 238000004140 cleaning Methods 0.000 claims description 4
- 238000002788 crimping Methods 0.000 claims description 4
- 239000004703 cross-linked polyethylene Substances 0.000 claims description 4
- 229920003020 cross-linked polyethylene Polymers 0.000 claims description 4
- 229920001778 nylon Polymers 0.000 claims description 4
- 229920000573 polyethylene Polymers 0.000 claims description 4
- 229920000098 polyolefin Polymers 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 229920002635 polyurethane Polymers 0.000 claims description 4
- 239000004814 polyurethane Substances 0.000 claims description 4
- 229920003225 polyurethane elastomer Polymers 0.000 claims description 4
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 4
- 239000004800 polyvinyl chloride Substances 0.000 claims description 4
- 229920002379 silicone rubber Polymers 0.000 claims description 4
- 239000004945 silicone rubber Substances 0.000 claims description 4
- 229920003051 synthetic elastomer Polymers 0.000 claims description 4
- 239000005061 synthetic rubber Substances 0.000 claims description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 3
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 3
- 229910052793 cadmium Inorganic materials 0.000 claims description 3
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 239000011651 chromium Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 229910017052 cobalt Inorganic materials 0.000 claims description 3
- 239000010941 cobalt Substances 0.000 claims description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 3
- 238000005553 drilling Methods 0.000 claims description 3
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052737 gold Inorganic materials 0.000 claims description 3
- 239000010931 gold Substances 0.000 claims description 3
- 238000001746 injection moulding Methods 0.000 claims description 3
- 229910052748 manganese Inorganic materials 0.000 claims description 3
- 239000011572 manganese Substances 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 229910052709 silver Inorganic materials 0.000 claims description 3
- 239000004332 silver Substances 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 239000010936 titanium Substances 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 229910052725 zinc Inorganic materials 0.000 claims description 3
- 239000011701 zinc Substances 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
- 238000004804 winding Methods 0.000 claims description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims 1
- 239000005977 Ethylene Substances 0.000 claims 1
- 238000012545 processing Methods 0.000 abstract description 9
- 230000009467 reduction Effects 0.000 abstract description 7
- 239000010410 layer Substances 0.000 description 119
- 239000011888 foil Substances 0.000 description 10
- 238000010586 diagram Methods 0.000 description 7
- 230000005855 radiation Effects 0.000 description 6
- 238000005520 cutting process Methods 0.000 description 5
- 238000003672 processing method Methods 0.000 description 4
- 238000004080 punching Methods 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 238000007605 air drying Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 230000017525 heat dissipation Effects 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229910000881 Cu alloy Inorganic materials 0.000 description 2
- 238000002679 ablation Methods 0.000 description 2
- 239000000110 cooling liquid Substances 0.000 description 2
- 239000011889 copper foil Substances 0.000 description 2
- 230000005684 electric field Effects 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 239000011241 protective layer Substances 0.000 description 2
- 238000012797 qualification Methods 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 238000010297 mechanical methods and process Methods 0.000 description 1
- 230000005226 mechanical processes and functions Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 238000007790 scraping Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 230000008054 signal transmission Effects 0.000 description 1
- 238000004506 ultrasonic cleaning Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
-
- 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 present application relates to the technical field of electrical connection, in particular to a method for manufacturing a wire harness and the wire harness.
- the wire harness used for electrical connection is processed and assembled from parts such as wires, terminals, sheaths, positioning parts and brackets.
- the manufacturing process is complicated, especially for wire harnesses using small-diameter wires.
- the production cost of wiring harness is high, the defect rate is also high, and the degree of automation is low.
- the wire harness production industry urgently needs a wire harness production method with a high degree of production automation and low cost.
- the present application provides a method for manufacturing a wire harness and the wire harness, so as to solve the problems of low degree of automation and high production cost of the current wire harness production.
- the embodiment of the first aspect of the present application provides a method for manufacturing a wire harness, which includes: step S110: providing a metal sheet; step S120: performing subtractive treatment on the metal sheet, so that the metal sheet has a predetermined At least one conductor of the conductive trace; step S130: forming an insulating layer on the conductor.
- the method for manufacturing a wire harness is used to manufacture a wire harness with n layers of conductors, where n is a positive integer greater than 1, and the method for manufacturing a wire harness further includes: step S100 before step S110: laying Insulating layer; step S140 after the step S130: (n-1) repeatedly execute the steps S110 to S130 until a wire harness with n layers of conductors is obtained; wherein, in each execution of the step S130 , the forming an insulating layer on the conductor is: laying an insulating layer on the previously formed conductor; in each execution of the step S110, the providing a metal sheet is: providing a metal sheet to on the previously laid insulation.
- the method for manufacturing a wire harness is used to manufacture a wire harness with n layers of conductors, where n is a positive integer greater than 1, and the method for manufacturing a wire harness further includes: after the step S110, the step S120 The previous step S115: fixing the metal sheet; the step S125 after the step S120 and before the step S130: repeating the steps S110 to S120 for (n-1) times until an n-layer conductor is formed; , the step S115 performed repeatedly each time includes: maintaining an insulating gap between the metal sheet fixed this time and the metal sheet fixed last time; in the step S130, forming an insulating gap on the conductor layer, which is to form an insulating layer on all of said conductor surfaces and all of said insulating gaps.
- the provided metal sheet is a metal sheet with a preset shape
- the preset shape is a planar shape or a curved surface shape.
- the predetermined shape is a curved shape
- the curved metal sheet is formed by forging, rolling, bending, stamping, extrusion or integral casting.
- the method for manufacturing a wire harness further includes: after step S125 and before step S130, step S127: welding or crimping predetermined different layers of conductors among the n-layer conductors electrical connection.
- the method for manufacturing a wire harness further includes: a step S150 after the step S130: punching a hole into the insulating layer and pouring a conductive material into the hole, forming the n-layer conductor The different layers of conductors predetermined in the electrical connection.
- the method for manufacturing a wire harness further includes: a step S150 after the step S140: punching a hole into the insulating layer and pouring a conductive material into the hole, forming the n-layer conductor The different layers of conductors predetermined in the electrical connection.
- the method for manufacturing a wire harness further includes: Step S160: After obtaining the wire harness with n layers of conductors, winding the wire bundle around a central line to form a cylindrical structure.
- step S155 before the step S160 disposing a cooling pipe at the central line.
- the method for manufacturing a wire harness further includes: step S170: drilling a hole into the insulating layer and inserting a conductive terminal into the hole, so that one end of the conductive terminal extends into the insulating layer and connects with the insulating layer.
- the designated conductors are electrically connected, and the other end of the conductive terminal is located outside the outermost insulating layer.
- the at least one conductor is a plurality of conductors insulated from each other.
- the material subtraction treatment is: using a laser or a plasma arc to perform ablative removal on the area to be removed of the metal sheet.
- performing the subtractive treatment on the metal sheet is: performing the subtractive treatment on the metal sheet in a nitrogen or inert gas environment.
- the process of forming the insulating layer is one or more of a coating process, a spraying process, a dipping process, an injection molding process, and a dipping process.
- the step S120 includes: after forming at least one conductor with a predetermined conductive track, performing cleaning and drying treatment on the conductor.
- the embodiment of the second aspect of the present application provides a wire harness manufactured by the method for manufacturing a wire harness according to the embodiment of the first aspect.
- the metal sheet is a rigid metal sheet.
- the metal sheet is a flexible metal sheet.
- the material of the metal sheet 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, gold or its alloys.
- the thickness of the metal sheet is 0.03mm-68mm.
- the material of the insulating layer includes one of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene or more.
- the breakdown strength of the insulating layer is 0.3KV/mm-35KV/mm.
- the thickness of the insulating layer is 0.03mm-5mm.
- the wire harness is a signal wire.
- This application provides a method for manufacturing wire harnesses in a subtractive manner.
- the unnecessary part of the metal sheet is removed, and the remaining part is the required conductor, and then an insulating protective layer is formed on the outside of the conductor to obtain the wire harness.
- Manufacturing method Simple, easy to make complex conductive circuits, can realize automation, mass production, and high processing speed, high precision, greatly reducing the cost of wiring harnesses, and improving the qualification rate of wiring harnesses;
- This application optimizes the design of the electrical circuit by electrically connecting conductors of different layers, and can manufacture wiring harnesses with more complex conductive circuits;
- This application reduces the material of the metal sheet in a nitrogen or inert gas environment to prevent oxidation of the metal sheet and improve the quality and pass rate of the wire harness;
- This application reduces the space occupied by the wire harness assembly by crimping the wire harness with multi-layer conductors into a cylindrical structure. Structure, easy to arrange wiring harness;
- This application solves the heat dissipation problem of the wire harness by setting a cooling pipe in the center of the curled wire harness, and passing flowing cold air or cooling liquid into the cooling pipe;
- FIG. 1 is a schematic flow diagram of a first embodiment of the method for manufacturing a wire harness of the present application
- FIG. 2 is a schematic flow diagram of a second embodiment of the method for manufacturing a wire harness of the present application
- FIG. 3 is a schematic flow diagram of a third embodiment of the method for manufacturing a wire harness of the present application.
- Fig. 4 is the schematic diagram that adopts laser or plasma arc torch to carry out material reduction treatment to metal sheet;
- Fig. 5 is a schematic structural view of the first embodiment of the wire harness of the present application.
- Fig. 6 is a schematic structural diagram of a second embodiment of the wire harness of the present application.
- Fig. 7 is a schematic structural diagram of a third embodiment of the wire harness of the present application.
- Fig. 8 is a partial enlarged view of place A in Fig. 7;
- Fig. 9 is a schematic structural diagram of a fourth embodiment of the wire harness of the present application.
- Fig. 10 is a partial enlarged view of place B in Fig. 9;
- Fig. 11 is a schematic structural view of a fifth embodiment of the wire harness of the present application.
- connection should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, a direct connection, or an indirect connection through an intermediary.
- the embodiment of the first aspect of the present application provides a method for manufacturing a wire harness, as shown in Figure 1, Figure 4, and Figure 5, including the following steps:
- Step S110 providing a metal sheet 1;
- Step S120 performing material reduction on the metal sheet 1, so that the metal sheet 1 forms at least one conductor 2 with a preset conductive track, wherein the preset conductive track can be a conductive track with any direction, and can be set according to actual needs;
- Step S130 forming an insulating layer 3 on the conductor 2 to wrap the conductor 2 through the insulating layer 3 .
- This application provides a method for manufacturing wire harnesses in a subtractive manner.
- the unnecessary parts on the metal sheet are removed, and the remaining part is the required conductor, and then an insulating protective layer is formed on the outside of the conductor to obtain the wire harness.
- the manufacturing method is simple. It is convenient to make complex conductive circuits, and can realize automation, mass production, and high processing speed and high precision, which greatly reduces the cost of wire harnesses and improves the pass rate of wire harnesses.
- the method is used to manufacture a wire harness with n layers of conductors 2, where n is a positive integer greater than 1, and the method further includes The following steps:
- Step S140 after step S130 repeat step S110 to step S130 (n-1) times until a wire harness with n layers of conductors 2 is obtained;
- step S130 the formation of the insulating layer 3 on the conductor 2 is: laying the insulation layer 3 on the previously formed conductor 2; in each execution of the step S110, the provision of a The metal sheet 1 is: provide a metal sheet 1 on the insulating layer 3 laid in the previous time, that is, fabricate the insulating layer 3 and the conductor 2 layer by layer, and obtain a wiring harness in which the multi-layer insulating layer 3 and the multi-layer conductor 2 are alternately arranged.
- the manufacturing method Simple, high manufacturing efficiency, and reduce the manufacturing cost of complex wiring harnesses.
- the metal sheet 1 can be either a rigid metal sheet or a flexible metal foil.
- the thickness of the flexible metal foil is small, the thickness is generally 0.05mm ⁇ 1mm, especially suitable for making wire harnesses with small wire diameter conductors (such as signal wires), which solves the difficult problem of making wire harnesses with small wire diameter conductors.
- the metal sheet 1 provided in the step S110 is a metal sheet with a preset shape, and the preset shape is a plane shape or a curved shape (three-dimensional shape).
- the metal sheet is a rigid metal sheet, it is necessary to pre-shape the metal sheet, and then place the shaped metal sheet on the insulating layer, such as forging, rolling, bending, stamping, extrusion or integral casting.
- the insulating layer can be made into a preset shape, such as making the surface of the insulating layer flat or curved, and then place the flexible metal foil on the surface of the insulating layer , the flexible metal foil will naturally adhere to the surface of the insulating layer, and the shape of the flexible metal foil is also consistent with the surface shape of the insulating layer.
- the method further includes the following electrical connection steps:
- the method is used to manufacture a wire harness with n layers of conductors 2, n is a positive integer greater than 1, and the method for manufacturing the wire harness is also Include the following steps:
- the step S115 that is repeatedly executed each time includes: maintaining an insulating gap between the metal sheet 1 fixed this time and the metal sheet 1 fixed last time; in step S130, the insulating layer 3 is formed on the conductor 2, as : Insulating layer 3 is formed on the surface of all conductors 2 and in all insulating gaps, that is, the multilayer conductor 2 is made earlier, and the insulating layer 3 (or called an insulator) is integrally formed outside the multilayer conductor 2 to obtain the multilayer insulating layer 3 and
- the wiring harness in which the multilayer conductors 2 are arranged alternately has a simple manufacturing method, high manufacturing efficiency, and reduces the manufacturing cost of the complex wiring harness.
- the metal sheet 1 is preferably a rigid metal sheet, because the rigid metal sheet has better rigidity and is easy to fix, while the thickness of the flexible metal foil is small, and it is difficult to fix without the support of an insulating layer, so the flexible metal foil
- the foil is more suitable to be made into a wire harness by the method of the first embodiment.
- the metal sheet 1 provided in the step S110 is a metal sheet with a preset shape, and the preset shape is a plane shape or a curved shape (three-dimensional shape).
- the metal sheet can be shaped by forging, rolling, bending, stamping, extrusion or integral casting, and then the shaped metal sheet can be fixed.
- Forging is a processing method that uses forging machinery to apply pressure to metal blanks to cause plastic deformation to obtain forgings with certain mechanical properties, certain shapes and sizes. It is mainly processed for rigid metal plates with large thickness.
- Rolling refers to the mechanical process of deformation of the rolled piece between the rolls, mainly for the processing of plane shapes and simple curved surfaces.
- Bending refers to the processing method in which the metal sheet is first elastically deformed and then plastically deformed under the pressure of the upper or lower die of the bending machine, mainly for the three-dimensional shape of straight-line bending.
- Stamping is a forming processing method that applies external force to plates, strips, pipes and profiles by presses and molds to cause plastic deformation or separation to obtain workpieces (stamping parts) of required shape and size. It is mainly used for processing rigid metal plates with small thickness and complex shapes.
- Extrusion is a pressure processing method that uses a punch or punch to pressurize the blank placed in the die to cause plastic flow to obtain a part corresponding to the shape of the die hole or the concave and convex die.
- One-piece casting is a method of casting liquid metal into a casting cavity suitable for the shape of the part, and obtaining the part at one time after it is cooled and solidified.
- the method for manufacturing a wire harness includes the following electrical connection steps:
- the method for connecting conductors in this scheme is simple and easy to operate.
- the method for manufacturing a wire harness includes the following electrical connection steps:
- the insulating layer 3 is made, and then holes are drilled into the insulating layer 3 and conductive material 4 is poured, so as to electrically connect predetermined conductors 2 of different layers.
- the method for manufacturing a wire harness includes the following steps: Step S160: After obtaining the wire harness with n-layer conductors 2, wind the wire bundle around a central line into a cylindrical structure (as shown in FIGS. 9 and 10 ), In order to reduce the space occupied when the wire harness is assembled, when the installation position of the wire harness is not a plane, but a groove or an angle position, the wire harness is rolled into a cylindrical structure to facilitate the layout of the wire harness. After the wire harness is rolled into a cylindrical structure, the wire harness can also be bent according to the shape of the installation position of the wire harness.
- step S155 before the above step S160 a cooling pipe 8 is installed at the centerline of the wire harness.
- flowing cold air or cooling liquid is passed into the cooling pipe 8 to solve the heat dissipation problem of the wire harness.
- the wire harness can be rolled into a cylindrical structure around the cooling pipe 8, or the wire harness can be rolled into a cylindrical structure first, and a central hole is reserved at the center line, and then the cooling pipe 8 can be rolled into a cylindrical structure. Tube 8 is inserted into the central hole.
- the method for manufacturing a wire harness includes the following steps:
- Step S170 Drill a hole into the insulating layer 3 and insert a conductive terminal 9 into the hole (as shown in FIG. 11 ), so that one end of the conductive terminal 9 extends into the insulating layer 3 and is electrically connected to the designated conductor 2.
- the conductive terminal 9 The other end of the wire is located outside the outermost insulating layer 3 to realize electrical branching.
- the electrical connection between the conductive terminal 9 and the designated conductor 2 can be a plug-in contact connection or welding, and the conductive terminal 9 can be a male terminal or a female terminal with a slot.
- the at least one conductor is a plurality of conductors insulated from each other, that is, each layer of conductors includes a plurality of conductors insulated from each other, so as to obtain a wire harness with a simple structure and a complex conductive loop.
- each layer of conductors may only include one conductor, or multiple conductors in each layer of conductors may be electrically connected with some conductors, which can be set according to actual needs.
- the method of subtractive treatment is: using laser or plasma arc to ablate and remove the area to be removed of the metal sheet.
- the width of laser or plasma arc ablation is 0.03 mm to 5 mm.
- a laser or plasma arc gun 5 is used to ablate and remove the area to be removed of the metal sheet 1.
- the laser or plasma arc gun 5 can be driven by a three-dimensional servo mechanism, and the laser or plasma arc gun 5 can be programmed and designed by using a three-dimensional servo mechanism.
- the moving path, so as to process the conductors of different circuits, has a high degree of flexible production, and can be applied to flexible production with many models and small batches.
- the method of subtractive treatment may also be mechanical cutting, die cutting, and the like.
- step S120 the metal sheet is subjected to subtractive treatment in a nitrogen or inert gas environment, so as to prevent the metal sheet from being oxidized.
- the process used for forming the insulating layer or laying the insulating layer is one or more of a coating process, a spraying process, a immersion plating process, an injection molding process, and a dipping process.
- the material of the insulating layer 3 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 step S120 further includes: after forming at least one conductor with a predetermined conductive track, performing cleaning and drying treatment on the conductor, and then forming an insulating layer on the conductor.
- the cleaning of copper foil can adopt one or more methods of solution washing, ultrasonic cleaning, and high-pressure washing
- the drying of copper foil can adopt one or more of natural drying, hot and cold air drying, and infrared radiation drying. kind.
- Natural drying is a method of drying parts by using solar radiation energy, hot air, etc. under natural conditions.
- the characteristics of natural drying are that it takes a long time to dry and occupies a large area, but it does not require any equipment and energy.
- Hot and cold air drying using hot and cold air as the drying medium, conducts moisture and heat exchange with the parts in the form of forced convection circulation, and takes away the moisture on the surface of the material.
- the characteristic of hot and cold air drying is that the drying time is longer and the efficiency is generally lower.
- Infrared radiation drying also known as radiation drying, refers to a drying method that uses infrared radiation to vaporize moisture in parts.
- the characteristic of drying by infrared radiation is that the drying speed is fast, but it needs to consume energy.
- the embodiment of the second aspect of the present application provides a wire harness manufactured by the method for manufacturing the wire harness of the embodiment of the first aspect.
- the beneficial effect of the wire harness in the embodiment of the second aspect is the same as that of the method in the embodiment of the first aspect, and will not be repeated here.
- the metal sheet 1 is a rigid metal sheet.
- the rigid metal sheet has good rigidity and is easy to fix.
- the metal sheet can be shaped by forging, rolling, bending, stamping, extrusion or integral casting, and then the shaped metal sheet can be fixed.
- the metal sheet 1 is a flexible metal sheet.
- the flexible metal sheet can be a thin metal plate or a metal foil, which can be easily deformed, and can be used in some wire harnesses that do not require high current but have complex shapes.
- the material of the metal sheet 1 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 its alloys.
- 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.
- the most commonly used metal material for conductors is copper or copper alloy, because copper has the best electrical conductivity 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 thickness of the metal sheet 1 is 0.03mm-68mm.
- 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 conductors that realize the power conduction, the current is relatively large
- the cross-sectional area of the conductor is also large.
- the maximum cross-sectional area of the automobile battery wiring harness reaches 260mm 2 .
- the thickness of the metal sheet 1 is less than 0.03mm, in order to obtain a conductor with a cross - sectional area of 0.1mm, it is necessary to cut out a conductor with a width of at least 3.3mm. The smaller the thickness, the greater the width, and the strength of the conductor cannot meet the requirements, and Also the layout of the wiring harness is restricted, and the area of the wiring harness cannot be reduced.
- the thickness of the metal sheet 1 is greater than 68mm, in order to obtain a conductor with a cross-sectional area of 260mm2 , it is necessary to cut a conductor with a width of at least 3.8mm.
- the inventor chooses the thickness of the metal sheet 1 to be 0.03 mm to 68 mm, which can ensure that wire harness conductors with different wire diameters and different conduction currents can be obtained by cutting the metal sheet 1 with different widths.
- the material of the insulating layer 3 includes one of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene. one or more species.
- the breakdown strength of the insulating layer 3 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 insulating layer is lower than 0.3KV/mm, some thinner insulating layers may be broken down under normal voltage, resulting in ineffective insulation. When the breakdown strength of the insulating 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 thickness of the insulating layer 3 is 0.03mm-5mm. If the thickness of the insulating layer is less than 0.03mm, not only the breakdown voltage of the insulating layer cannot be guaranteed to be higher than the working voltage, but also the wear resistance of the insulating layer cannot be guaranteed. After repeated scraping, the insulating layer will be damaged and the conductor will be exposed. 2. It will lead to leakage or short circuit, resulting in line damage and function failure.
- the thickness of the insulating layer is equal to 5mm, the breakdown voltage, insulation resistance and wear resistance of the insulating layer can meet the requirements, but if the thickness is greater than 5mm, the thickness of the insulating layer is relatively large, and problems such as pores and collapse may occur during processing.
- the wire harness is a signal wire.
- the existing electrical appliances in the field of electrical connection have more and more functions, and more and more signal transmission lines.
- the signal line accounts for more than 80% of the existing wiring harness loops.
- the signal line is characterized by a small conduction current and does not require a large wire diameter.
- the wires are conducted.
- the signal wires mainly use small-diameter wires with a cross-sectional area of 0.5m 2 , and gradually begin to use smaller wire-diameter wires of 0.13m 2 .
- the material reduction method of the present application makes the method of manufacturing signal wires very simple and efficient, with high manufacturing precision and low manufacturing cost, and provides support for the application of small-diameter wires on wire harnesses.
- the conductor 2 of the wiring harness has a terminal located outside the insulating layer 3, and the terminals of the conductors 2 of different layers can form a connection point 6 (as shown in FIG. 7 (as shown in FIG. 6 ), for example, connect with other electrical circuits through golden fingers, pin terminals, welding wires, etc.
- the shape of the wire harness is a rolled cylindrical structure, so as to reduce the occupied space when the wire harness is assembled.
- a cooling pipe 8 is provided at the crimped center of the wire harness to improve the heat dissipation performance of the wire harness.
- a conductive terminal 9 is inserted in the insulating layer 3 of the wiring harness, one end of the conductive terminal 9 is electrically connected to the designated conductor 2, and the other end of the conductive terminal 9 is located outside the outermost insulating layer 3, so as to Realize electrical branch leads.
- the conductive terminal 9 can be a male terminal or a female terminal with a slot.
- the method for manufacturing a wire harness and the wire harness of the present application have at least the following advantages:
- harnesses by reducing materials can realize automation, large-scale and rapid production, and the processing speed is fast and the precision is high, which greatly reduces the cost of wiring harnesses and improves the qualification rate of wiring harnesses;
- the metal sheet can form a wire harness with a three-dimensional space structure, which can be applied to wire harness assembly in different environments;
- conductors of different conductive circuits can be processed, with a high degree of flexible production, and can be applied to flexible production with many models and small batches;
- nitrogen or inert gas protection is used to effectively prevent the metal sheet from being oxidized.
Abstract
一种制造线束的方法及线束，该方法包括：步骤S110：提供一金属片；步骤S120：对所述金属片进行减材处理，以使所述金属片形成具有预设导电轨迹的至少一个导体；步骤S130：在所述导体上形成绝缘层。线束由所述制造线束的方法制造而成。本申请提供了一种减材方式制造线束的方法，制造方法简单，便于制作复杂的导电回路，能够实现自动化、大批量快速生产，并且加工速度快，精度高，极大的降低了线束的成本，提高了线束的合格率。
Description
相关申请
本申请要求于2021年7月30日递交的申请号为202110873848.5的中国发明专利申请的优先权，并引用上述专利申请公开的内容作为本申请的一部分。
本申请涉及电气连接技术领域，尤其是一种制造线束的方法及线束。
目前电气连接使用的线束，是由电线、端子、护套、定位件和支架等零件加工组装而成，制造工艺复杂，尤其是使用小线径导线的线束，导线加工困难，加工效率低，导致线束生产成本高，不良率也居高不下，自动化程度较低。
因此，线束生产行业急需一种生产自动化程度高，成本低的线束生产方式。
发明内容
本申请提供一种制造线束的方法及线束，以解决目前线束生产自动化程度较低、生产成本高的问题。
本申请第一方面的实施例提供一种制造线束的方法，其包括：步骤S110：提供一金属片；步骤S120：对所述金属片进行减材处理，以使所述金属片形成具有预设导电轨迹的至少一个导体；步骤S130：在所述导体上形成绝缘层。
在一些实施例中，所述制造线束的方法用于制造具有n层导体的线束，n为大于1的正整数，所述制造线束的方法还包括：位于所述步骤S110之前的步骤S100：铺设绝缘层；位于所述步骤S130之后的步骤S140：(n-1)次重复执行所述步骤S110～步骤S130，直至得到具有n层导体的线束；其中，在每一次执行的所述步骤S130中，所述在所述导体上形成绝缘层，为：在前一次形成的导体上铺设绝缘层；在每一次执行的所述步骤S110中，所述提供一金属片，为：提供一金属片至前一次铺设的绝缘层上。
在一些实施例中，所述制造线束的方法用于制造具有n层导体的线束，n为大于1的正整数，所述制造线束的方法还包括：位于所述步骤S110之后、所述步骤S120之前的步骤S115：固定所述金属片；位于所述步骤S120之后、所述步骤S130之前的步骤S125：(n-1)次重复 执行所述步骤S110～步骤S120，直至形成n层导体；其中，每一次重复执行的所述步骤S115包括：使本次固定的所述金属片与前一次固定的金属片之间保持绝缘间隙；在所述步骤S130中，所述在所述导体上形成绝缘层，为：在全部所述导体表面和全部所述绝缘间隙内形成绝缘层。
在一些实施例中，在所述步骤S110中，提供的所述金属片为具有预设形状的金属片，所述预设形状为平面形状或曲面形状。
在一些实施例中，所述预设形状为曲面形状，曲面形状的所述金属片通过锻造、轧制、折弯、冲压、挤压或一体铸造的方式成型。
在一些实施例中，所述制造线束的方法还包括：位于所述步骤S125之后、所述步骤S130之前的步骤S127：将所述n层导体中预定的不同层导体通过焊接或压接的方式电连接。
在一些实施例中，所述制造线束的方法还包括：位于所述步骤S130之后的步骤S150：通过向所述绝缘层内打孔并向孔内灌注导电材料的方式，将所述n层导体中预定的不同层导体电连接。
在一些实施例中，所述制造线束的方法还包括：位于所述步骤S140之后的步骤S150：通过向所述绝缘层内打孔并向孔内灌注导电材料的方式，将所述n层导体中预定的不同层导体电连接。
在一些实施例中，所述制造线束的方法还包括：步骤S160：在得到具有n层导体的线束之后，将所述线束绕一中心线卷为筒状结构。
在一些实施例中，位于所述步骤S160之前的步骤S155：在所述中心线处设置冷却管。
在一些实施例中，所述制造线束的方法还包括：步骤S170：向所述绝缘层内打孔并向孔内插入导电端子，使所述导电端子的一端伸入所述绝缘层内并与指定的导体电连接，所述导电端子的另一端位于最外侧的绝缘层外部。
在一些实施例中，在所述步骤S120中，所述至少一个导体为相互绝缘的多个导体。
在一些实施例中，在所述步骤S120中，所述减材处理为：采用激光或等离子弧对所述金属片的待去除区域进行烧蚀去除。
在一些实施例中，在所述步骤S120中，所述对所述金属片进行减材处理，为：在氮气或惰性气体环境中，对所述金属片进行减材处理。
在一些实施例中，在所述步骤S130中，形成所述绝缘层的工艺为涂覆工艺、喷涂工艺、浸镀工艺、注塑工艺、浸塑工艺中的一种或多种。
在一些实施例中，所述步骤S120包括：在形成具有预设导电轨迹的至少一个导体后，对所述导体进行清洗处理和烘干处理。
本申请第二方面的实施例提供一种线束，其由第一方面实施例的制造线束的方法制造而成。
在一些实施例中，所述金属片为刚性金属片。
在一些实施例中，所述金属片为柔性金属片。
在一些实施例中，所述金属片的材质包括镍或其合金、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、金或其合金中的一种或多种。
在一些实施例中，所述金属片的厚度为0.03mm～68mm。
在一些实施例中，所述绝缘层的材质包括聚氯乙烯、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。
在一些实施例中，所述绝缘层的击穿强度为0.3KV/mm-35KV/mm。
在一些实施例中，所述绝缘层的厚度为0.03mm-5mm。
在一些实施例中，所述线束为信号线。
本申请的制造线束的方法及线束的特点和优点包括：
1.本申请提供了一种减材方式制造线束的方法，将金属片上不需要的部分去除，留下的部分即为所需导体，然后在导体外侧形成绝缘保护层，即得到线束，制造方法简单，便于制作复杂的导电回路，能够实现自动化、大批量快速生产，并且加工速度快，精度高，极大的降低了线束的成本，提高了线束的合格率；
2.本申请通过逐层交替制作多层绝缘层和多层导体，得到多层绝缘层和多层导体交替设置的线束，制造方法简单，制造效率高，降低复杂线束的制造成本；
3.本申请通过制作多层导体，再在多层导体外部一体成型绝缘层，得到多层绝缘层和多层导体交替设置的线束，制造方法简单，制造效率高，降低复杂线束的制造成本；
4.本申请通过将不同层的导体电连接，优化了电气回路的设计方案，能够制造导电回路更加复杂的线束；
5.本申请通过在氮气或惰性气体环境中，对金属片进行减材处理，防止金属片发生氧化，提高线束质量和合格率；
6.本申请通过将具有多层导体的线束卷曲为筒状结构，减少线束装配时的占用空间，当线束安装位置不是平面，而是凹槽或夹角位置时，通过将线束卷为筒状结构，方便布置线束；
7.本申请通过在卷曲线束的中心设置冷却管，向冷却管内通入流动的冷空气或冷却液，解决线束散热问题；
8.本申请通过向卷曲线束内插入导电端子，实现电气分支引出。
以下附图仅旨在于对本申请做示意性说明和解释，并不限定本申请的范围。其中：
图1是本申请的制造线束的方法的第一实施例的流程示意图；
图2是本申请的制造线束的方法的第二实施例的流程示意图；
图3是本申请的制造线束的方法的第三实施例的流程示意图；
图4是采用激光或等离子弧枪对金属片进行减材处理的示意图；
图5是本申请的线束的第一实施例的结构示意图；
图6是本申请的线束的第二实施例的结构示意图；
图7是本申请的线束的第三实施例的结构示意图；
图8是图7中A处的局部放大图；
图9是本申请的线束的第四实施例的结构示意图；
图10是图9中B处的局部放大图；
图11是本申请的线束的第五实施例的结构示意图。
为了对本申请的技术特征、目的和效果有更加清楚的理解，现对照附图说明本申请的具体实施方式。在本申请的描述中，除非另有说明，“多个”的含义是两个或两个以上。在本申请的描述中，除非另有说明，术语“连接”应做广义理解，例如，可以是固定连接，可以是可拆卸连接，可以是直接连接，可以是通过中间媒介间接连接，对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本专利中的具体含义。
本申请第一方面的实施例提供一种制造线束的方法，如图1、图4、图5所示，包括以下步骤：
步骤S110：提供一金属片1；
步骤S120：对金属片1进行减材处理，以使金属片1形成具有预设导电轨迹的至少一个导体2，其中预设导电轨迹可以是任意走向的导电轨迹，可以根据实际需要设置；
步骤S130：在导体2上形成绝缘层3，以通过绝缘层3包裹导体2。
本申请提供了一种减材方式制造线束的方法，将金属片上不需要的部分去除，留下的部分即为所需导体，然后在导体外侧形成绝缘保护层，即得到线束，制造方法简单，便于制作复杂的导电回路，能够实现自动化、大批量快速生产，并且加工速度快，精度高，极大的降低了线束的成本，提高了线束的合格率。
在第一种实施例中，如图2、图6、图7、图8所示，所述方法用于制造具有n层导体2 的线束，n为大于1的正整数，所述方法还包括以下步骤：
位于步骤S110之前的步骤S100：铺设绝缘层3；
位于步骤S130之后的步骤S140：(n-1)次重复执行步骤S110～步骤S130，直至得到具有n层导体2的线束；
其中，在每一次执行的步骤S130中，所述在导体2上形成绝缘层3，为：在前一次形成的导体2上铺设绝缘层3；在每一次执行的步骤S110中，所述提供一金属片1，为：提供一金属片1至前一次铺设的绝缘层3上，即逐层制作绝缘层3和导体2，得到多层绝缘层3和多层导体2交替设置的线束，制造方法简单，制造效率高，降低复杂线束的制造成本。
本实施例中，金属片1既可以是刚性金属片，也可以是柔性金属箔片。其中柔性金属箔片的厚度较小，厚度一般为0.05mm～1mm，尤其适用于制作小线径导体的线束(例如信号线)，解决了小线径导体的线束难以制作的难题。
本实施例中，进一步，所述步骤S110中提供的金属片1为具有预设形状的金属片，所述预设形状为平面形状或曲面形状(三维形状)。当金属片为刚性金属片时，需要对金属片预先定型，再将定型的金属片放置于绝缘层上，例如可以采用锻造、轧制、折弯、冲压、挤压或一体铸造的方式，对金属片进行定型；当金属片为柔性金属箔片时，可以将绝缘层制作成预设形状，比如使绝缘层的表面为平面状或曲面状，然后将柔性金属箔片放置于绝缘层的表面，柔性金属箔片自然会与绝缘层的表面贴合，柔性金属箔片的形状也与绝缘层的表面形状一致。
本实施例中，进一步，所述方法还包括以下电连接步骤：
位于步骤S140之后的步骤S150：通过向绝缘层3内打孔并向孔内灌注导电材料4的方式，将n层导体2中预定的不同层导体2电连接，也就是在得到交替设置的多层绝缘层3和多层导体2之后，向绝缘层3内打孔并灌注导电材料4，从而将预定的不同层导体2电连接。
在第二种实施例中，如图3、图6、图7、图8所示，所述方法用于制造具有n层导体2的线束，n为大于1的正整数，制造线束的方法还包括以下步骤：
位于步骤S110之后、步骤S120之前的步骤S115：固定金属片1，例如采用夹具等夹持部件对其进行夹持固定；
位于步骤S120之后、步骤S130之前的步骤S125：(n-1)次重复执行步骤S110～步骤S120，直至形成n层导体2；
其中，每一次重复执行的步骤S115包括：使本次固定的金属片1与前一次固定的金属片1之间保持绝缘间隙；在步骤S130中，所述在导体2上形成绝缘层3，为：在全部导体2表面和全部绝缘间隙内形成绝缘层3，即先制作多层导体2，再在多层导体2外部一体成型绝缘层3(或称为绝缘体)，得到多层绝缘层3和多层导体2交替设置的线束，制造方法简单，制 造效率高，降低复杂线束的制造成本。
本实施例，金属片1优选为刚性金属片，因为刚性金属片的刚性较好，易于固定，而柔性金属箔片厚度较小，在没有绝缘层支撑的情况下，较难固定，因此柔性金属箔片更适合采用第一种实施例的方法制作成线束。
本实施例中，进一步，所述步骤S110中提供的金属片1为具有预设形状的金属片，所述预设形状为平面形状或曲面形状(三维形状)。例如可以采用锻造、轧制、折弯、冲压、挤压或一体铸造的方式，对金属片进行定型，然后将定型的金属片固定。
锻造，是一种利用锻压机械对金属坯料施加压力，使其产生塑性变形以获得具有一定机械性能、一定形状和尺寸锻件的加工方法，主要针对厚度较大的刚性金属板进行加工。
轧制，是指轧件在轧辊间变形的力学过程，主要针对平面形状以及简单曲面的加工。
折弯，是指金属板料在折弯机上模或下模的压力下，首先经过弹性变形，然后经过塑性变形的加工方法，主要针对直线弯折的三维形状。
冲压，是靠压力机和模具对板材、带材、管材和型材等施加外力，使之产生塑性变形或分离，从而获得所需形状和尺寸的工件(冲压件)的成形加工方法。主要针对厚度较小，形状较复杂的刚性金属板进行加工。
挤压，是用冲头或凸模对放置在凹模中的坯料加压，使之产生塑性流动，从而获得相应于模具的型孔或凹凸模形状的制件的一种压力加工方法。
一体铸造，是将液体金属浇铸到与零件形状相适应的铸造空腔中，待其冷却凝固后，一次性获得零件的方法。
本实施例中，若需要将不同层的导体电连接，有以下两种方案。
在一种可行的技术方案中，制造线束的方法包括以下电连接步骤：
位于步骤S125之后、步骤S130之前的步骤S127：将n层导体中预定的不同层导体通过焊接或压接的方式电连接，也就是在形成绝缘层之前，将预定的不同层导体电连接，然后在所有导体外部制作绝缘层。本方案中连接导体的方法简单，操作方便。
在另一种可行的技术方案中，制造线束的方法包括以下电连接步骤：
位于步骤S130之后的步骤S150：通过向绝缘层3内打孔并向孔内灌注导电材料4的方式，将n层导体2中预定的不同层导体2电连接，也就是先在所有导体2外部制作绝缘层3，然后向绝缘层3内打孔并灌注导电材料4，从而将预定的不同层导体2电连接。
在一实施例中，制造线束的方法包括以下步骤：步骤S160：在得到具有n层导体2的线束之后，将线束绕一中心线卷为筒状结构(如图9、图10所示)，以减少线束装配时的占用空间，当线束安装位置不是平面，而是凹槽或夹角位置时，通过将线束卷为筒状结构，方便 布置线束。在将线束卷为筒状结构后，还可以根据线束安装位置的形状，将线束进行弯折。
进一步，位于所述步骤S160之前的步骤S155：线束的中心线处设置冷却管8，线束工作时，向冷却管8内通入流动的冷空气或冷却液，解决线束散热问题。
但本申请并不限定冷却管8的安装时机，可以将线束绕冷却管8卷为筒状结构，也可以先将线束卷为筒状结构，并在中心线处预留中心孔，再将冷却管8插入中心孔内。
进一步，制造线束的方法包括以下步骤：
步骤S170：向绝缘层3内打孔并向孔内插入导电端子9(如图11所示)，使导电端子9的一端伸入绝缘层3内并与指定的导体2电连接，导电端子9的另一端位于最外侧的绝缘层3外部，以实现电气分支引出。导电端子9与指定的导体2之间的电连接，可以是插入式接触连接，也可以是焊接，导电端子9可以是公端子或具有插槽的母端子。
在一实施例中，在步骤S120中，所述至少一个导体为相互绝缘的多个导体，也就是每层导体包括多个相互绝缘的导体，从而得到结构简单、导电回路复杂的线束。
但本申请并不以此为限，在其它实施例中，每层导体也可以只包括一个导体，或者每层导体中的多个导体可以有部分导体电连接，均可根据实际需要设置。
在一实施例中，在步骤S120中，减材处理的方法为：采用激光或等离子弧对金属片的待去除区域进行烧蚀去除。例如激光或等离子弧烧蚀的宽度为0.03mm～5mm。
具体是，采用激光或等离子弧枪5，对金属片1的待去除区域进行烧蚀去除，激光或等离子弧枪5可以由三维伺服机构驱动，采用三维伺服机构可以编程设计激光或等离子弧枪5的移动路径，从而加工出不同回路的导体，柔性化生产程度高，可以适用于型号多，批量少的柔性化生产。
但本申请并不以此为限，在其它实施例中，减材处理的方法也可以是机械切割、模切等。
在一实施例中，在步骤S120中，在氮气或惰性气体环境中，对金属片进行减材处理，以防止金属片氧化。
在一实施例中，形成绝缘层或者铺设绝缘层采用的工艺为涂覆工艺、喷涂工艺、浸镀工艺、注塑工艺、浸塑工艺中的一种或多种。
在一实施例中，绝缘层3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组合。
在一实施例中，所述步骤S120还包括：在形成具有预设导电轨迹的至少一个导体后，对导体进行清洗处理和烘干处理，然后再在导体上形成绝缘层。
其中，铜箔清洁可以采用溶液冲清洗、超声波清洗、高压冲洗方式中的一种或多种，铜箔烘干可以采用自然烘干、冷热风干燥、红外线照射干燥方式中的一种或多种。
自然烘干，是在自然条件下，利用太阳辐射能、热风等使零件干燥的方法。自然烘干的特点是，干燥时间长，占地大，但不需要任何设备和能源。
冷热风干燥，以冷热空气为干燥介质，强制地对流循环的方式与零件进行湿热交换，带走物料表面上的水分。冷热风干燥的特点是，干燥时间较长，效率一般较低。
红外线照射干燥，又称辐射干燥，是指利用红外线辐射使零件中的水分汽化的干燥方法。红外线照射干燥的特点是，干燥速度快，但是需要消耗能源。
如图5至图7所示，本申请第二方面的实施例提供一种线束，其由第一方面实施例的制造线束的方法制造而成。第二方面实施例的线束的有益效果与第一方面实施例的方法相同，在此不再赘述。
在一实施例中，金属片1为刚性金属片。刚性金属片的刚性较好，易于固定，可以采用锻造、轧制、折弯、冲压、挤压或一体铸造的方式，对金属片进行定型，然后将定型的金属片固定。
在一实施例中，金属片1为柔性金属片。柔性金属片可以是薄金属板或者是金属箔类，可以较轻易的使之变形，可以使用在一些对电流要求不高，但是线束形状较复杂的线束。
在一实施例中，金属片1的材质包括镍或其合金、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、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，因此铝或铝合金在电气连接领域可以替代部分铜或铜合金。
在一实施例中，所述金属片1的厚度为0.03mm～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。
当金属片1厚度小于0.03mm时，为了能获得截面积为0.1mm
2的导体，就要切割出宽度至少为3.3mm的导体，厚度越小，宽度越大，导体的强度不能满足要求，而且也使线束的布局受到限制，无法缩小线束的面积。
当金属片1厚度大于68mm时，为了能获得截面积为260mm
2的导体，就要切割出宽度至少为3.8mm的导体，厚度越大，宽度越小，但是厚度越大，对金属片的切割难度就越大， 对切割口的平整度也无法保证。
因此，发明人选择金属片1的厚度为0.03mm～68mm，能够保证通过切割不同宽度的金属片1，获得不同线径，不同导通电流的线束导体。
在一实施例中，所述绝缘层3的材质包括聚氯乙烯、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。
在一实施例中，所述绝缘层3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。当绝缘层的击穿强度低于0.3KV/mm，有部分较薄绝缘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。
在一实施例中，所述绝缘层3的厚度为0.03mm-5mm。若绝缘层的厚度低于0.03mm，不仅不能够保证绝缘层的击穿电压高于工作电压，也不能保证绝缘层的耐磨性能，在多次刮磨后，会使绝缘层破损，露出导体2，会导致漏电或短路的情况，造成线路损坏，功能失效。绝缘层厚度等于5mm时，绝缘层的击穿电压、绝缘电阻和耐磨性能都能满足要求，但是若厚度大于5mm，绝缘层厚度较大，在加工过程中或出现气孔、塌陷等问题点，降低了绝缘层的性能，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，发明人选用绝缘层的厚度为0.03mm-5mm。在一实施例中，线束为信号线。
现有电气连接领域的电器，功能越来越多，信号传输线路也越来越多，信号线占现有线束回路的80％以上，信号线的特点是导通电流小，不需要大线径导线进行导通，目前信号线主要使用横截面积为0.5m
2的小线径导线，并逐渐开始使用0.13m
2的更小线径导线，线径越小，对导线的性能要求，以及对导线生产工艺的要求就越高，成本也会增加，这已经成为阻碍小线径导线在线束上应用的瓶颈。
而采用本申请的减材方式，使得制造信号线的方法非常简单高效，制造精度高，制造成本低，为小线径导线在线束上应用提供了支撑。
在一实施例中，线束的导体2具有位于绝缘层3外部的终端，不同层导体2的终端可以通过压接或焊接等方式形成连接点6(如图7所示)，终端也可以通过端子7(如图6所示)，例如通过金手指、插针端子、焊接电线等，与其他电器回路进行连接。
在一实施例中，如图9、图10所示，线束的形状为卷曲的筒状结构，以减少线束装配时的占用空间。
如图9所示，进一步，线束的卷曲中心设有冷却管8，以提高线束的散热性能。
如图11所示，进一步，线束的绝缘层3内插设有导电端子9，导电端子9的一端与指定 的导体2电连接，导电端子9的另一端位于最外侧的绝缘层3外部，以实现电气分支引出。其中导电端子9可以是公端子或具有插槽的母端子。
本申请的制造线束的方法及线束与现有技术相比，至少具有以下优点：
1、通过减材方式生产线束，能够实现自动化、大批量快速生产，并且加工速度快，精度高，极大的降低了线束的成本，提高了线束的合格率；
2、金属片可以形成三维空间结构的线束，能够适用于不同环境的线束装配；
3、通过减材方式，可以加工出不同导电回路的导体，柔性化生产程度高，可以适用于型号多、批量少的柔性化生产；
4、通过减材方式，可以在面积较小的金属片上，加工出较多的回路，满足电气回路较多的要求；
5、通过将不同层的导体进行电连接，优化了电气回路的设计方案，能够适用于更加复杂的线束；
6、在对金属片减材烧蚀加工时，通过采用氮气或惰性气体保护，有效防止金属片被氧化。
以上所述仅为本申请示意性的具体实施方式，并非用以限定本申请的范围。任何本领域的技术人员，在不脱离本申请的构思和原则的前提下所作的等同变化与修改，均应属于本申请保护的范围。而且需要说明的是，本申请的各组成部分并不仅限于上述整体应用，本申请的说明书中描述的各技术特征可以根据实际需要选择一项单独采用或选择多项组合起来使用，因此，本申请理所当然地涵盖了与本案发明点有关的其它组合及具体应用。
Claims (25)
- 一种制造线束的方法，其中，所述制造线束的方法包括：步骤S110：提供一金属片；步骤S120：对所述金属片进行减材处理，以使所述金属片形成具有预设导电轨迹的至少一个导体；步骤S130：在所述导体上形成绝缘层。
- 如权利要求1所述的制造线束的方法，其中，所述制造线束的方法用于制造具有n层导体的线束，n为大于1的正整数，所述制造线束的方法还包括：位于所述步骤S110之前的步骤S100：铺设绝缘层；位于所述步骤S130之后的步骤S140：(n-1)次重复执行所述步骤S110～步骤S130，直至得到具有n层导体的线束；其中，在每一次执行的所述步骤S130中，所述在所述导体上形成绝缘层，为：在前一次形成的导体上铺设绝缘层；在每一次执行的所述步骤S110中，所述提供一金属片，为：提供一金属片至前一次铺设的绝缘层上。
- 如权利要求1所述的制造线束的方法，其中，所述制造线束的方法用于制造具有n层导体的线束，n为大于1的正整数，所述制造线束的方法还包括：位于所述步骤S110之后、所述步骤S120之前的步骤S115：固定所述金属片；位于所述步骤S120之后、所述步骤S130之前的步骤S125：(n-1)次重复执行所述步骤S110～步骤S120，直至形成n层导体；其中，每一次重复执行的所述步骤S115包括：使本次固定的所述金属片与前一次固定的金属片之间保持绝缘间隙；在所述步骤S130中，所述在所述导体上形成绝缘层，为：在全部所述导体表面和全部所述绝缘间隙内形成绝缘层。
- 如权利要求1至3任一项所述的制造线束的方法，其中，在所述步骤S110中，提供的所述金属片为具有预设形状的金属片，所述预设形状为平面形状或曲面形状。
- 如权利要求4所述的制造线束的方法，其中，所述预设形状为曲面形状，曲面形状的所述金属片通过锻造、轧制、折弯、冲压、挤压或一体铸造的方式成型。
- 如权利要求3所述的制造线束的方法，其中，所述制造线束的方法还包括：位于所述步骤S125之后、所述步骤S130之前的步骤S127：将所述n层导体中预定的不同层导体通过焊接或压接的方式电连接。
- 如权利要求2或3所述的制造线束的方法，其中，所述制造线束的方法还包括：位于所述步骤S130之后的步骤S150：通过向所述绝缘层内打孔并向孔内灌注导电材料的方式，将所述n层导体中预定的不同层导体电连接。
- 如权利要求2所述的制造线束的方法，其中，所述制造线束的方法还包括：位于所述步骤S140之后的步骤S150：通过向所述绝缘层内打孔并向孔内灌注导电材料的方式，将所述n层导体中预定的不同层导体电连接。
- 如权利要求1至3任一项所述的制造线束的方法，其中，所述制造线束的方法还包括：步骤S160：将所述线束绕一中心线卷为筒状结构。
- 如权利要求9所述的制造线束的方法，其中，所述制造线束的方法还包括：位于所述步骤S160之前的步骤S155：在所述中心线处设置冷却管。
- 如权利要求1至3任一项所述的制造线束的方法，其中，所述制造线束的方法还包括：步骤S170：向所述绝缘层内打孔并向孔内插入导电端子，使所述导电端子的一端伸入所述绝缘层内并与指定的导体电连接，所述导电端子的另一端位于最外侧的绝缘层外部。
- 如权利要求1至3任一项所述的制造线束的方法，其中，在所述步骤S120中，所述至少一个导体为相互绝缘的多个导体。
- 如权利要求1至3任一项所述的制造线束的方法，其中，在所述步骤S120中，所述减材处理为：采用激光或等离子弧对所述金属片的待去除区域进行烧蚀去除。
- 如权利要求1至3任一项所述的制造线束的方法，其中，在所述步骤S120中，所述对所述金属片进行减材处理，为：在氮气或惰性气体环境中，对所述金属片进行减材处理。
- 如权利要求1至3任一项所述的制造线束的方法，其中，在所述步骤S130中，形成所述绝缘层的工艺为涂覆工艺、喷涂工艺、浸镀工艺、注塑工艺、浸塑工艺中的一种或多种。
- 如权利要求1至3任一项所述的制造线束的方法，其中，所述步骤S120包括：在形成具有预设导电轨迹的至少一个导体后，对所述导体进行清洗处理和烘干处理。
- 一种线束，其中，所述线束由权利要求1至16任一项所述的制造线束的方法制造而成。
- 如权利要求17所述的线束，其中，所述金属片为刚性金属片。
- 如权利要求17所述的线束，其中，所述金属片为柔性金属片。
- 如权利要求17所述的线束，其中，所述金属片的材质包括镍或其合金、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、金或其合金中的一种或多种。
- 如权利要求17所述的线束，其中，所述金属片的厚度为0.03mm～68mm。
- 如权利要求17所述的线束，其中，所述绝缘层的材质包括聚氯乙烯、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。
- 如权利要求17所述的线束，其中，所述绝缘层的击穿强度为0.3KV/mm-35KV/mm。
- 如权利要求17所述的线束，其中，所述绝缘层的厚度为0.03mm-5mm。
- 如权利要求17所述的线束，其中，所述线束为信号线。
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110873848.5 | 2021-07-30 | ||
| CN202110873848.5A CN113593775B (zh) | 2021-07-30 | 2021-07-30 | 一种制造线束的方法及线束 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2023006078A1 true WO2023006078A1 (zh) | 2023-02-02 |
Family
ID=78252850
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/CN2022/108998 WO2023006078A1 (zh) | 2021-07-30 | 2022-07-29 | 制造线束的方法及线束 |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN113593775B (zh) |
| WO (1) | WO2023006078A1 (zh) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113593775B (zh) * | 2021-07-30 | 2023-04-14 | 长春捷翼汽车科技股份有限公司 | 一种制造线束的方法及线束 |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH1075057A (ja) * | 1996-08-30 | 1998-03-17 | Kyocera Corp | フレキシブル多層配線基板の製造方法 |
| JP2000268647A (ja) * | 1999-03-19 | 2000-09-29 | Showa Electric Wire & Cable Co Ltd | 温度センサー付水冷ケーブル |
| CN102870504A (zh) * | 2010-04-19 | 2013-01-09 | 日本梅克特隆株式会社 | 柔性电路基板及其制造方法 |
| CN106034373A (zh) * | 2015-03-10 | 2016-10-19 | 上海量子绘景电子股份有限公司 | 高密度多层铜线路板及其制备方法 |
| CN113593775A (zh) * | 2021-07-30 | 2021-11-02 | 长春捷翼汽车零部件有限公司 | 一种制造线束的方法及线束 |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2009176770A (ja) * | 2008-01-21 | 2009-08-06 | Ube Ind Ltd | 銅配線絶縁フィルムの製造法、及びこれらから製造された銅配線絶縁フィルム |
| JP2011138869A (ja) * | 2009-12-28 | 2011-07-14 | Ngk Spark Plug Co Ltd | 多層配線基板の製造方法及び多層配線基板 |
| CN203038681U (zh) * | 2012-11-02 | 2013-07-03 | 中国电子科技集团公司第二十三研究所 | 一种低电感扁平电缆 |
| CN107644699A (zh) * | 2017-10-25 | 2018-01-30 | 苏州科伦特电源科技有限公司 | 用于大电流传输的扁导线式导电排结构及其制作方法 |
| CN208861717U (zh) * | 2018-10-16 | 2019-05-14 | 比亚迪股份有限公司 | 高压线束和车辆 |
| CN213635424U (zh) * | 2020-11-30 | 2021-07-06 | 重庆长安汽车股份有限公司 | 一种车用线束、车用线束连接结构及汽车 |
| CN112937473A (zh) * | 2021-03-25 | 2021-06-11 | 上海瓒如企业管理中心 | 一种柔性智能汽车线束 |
-
2021
- 2021-07-30 CN CN202110873848.5A patent/CN113593775B/zh active Active
-
2022
- 2022-07-29 WO PCT/CN2022/108998 patent/WO2023006078A1/zh active Application Filing
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH1075057A (ja) * | 1996-08-30 | 1998-03-17 | Kyocera Corp | フレキシブル多層配線基板の製造方法 |
| JP2000268647A (ja) * | 1999-03-19 | 2000-09-29 | Showa Electric Wire & Cable Co Ltd | 温度センサー付水冷ケーブル |
| CN102870504A (zh) * | 2010-04-19 | 2013-01-09 | 日本梅克特隆株式会社 | 柔性电路基板及其制造方法 |
| CN106034373A (zh) * | 2015-03-10 | 2016-10-19 | 上海量子绘景电子股份有限公司 | 高密度多层铜线路板及其制备方法 |
| CN113593775A (zh) * | 2021-07-30 | 2021-11-02 | 长春捷翼汽车零部件有限公司 | 一种制造线束的方法及线束 |
Also Published As
| Publication number | Publication date |
|---|---|
| CN113593775B (zh) | 2023-04-14 |
| CN113593775A (zh) | 2021-11-02 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US10348009B2 (en) | Flexible circuits for electrical harnesses | |
| KR100434617B1 (ko) | 배전어셈블리 | |
| WO2018095177A1 (zh) | 一种异形电缆及其制备方法 | |
| CN102089940A (zh) | 具有端子接头的电线和制造具有端子接头的电线的方法 | |
| US20110094099A1 (en) | Method for manufacturing copper clad aluminium bus bar | |
| JP2007012329A (ja) | 接続端子、接続端子付きアルミケーブル、超音波溶接方法、および超音波接続装置 | |
| WO2023006078A1 (zh) | 制造线束的方法及线束 | |
| CN103392281A (zh) | 汇流条及汇流条的制造方法 | |
| WO2018223885A1 (zh) | 一种铜端子与铝导线的接头及其磁感应焊接方法 | |
| EP3029773B1 (en) | Litz wire terminal assembly | |
| WO2023006076A1 (zh) | 制造线束的方法及线束 | |
| CN203674514U (zh) | 一种软连接铜排 | |
| JP2010225529A (ja) | 端子金具付き電線 | |
| CN112310776B (zh) | 将接触件导电地连接至导体的方法以及电线 | |
| CN109326899A (zh) | 一种铝线束超声波焊接用铜铝复合端子及其制造工艺 | |
| CN108010712A (zh) | 一种平面变压器绕组及其制作方法 | |
| JPS5825015A (ja) | 超電導中空導体の製造方法 | |
| CN209232969U (zh) | 铜端头 | |
| JP2018014235A (ja) | 平編組線導体の製造方法 | |
| WO2022127345A1 (zh) | 一种端子组件及其制备方法 | |
| CN217215128U (zh) | 一种铜铝分线连接结构 | |
| CN106711627A (zh) | 一种铝导线抗蠕变压接端子 | |
| CN220041440U (zh) | 一种抗氧化覆铜钢丝 | |
| CN220305999U (zh) | 一种绝缘电线及其制造设备 | |
| CN217691753U (zh) | 用于电能传输的连接结构 |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 22848682 Country of ref document: EP Kind code of ref document: A1 |
|
| WWE | Wipo information: entry into national phase |
Ref document number: MX/A/2024/001448 Country of ref document: MX |
|
| WWE | Wipo information: entry into national phase |
Ref document number: 2022848682 Country of ref document: EP |
|
| NENP | Non-entry into the national phase |
Ref country code: DE |
|
| ENP | Entry into the national phase |
Ref document number: 2022848682 Country of ref document: EP Effective date: 20240229 |