阅读说明：本技术 一种制造线束的方法及线束 (Method for manufacturing wire harness and wire harness ) 是由 王超 苗云 于 2021-07-30 设计创作，主要内容包括：本发明提供了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。本发明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。(The invention provides a method of manufacturing a wire harness and the wire harness, the method including: step S110: providing a metal sheet; step S120: performing material reduction treatment on the metal sheet to enable the metal sheet to form at least one conductor with a preset conductive track; step S130: an insulating layer is formed on the conductor. The wire harness is manufactured by the method for manufacturing the wire harness. The invention provides a method for manufacturing a wire harness in a material reducing mode, which is simple in manufacturing method, convenient for manufacturing a complex conductive loop, capable of realizing automatic, large-batch and rapid production, high in processing speed and high in precision, greatly reduces the cost of the wire harness, and improves the qualified rate of the wire harness.)

1. A method of manufacturing a wire harness, characterized by comprising:

step S110: providing a metal sheet;

step S120: performing material reduction treatment on the metal sheet to enable the metal sheet to form at least one conductor with a preset conductive track;

step S130: an insulating layer is formed on the conductor.

2. The method of manufacturing a wire harness according to claim 1, wherein the method of manufacturing a wire harness is used to manufacture a wire harness having n layers of conductors, n being a positive integer greater than 1, the method of manufacturing a wire harness further comprising:

step S100, which precedes step S110: laying an insulating layer;

step S140 located after the step S130: (n-1) repeating the steps S110 to S130 for times until a wire harness having n layers of conductors is obtained;

wherein the content of the first and second substances,

in step S130, the forming an insulating layer on the conductor is: laying an insulating layer on the conductor formed at the previous time;

in each step S110, the providing a metal sheet is: providing a metal sheet on the insulating layer laid at the previous time.

3. The method of manufacturing a wire harness according to claim 1, wherein the method of manufacturing a wire harness is used to manufacture a wire harness having n layers of conductors, n being a positive integer greater than 1, the method of manufacturing a wire harness further comprising:

step S115, which is located after step S110 and before step S120: fixing the metal sheet;

step S125 located after step S120 and before step S130: repeating the step S110 to the step S120 (n-1) times until n layers of conductors are formed;

wherein the content of the first and second substances,

the step S115 repeatedly performed each time includes: keeping an insulation gap between the metal sheet fixed this time and the metal sheet fixed last time;

in step S130, the forming an insulating layer on the conductor is: and forming an insulating layer on all the conductor surfaces and all the insulating gaps.

4. The method of manufacturing a wire harness according to any one of claims 1 to 3, wherein in the step S110, the metal sheet is provided as a metal sheet having a predetermined shape, the predetermined shape being a planar shape or a curved surface shape.

5. The method of manufacturing a wire harness according to claim 4, wherein the predetermined shape is a curved shape, and the metal piece in the curved shape is formed by forging, rolling, bending, stamping, extruding, or integral casting.

6. The method of manufacturing a wire harness according to claim 3, further comprising:

step S127, which is located after step S125 and before step S130: and electrically connecting preset different layers of conductors in the n layers of conductors by welding or crimping.

7. The method of manufacturing a wire harness according to claim 2 or 3, further comprising:

step S150 located after the step S130: and electrically connecting the preset different layers of conductors in the n layers of conductors by punching holes in the insulating layer and pouring a conductive material into the holes.

8. The method of manufacturing a wire harness according to claim 2, further comprising:

step S150 located after the step S140: and electrically connecting the preset different layers of conductors in the n layers of conductors by punching holes in the insulating layer and pouring a conductive material into the holes.

9. The method of manufacturing a wire harness according to any one of claims 1 to 3, further comprising:

step S160: and winding the wire harness into a cylindrical structure around a center wire.

10. The method of manufacturing a wire harness according to claim 9, further comprising:

step S155 preceding step S160: a cooling tube is disposed at the centerline.

11. The method of manufacturing a wire harness according to any one of claims 1 to 3, further comprising:

step S170: and punching 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 is electrically connected with a specified conductor, and the other end of the conductive terminal is positioned outside the insulating layer on the outermost side.

12. The method of manufacturing a wire harness according to any one of claims 1 to 3, wherein in the step S120, the at least one conductor is a plurality of conductors insulated from each other.

13. The method of manufacturing a wire harness according to any one of claims 1 to 3, wherein in the step S120, the material reducing process is: and (3) removing the area to be removed of the metal sheet by ablation by adopting laser or plasma arc.

14. The method of manufacturing a wire harness according to any one of claims 1 to 3, wherein in the step S120, the material reduction processing is performed on the metal sheet by: and performing material reduction treatment on the metal sheet in a nitrogen or inert gas environment.

15. The method of manufacturing a wire harness according to any one of claims 1 to 3, wherein in the step S130, the process of forming the insulating layer is one or more of a coating process, a spray process, a dip plating process, an injection molding process, a dip molding process.

16. The method of manufacturing a wire harness according to any one of claims 1 to 3, wherein the step S120 includes: after at least one conductor with a preset conductive track is formed, cleaning and drying are carried out on the conductor.

17. A wire harness, characterized in that the wire harness is manufactured by the method of manufacturing a wire harness according to any one of claims 1 to 16.

18. The wire harness of claim 17, wherein the metal sheet is a rigid metal sheet.

19. The wire harness of claim 17, wherein the metal sheet is a flexible metal sheet.

20. The wire harness of claim 17, wherein the metallic sheet comprises one or more of nickel or an alloy thereof, cadmium or an alloy thereof, zirconium or an alloy thereof, chromium or an alloy thereof, cobalt or an alloy thereof, manganese or an alloy thereof, aluminum or an alloy thereof, tin or an alloy thereof, titanium or an alloy thereof, zinc or an alloy thereof, copper or an alloy thereof, silver or an alloy thereof, and gold or an alloy thereof.

21. The wire harness of claim 17, wherein the metal sheet has a thickness of 0.03mm to 68 mm.

22. The wire harness of claim 17, wherein the insulating layer comprises one or more of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene.

23. The wire harness of claim 17, wherein the insulating layer has a breakdown strength of 0.3KV/mm to 35 KV/mm.

24. The wire harness of claim 17, wherein the insulating layer has a thickness of 0.03mm to 5 mm.

25. The wiring harness of claim 17, wherein the wiring harness is a signal wire.

Technical Field

The invention relates to the technical field of electrical connection, in particular to a method for manufacturing a wire harness and the wire harness.

Background

At present, a wire harness used for electrical connection is formed by processing and assembling parts such as electric wires, terminals, sheaths, positioning pieces, supports and the like, the manufacturing process is complex, particularly, the wire harness using small-wire-diameter wires is difficult to process, the processing efficiency is low, the production cost of the wire harness is high, the reject ratio is high, and the automation degree is low.

Therefore, a wire harness production mode with high production automation degree and low cost is urgently needed in the wire harness production industry.

Disclosure of Invention

The invention aims to provide a method for manufacturing a wire harness and the wire harness, which are used for solving the problems of low automation degree and high production cost of the conventional wire harness production.

To achieve the above object, the present invention provides a method of manufacturing a wire harness, comprising: step S110: providing a metal sheet; step S120: performing material reduction treatment on the metal sheet to enable the metal sheet to form at least one conductor with a preset conductive track; step S130: an insulating layer is formed on the conductor.

The method of manufacturing a wire harness as described above, wherein the method of manufacturing a wire harness is used to manufacture a wire harness having n layers of conductors, n being a positive integer greater than 1, the method of manufacturing a wire harness further comprising: step S100, which precedes step S110: laying an insulating layer; step S140 located after the step S130: (n-1) repeating the steps S110 to S130 for times until a wire harness having n layers of conductors is obtained; wherein, in each step S130, the forming an insulating layer on the conductor is: laying an insulating layer on the conductor formed at the previous time; in each step S110, the providing a metal sheet is: providing a metal sheet on the insulating layer laid at the previous time.

The method of manufacturing a wire harness as described above, wherein the method of manufacturing a wire harness is used to manufacture a wire harness having n layers of conductors, n being a positive integer greater than 1, the method of manufacturing a wire harness further comprising: step S115, which is located after step S110 and before step S120: fixing the metal sheet; step S125 located after step S120 and before step S130: repeating the step S110 to the step S120 (n-1) times until n layers of conductors are formed; wherein each repeated execution of the step S115 includes: keeping an insulation gap between the metal sheet fixed this time and the metal sheet fixed last time; in step S130, the forming an insulating layer on the conductor is: and forming an insulating layer on all the conductor surfaces and all the insulating gaps.

The method of manufacturing a wire harness as described above, wherein, in the step S110, the metal sheet provided is a metal sheet having a predetermined shape, the predetermined shape being a planar shape or a curved surface shape.

The method of manufacturing a wire harness as described above, wherein the predetermined shape is a curved shape, and the metal piece in the curved shape is formed by forging, rolling, bending, stamping, extruding, or integral casting.

The method of manufacturing a wire harness as described above, wherein the method of manufacturing a wire harness further includes: step S127, which is located after step S125 and before step S130: and electrically connecting preset different layers of conductors in the n layers of conductors by welding or crimping.

The method of manufacturing a wire harness as described above, wherein the method of manufacturing a wire harness further includes: step S150 located after the step S130: and electrically connecting the preset different layers of conductors in the n layers of conductors by punching holes in the insulating layer and pouring a conductive material into the holes.

The method of manufacturing a wire harness as described above, wherein the method of manufacturing a wire harness further includes: step S150 located after the step S140: and electrically connecting the preset different layers of conductors in the n layers of conductors by punching holes in the insulating layer and pouring a conductive material into the holes.

The method of manufacturing a wire harness as described above, wherein the method of manufacturing a wire harness further includes: step S160: after obtaining a wire harness having n layers of conductors, the wire harness is wound into a cylindrical structure around a center wire.

The method of manufacturing a wire harness as described above, wherein step S155 located before the step S160: a cooling tube is disposed at the centerline.

The method of manufacturing a wire harness as described above, wherein the method of manufacturing a wire harness further includes: step S170: and punching 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 is electrically connected with a specified conductor, and the other end of the conductive terminal is positioned outside the insulating layer on the outermost side.

The method of manufacturing a wire harness as described above, wherein in the step S120, the at least one conductor is a plurality of conductors insulated from each other.

The method of manufacturing a wire harness as described above, wherein in the step S120, the material reducing process is: and (3) removing the area to be removed of the metal sheet by ablation by adopting laser or plasma arc.

The method of manufacturing a wire harness as described above, wherein, in the step S120, the performing of the material reduction process on the metal sheet is: and performing material reduction treatment on the metal sheet in a nitrogen or inert gas environment.

The method of manufacturing a wire harness as set forth above, wherein in the step S130, the process of forming the insulating layer is one or more of a coating process, a spray coating process, a dip plating process, an injection molding process, and a dip molding process.

The method of manufacturing a wire harness as described above, wherein the step S120 includes: after at least one conductor with a preset conductive track is formed, cleaning and drying are carried out on the conductor.

The invention also provides a wire harness manufactured by the method for manufacturing the wire harness.

The wire harness as described above, wherein the metal sheet is a rigid metal sheet.

The wire harness as described above, wherein the metal sheet is a flexible metal sheet.

The wire harness as described above, wherein the material of the metal sheet includes one or more of nickel or an alloy thereof, cadmium or an alloy thereof, zirconium or an alloy thereof, chromium or an alloy thereof, cobalt or an alloy thereof, manganese or an alloy thereof, aluminum or an alloy thereof, tin or an alloy thereof, titanium or an alloy thereof, zinc or an alloy thereof, copper or an alloy thereof, silver or an alloy thereof, and gold or an alloy thereof.

The wire harness as described above, wherein the metal sheet has a thickness of 0.03mm to 68 mm.

The wire harness as described above, wherein the insulating layer is made of one or more of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene.

The wire harness as described above, wherein the insulating layer has a breakdown strength of 0.3KV/mm to 35 KV/mm.

The wire harness as described above, wherein the insulating layer has a thickness of 0.03mm to 5 mm.

The wire harness as described above, wherein the wire harness is a signal wire.

The method for manufacturing the wire harness and the wire harness of the invention have the characteristics and advantages that:

1. the invention provides a method for manufacturing a wire harness in a material reducing mode, which is characterized in that unnecessary parts on a metal sheet are removed, the remaining parts are required conductors, and then an insulating protective layer is formed on the outer side of each conductor to obtain the wire harness;

2. according to the invention, the multilayer insulating layers and the multilayer conductors are alternately manufactured layer by layer to obtain the wire harness with the multilayer insulating layers and the multilayer conductors alternately arranged, the manufacturing method is simple, the manufacturing efficiency is high, and the manufacturing cost of the complex wire harness is reduced;

3. according to the invention, the multilayer conductors are manufactured, and the insulating layers are integrally formed outside the multilayer conductors, so that the wiring harness with the multilayer insulating layers and the multilayer conductors alternately arranged is obtained, the manufacturing method is simple, the manufacturing efficiency is high, and the manufacturing cost of the complex wiring harness is reduced;

4. according to the invention, the conductors of different layers are electrically connected, so that the design scheme of the electric circuit is optimized, and a more complex wiring harness of the conductive circuit can be manufactured;

5. according to the invention, the metal sheet is subjected to material reduction treatment in a nitrogen or inert gas environment, so that the metal sheet is prevented from being oxidized, and the quality and the qualification rate of the wire harness are improved;

6. according to the invention, the wiring harness with the multilayer conductors is curled into the cylindrical structure, so that the occupied space during the assembly of the wiring harness is reduced, and when the mounting position of the wiring harness is not a plane but a groove or an included angle, the wiring harness is curled into the cylindrical structure, so that the wiring harness is convenient to arrange;

7. the cooling pipe is arranged in the center of the coiled wire bundle, and flowing cold air or cooling liquid is introduced into the cooling pipe, so that the problem of heat dissipation of the wire bundle is solved;

8. the invention realizes the leading-out of the electrical branch by inserting the conductive terminal into the coiled wire bundle.

Drawings

The drawings are only for purposes of illustrating and explaining the present invention and are not to be construed as limiting the scope of the present invention. Wherein:

fig. 1 is a schematic flow chart of a first embodiment of a method of manufacturing a wire harness of the present invention;

fig. 2 is a schematic flow chart of a second embodiment of the method of manufacturing a wire harness of the present invention;

fig. 3 is a schematic flow chart of a third embodiment of the method of manufacturing a wire harness of the present invention;

FIG. 4 is a schematic view of a laser or plasma arc gun for subtractive processing of a metal sheet;

fig. 5 is a schematic structural view of a first embodiment of the wire harness of the present invention;

fig. 6 is a schematic structural view of a second embodiment of the wire harness of the present invention;

fig. 7 is a schematic structural view of a third embodiment of the wire harness of the present invention;

FIG. 8 is an enlarged view of a portion of FIG. 7 at A;

fig. 9 is a schematic structural view of a fourth embodiment of the wire harness of the present invention;

fig. 10 is a partial enlarged view at B in fig. 9;

fig. 11 is a schematic structural view of a fifth embodiment of the wire harness of the present invention.

Main element number description:

1. a metal sheet; 2. a conductor; 3. an insulating layer; 4. a conductive material; 5. a laser or plasma arc gun;

6. a connection point; 7. a terminal; 8. a cooling tube; 9. and a conductive terminal.

Detailed Description

In order to more clearly understand the technical features, objects, and effects of the present invention, embodiments of the present invention will now be described with reference to the accompanying drawings. In the description of the present invention, "a plurality" means two or more unless otherwise specified. In the description of the present invention, unless otherwise specified, the term "connected" is to be understood broadly, for example, it may be a fixed connection, a detachable connection, a direct connection, or an indirect connection via an intermediate medium, and it is obvious to those skilled in the art that the above terms are used in the patent in a specific sense.

Implementation mode one

The present invention provides a method of manufacturing a wire harness, as shown in fig. 1, 4, 5, comprising the steps of:

step S110: providing a metal sheet 1;

step S120: performing material reduction treatment on the metal sheet 1 to enable the metal sheet 1 to form at least one conductor 2 with a preset conductive track, wherein the preset conductive track can be a conductive track with any trend and can be arranged according to actual needs;

step S130: an insulating layer 3 is formed on the conductor 2 so as to wrap the conductor 2 by the insulating layer 3.

The invention provides a method for manufacturing a wire harness in a material reducing mode, which is characterized in that unnecessary parts on a metal sheet are removed, the remaining parts are required conductors, and then an insulating protective layer is formed on the outer side of each conductor to obtain the wire harness.

In a first embodiment, as shown in fig. 2, 6, 7, 8, the method is for manufacturing a wire harness having n layers of conductors 2, n being a positive integer greater than 1, the method further comprising the steps of:

step S100 before step S110: laying an insulating layer 3;

step S140 located after step S130: repeating the step S110 to the step S130 (n-1) times until a wire harness having n layers of conductors 2 is obtained;

in step S130, the forming of the insulating layer 3 on the conductor 2 is: laying an insulating layer 3 on the conductor 2 formed at the previous time; in each step S110, the providing a metal sheet 1 is: the metal sheet 1 is arranged on the insulating layer 3 laid at the previous time, namely the insulating layer 3 and the conductor 2 are manufactured layer by layer, so that the wire harness with the multiple layers of insulating layers 3 and the multiple layers of conductors 2 arranged alternately is obtained, the manufacturing method is simple, the manufacturing efficiency is high, and the manufacturing cost of the complex wire harness is reduced.

In this embodiment, the metal sheet 1 may be a rigid metal sheet or a flexible metal foil. The thickness of the flexible metal foil is smaller, the thickness is generally 0.05 mm-1 mm, the flexible metal foil is particularly suitable for manufacturing wiring harnesses (such as signal wires) of small-wire-diameter conductors, and the problem that the wiring harnesses of the small-wire-diameter conductors are difficult to manufacture is solved.

In this embodiment, the metal sheet 1 provided in step S110 is a metal sheet having a predetermined shape, and the predetermined shape is a planar shape or a curved shape (three-dimensional shape). When the metal sheet is a rigid metal sheet, the metal sheet needs to be shaped in advance, and then the shaped metal sheet is placed on the insulating layer, for example, the metal sheet can be shaped in a forging, rolling, bending, stamping, extruding or integral casting manner; when the metal sheet is a flexible metal foil, the insulating layer can be made into a preset shape, for example, the surface of the insulating layer is planar or curved, then the flexible metal foil is placed on the surface of the insulating layer, the flexible metal foil can be naturally attached to the surface of the insulating layer, and the shape of the flexible metal foil is consistent with the shape of the surface of the insulating layer.

In this embodiment, the method further includes the following step of electrically connecting:

step S150 located after step S140: predetermined different layers of conductors 2 among the n layers of conductors 2 are electrically connected by punching holes in the insulating layer 3 and pouring the conductive material 4 into the holes, that is, after the multilayer insulating layer 3 and the multilayer conductors 2 are alternately arranged, the insulating layer 3 is punched and poured with the conductive material 4, thereby electrically connecting the predetermined different layers of conductors 2.

In a second embodiment, as shown in fig. 3, 6, 7, 8, the method is for manufacturing a wire harness having n layers of conductors 2, n being a positive integer greater than 1, the method for manufacturing the wire harness further comprising the steps of:

step S115 located after step S110 and before step S120: fixing the metal sheet 1 by clamping it with a clamping member such as a jig;

step S125 located after step S120 and before step S130: repeating the step S110 to the step S120 (n-1) times until n layers of conductors 2 are formed;

wherein, each step S115 repeatedly executed includes: keeping an insulation gap between the metal sheet 1 fixed this time and the metal sheet 1 fixed last time; in step S130, the forming of the insulating layer 3 on the conductor 2 is: the insulating layers 3 are formed on the surfaces of all the conductors 2 and in all the insulating gaps, namely, the multilayer conductors 2 are firstly manufactured, and then the insulating layers 3 (or called insulators) are integrally formed outside the multilayer conductors 2, so that the wiring harness with the multilayer insulating layers 3 and the multilayer conductors 2 alternately arranged is obtained, the manufacturing method is simple, the manufacturing efficiency is high, and the manufacturing cost of the complex wiring harness is reduced.

In this embodiment, the metal sheet 1 is preferably a rigid metal sheet, because the rigid metal sheet has better rigidity and is easy to fix, and the flexible metal foil has smaller thickness and is difficult to fix without the support of the insulating layer, so the flexible metal foil is more suitable for being made into a wire harness by the method of the first embodiment.

In this embodiment, the metal sheet 1 provided in step S110 is a metal sheet having a predetermined shape, and the predetermined shape is a planar shape or a curved shape (three-dimensional shape). For example, the metal sheet may be shaped by forging, rolling, bending, stamping, extruding or integral casting, and then the shaped metal sheet may be fixed.

Forging, which is a processing method for obtaining a forging with certain mechanical property, certain shape and size by applying pressure to a metal blank by using a forging machine to generate plastic deformation, and mainly processes a rigid metal plate with larger thickness.

The rolling refers to the mechanical process of deformation of a rolled piece between rollers and mainly aims at processing a plane shape and a simple curved surface.

Bending, which means that a metal plate is subjected to elastic deformation and then plastic deformation under the pressure of an upper die or a lower die of a bending machine, and mainly aims at a three-dimensional shape of linear bending.

The stamping is a forming method in which a press and a die are used to apply external force to a plate, a strip, a pipe, a profile and the like to cause plastic deformation or separation, thereby obtaining a workpiece (stamping part) with a required shape and size. The method mainly aims at processing the rigid metal plate with small thickness and complex shape.

Extrusion is a press working method in which a blank placed in a female die is pressed by a punch or a male die to cause plastic flow, thereby obtaining a product corresponding to the shape of a hole or a male-female die of a die.

The integral casting is a method that liquid metal is cast into a casting cavity with a shape matched with that of a part, and the part is obtained at one time after the liquid metal is cooled and solidified.

In this embodiment, if the conductors of different layers need to be electrically connected, there are the following two schemes.

In one possible solution, the method of manufacturing a wire harness comprises the following electrical connection steps:

step S127 after step S125 and before step S130: the predetermined different conductors in the n conductors are electrically connected by welding or crimping, that is, the predetermined different conductors are electrically connected before the insulating layer is formed, and then the insulating layer is formed outside all the conductors. The method for connecting the conductors in the scheme is simple and convenient to operate.

In another possible embodiment, a method of manufacturing a wire harness includes the steps of:

step S150 located after step S130: the conductors 2 of different layers are electrically connected by punching holes in the insulating layer 3 and pouring the conductive material 4 into the holes, that is, the insulating layer 3 is firstly manufactured outside all the conductors 2, and then the conductive material 4 is punched and poured into the insulating layer 3, so that the conductors 2 of different layers are electrically connected.

In one embodiment, a method of manufacturing a wire harness includes the steps of: step S160: after obtaining the wire harness having n layers of conductors 2, the wire harness is rolled around a center line into a cylindrical structure (as shown in fig. 9, 10) to reduce the occupied space when the wire harness is assembled, and when the wire harness is installed not in a plane but in a groove or an angle position, the wire harness is conveniently arranged by rolling the wire harness into a cylindrical structure. After the wire harness is wound into a tubular structure, the wire harness may be bent according to the shape of the wire harness installation position.

Further, step S155, which precedes step S160, of: the central line department of pencil sets up cooling tube 8, and the pencil during operation lets in the cold air or the coolant liquid that flow in to cooling tube 8, solves the pencil heat dissipation problem.

However, the present invention is not limited to the installation timing of the cooling pipe 8, and the wire harness may be wound around the cooling pipe 8 to form a tubular structure, or the wire harness may be wound to form a tubular structure, and a center hole may be provided at the center line, and then the cooling pipe 8 may be inserted into the center hole.

Further, the method of manufacturing a wire harness includes the steps of:

step S170: the insulating layer 3 is punched, and the conductive terminal 9 (as shown in fig. 11) is inserted into the hole, so that one end of the conductive terminal 9 extends into the insulating layer 3 and is electrically connected with the designated conductor 2, and the other end of the conductive terminal 9 is positioned outside the insulating layer 3 at the outermost side, so as to realize the leading-out of the electrical branch. The conductive terminal 9 is electrically connected with the designated conductor 2 by either plug-in contact connection or welding, and the conductive terminal 9 may be a male terminal or a female terminal with a slot.

In one embodiment, in step S120, the at least one conductor is a plurality of mutually insulated conductors, that is, each layer of conductors includes a plurality of mutually insulated conductors, so as to obtain a wiring harness with a simple structure and a complex conductive loop.

However, the invention is not limited thereto, and in other embodiments, each layer of conductor may include only one conductor, or a plurality of conductors in each layer of conductor may have some conductors electrically connected, and all of them may be arranged according to actual needs.

In one embodiment, in step S120, the material reduction method includes: and (3) removing the area to be removed of the metal sheet by ablation by adopting laser or plasma arc. For example, the width of laser or plasma arc ablation is 0.03mm to 5 mm.

Specifically, the laser or plasma arc gun 5 is adopted 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 three-dimensional servo mechanism can be adopted to program and design the moving path of the laser or plasma arc gun 5, so that conductors of different loops are processed, the flexible production degree is high, and the flexible production device can be suitable for flexible production with multiple models and less batches.

However, the invention is not limited thereto, and in other embodiments, the material reduction processing method may be mechanical cutting, die cutting, or the like.

In one embodiment, in step S120, the metal sheet is subjected to a material reduction process in a nitrogen or inert gas environment to prevent oxidation of the metal sheet.

In one embodiment, the process for forming the insulating layer or laying the insulating layer is one or more of a coating process, a spraying process, a dip plating process, an injection molding process and a dip molding process.

In one embodiment, the insulating layer 3 is made of one or more of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene.

In an embodiment, the step S120 further includes: after at least one conductor with a preset conductive track is formed, the conductor is subjected to cleaning treatment and drying treatment, and then an insulating layer is formed on the conductor.

The copper foil cleaning can adopt one or more of a solution washing mode, an ultrasonic washing mode and a high-pressure washing mode, and the copper foil drying can adopt one or more of a natural drying mode, a cold-hot air drying mode and an infrared irradiation drying mode.

Natural drying is a method of drying parts by using solar radiation energy, hot air, and the like under natural conditions. The natural drying is characterized by long drying time and large occupied area, but does not need any equipment and energy.

And (4) drying by cold and hot air, namely performing heat and moisture exchange with the parts in a forced convection circulation mode by taking cold and hot air as a drying medium to take away moisture on the surface of the material. The cold and hot air drying is characterized by longer drying time and generally lower efficiency.

Infrared radiation drying, also known as radiation drying, refers to a drying method that uses infrared radiation to vaporize moisture in a part. The infrared irradiation drying is characterized by high drying speed but energy consumption.

Second embodiment

As shown in fig. 5 to 7, the present invention also provides a wire harness manufactured by the method of manufacturing a wire harness of the first embodiment. The beneficial effects of this embodiment are the same as those of the first embodiment, and are not described herein again.

In one embodiment, the metal sheet 1 is a rigid metal sheet. The rigid metal sheet has better rigidity and is easy to fix, and the metal sheet can be shaped by adopting a forging, rolling, bending, stamping, extruding or integral casting mode and then fixed.

In an embodiment, the metal sheet 1 is a flexible metal sheet. The flexible metal sheet can be a thin metal plate or a metal foil, can be easily deformed, and can be used for some wire harnesses which have low current requirements but complex wire harness shapes.

In one embodiment, the material of the metal sheet 1 includes one or more of nickel or its alloy, cadmium or its alloy, zirconium or its alloy, chromium or its alloy, cobalt or its alloy, manganese or its alloy, aluminum or its alloy, tin or its alloy, titanium or its alloy, zinc or its alloy, copper or its alloy, silver or its alloy, and gold or its alloy. The most common metal material for the conductor is copper or copper alloy, because the conductivity of copper is better in metal, and copper is not precious metal, the processing is more convenient, and the extensibility is good. However, as copper prices have increased, the material cost of using copper as a conductor has become higher. For this reason, alternatives to metallic copper are being sought to reduce costs. The content of metal aluminum in the earth crust is about 7.73%, the price is relatively low after the refining technology is optimized, the weight of the aluminum is lighter than that of copper, and the conductivity is inferior to that of the copper, so that the aluminum or the aluminum alloy can replace part of the copper or the copper alloy in the field of electrical connection.

In one embodiment, the thickness of the metal sheet 1 is 0.03mm to 68 mm. In the wire harness, the sectional area of the conductor determines the current which can be conducted by the conductor, and generally, the conductor for realizing signal conduction has smaller current and smaller conductor sectional area, for example, the minimum sectional area of a signal wire of the automobile wire harness can reach 0.1mm²The conductor for realizing the power supply conduction has larger current and larger conductor sectional area, for example, the maximum sectional area of a wire harness of an automobile storage battery reaches 260mm²。

When the thickness of the metal sheet 1 is less than 0.03mm, it is preferable to obtain a sectional area of 0.1mm²The conductor of (2) is to cut a conductor having a width of at least 3.3mm, and the smaller the thickness, the larger the width, the strength of the conductor cannot be satisfied, and the layout of the wire harness is restricted, and the area of the wire harness cannot be reduced.

When the thickness of the metal sheet 1 is more than 68mm, it is desirable to obtain a sectional area of 260mm²The conductor of (2) is to cut a conductor with the width of at least 3.8mm, the larger the thickness is, the smaller the width is, but the larger the thickness is, the more difficult the cutting of the metal sheet is, and the flatness of the cut can not be guaranteed.

Therefore, the inventor selects the thickness of the metal sheet 1 to be 0.03mm to 68mm, and 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.

In one embodiment, the material of the insulating layer 3 includes one or more of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and polyethylene.

In one embodiment, the breakdown strength of the insulating layer 3 is 0.3KV/mm-35 KV/mm. The breakdown strength is also called dielectric breakdown strength. Indicating that the material can bear the highest electric field strength without being damaged (broken down) under the action of the electric field. When the breakdown strength of the insulating layer is lower than 0.3KV/mm, a part of the thinner insulating layer is likely to be broken down under normal voltage, thereby causing the insulation to be ineffective. When the breakdown strength of the insulating layer is higher than 35KV/mm, the high voltage higher than 35KV cannot occur in a common vehicle-mounted environment, and the cost of the integrated wiring harness assembly can be increased due to the adoption of a material with excessively high breakdown strength, so that design waste is caused.

In one embodiment, the thickness of the insulating layer 3 is 0.03mm to 5 mm. If the thickness of insulating layer is less than 0.03mm, not only can not guarantee that the breakdown voltage of insulating layer is higher than operating voltage, also can not guarantee the wear resistance of insulating layer, scrape the back many times, can make the insulating layer damaged, expose conductor 2, can lead to the condition of electric leakage or short circuit, cause the circuit to damage, the functional failure. When the thickness of the insulating layer is equal to 5mm, the breakdown voltage, the insulation resistance and the wear resistance of the insulating layer can meet the requirements, but if the thickness is larger than 5mm, the thickness of the insulating layer is larger, and in the processing process or problems such as air holes, collapse and the like occur, the performance of the insulating layer is reduced, in addition, the material of the insulating layer is wasted, and the processing procedures and time are increased, so that the thickness of the insulating layer selected by an inventor is 0.03mm-5 mm. In one embodiment, the wiring harness is a signal wire.

The electric appliances in the existing electric connection field have more and more functions and more signal transmission lines, the signal lines account for more than 80 percent of the existing wiring harness loop, the signal lines are characterized by small conduction current and do not need large-diameter wires for conduction, and the existing signal lines mainly use the cross-sectional area of 0.5m²And gradually starts to use 0.13m of small-diameter wire²The smaller the wire diameter, the higher the performance requirements of the wire and the requirements of the wire production process, and the higher the costIncreasingly, this has been a bottleneck that prevents the use of small wire diameter wires in wire harnesses.

By adopting the material reducing mode, the method for manufacturing the signal wire is very simple and efficient, has high manufacturing precision and low manufacturing cost, and provides support for the application of the small-wire-diameter wire on the wire harness.

In one embodiment, the conductors 2 of the wire harness have terminals located outside the insulating layer 3, the terminals of the conductors 2 of different layers may be connected to the connection point 6 (as shown in fig. 7) by crimping or welding, and the terminals may also be connected to other electrical circuits by terminals 7 (as shown in fig. 6), such as by gold fingers, pin terminals, soldered wires, and the like.

In one embodiment, as shown in fig. 9 and 10, the shape of the wire harness is a curled cylindrical structure to reduce the occupied space when the wire harness is assembled.

As shown in fig. 9, further, a cooling pipe 8 is provided at the center of the curl of the wire harness to improve the heat radiation performance of the wire harness.

As shown in fig. 11, further, a conductive terminal 9 is inserted into the insulating layer 3 of the wire 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 to implement electrical branch extraction. Wherein the conductive terminal 9 can be a male terminal or a female terminal with a slot.

Compared with the prior art, the method for manufacturing the wire harness and the wire harness have the advantages that:

1. the wire harness is produced in a material reducing mode, automatic, large-batch and rapid production can be realized, the processing speed is high, the precision is high, the cost of the wire harness is greatly reduced, and the qualification rate of the wire harness is improved;

2. the metal sheet can form a wire harness with a three-dimensional space structure, and can be suitable for assembling the wire harness in different environments;

3. through the material reduction mode, conductors of different conductive loops can be processed, the flexible production degree is high, and the flexible production method is suitable for flexible production with multiple models and less batches;

4. through a material reduction mode, more loops can be processed on a metal sheet with a smaller area, and the requirement of more electrical loops is met;

5. the conductors of different layers are electrically connected, so that the design scheme of the electric loop is optimized, and the method can be suitable for more complicated wiring harnesses;

6. when the metal sheet is subjected to material reduction and ablation processing, the metal sheet is effectively prevented from being oxidized by adopting nitrogen or inert gas for protection.

The above description is only an exemplary embodiment of the present invention, and is not intended to limit the scope of the present invention. Any equivalent changes and modifications that can be made by one skilled in the art without departing from the spirit and principles of the invention should be considered within the scope of the invention. It should be noted that the components of the present invention are not limited to the above-mentioned whole application, and various technical features described in the present specification can be selected to be used alone or in combination according to actual needs, so that the present invention naturally covers other combinations and specific applications related to the invention.