Method for producing wire harness using additive manufacturing, and wire harness

1 . A method for producing a wire harness, comprising:

Step S 10 : arranging a plurality of wire harness conductors; and

Step S 20 : forming an insulator by additive manufacturing,

wherein gaps are disposed between the wire harness conductors, and wherein the insulator wraps the wire harness conductors and is filled in the gaps;

wherein the method further comprises Step S 01 performed before the Step S 10 , the Step S 01 comprising preparing a molding housing provided with a mold cavity, wherein in the Step S 10 wire harness conductors are arranged in the mold cavity, and wherein in the Step S 20 the insulator is formed in the mold cavity;

wherein the method further comprises Step S 02 performed before the Step S 10 , wherein the Step S 02 comprises disposing supporting pieces in the mold cavity at intervals along an axial direction of wire harness conductors for supporting the wire harness conductors, with each supporting piece comprising a side surface and a peripheral surface, wherein the side surfaces and the peripheral surfaces are connected to the insulator, wherein each of the wire harness conductors passes through the side surface or contacts the peripheral surface of a respective supporting piece, the insulator forms an integrated structure with the supporting pieces, the supporting pieces serve as a part of the produced wire harness, and the supporting pieces and the insulator are made of a same material; and

wherein in the Step S 10 , at least two of wire harness conductors are electrically connected to each other to enable the plurality of wire harness conductors in the wire harness to realize a function of complex circuits.

2 . The method for producing the wire harness according to claim 1 , further comprising Step S 30 performed after the Step S 20 , wherein the Step S 30 comprises taking the insulator and the wrapped wire harness conductors out of the mold cavity.

3 . The method for producing the wire harness according to claim 1 , wherein in the Step S 10 , the plurality of wire harness conductors are disconnected from each other, or at least two of the wire harness conductors are electrically connected by one or more selected from crimping, welding, 3D printing connection, laser sintering connection and connection point printing.

4 . The method for producing the wire harness according to claim 1 , wherein in the Step S 10 , each of the wire harness conductors is extended along a straight line or a curved line.

5 . The method for producing the wire harness according to claim 1 , wherein in the Step S 10 , the plurality of wire harness conductors are distributed in a same plane, or are distributed and extended in a space.

6 . The method for producing the wire harness according to claim 1 , wherein the Step S 10 is performed by a process selected from one or more of a 3D printing process, a laser powder sintering process, a metal injection molding process, a laser subtracting process, a conductive ink printing process and a printed circuit board process.

7 . The method for producing the wire harness according to claim 1 , wherein:

the method for producing the wire harness adopts a wire feeder; and

in the Step S 10 , the wire harness conductors are delivered into the mold cavity by the wire feeder.

8 . The method for producing the wire harness according to claim 1 , wherein in the Step S 20 , the insulator is formed by a 3D printing process, an injection molding process, a spraying process or a dip molding process.

9 . The method for producing the wire harness according to claim 1 , wherein there are a plurality of supporting pieces disposed at intervals along an axis direction of the wire harness conductors in the cavity, and each of the supporting pieces has multiple recesses along an arrangement direction in which the multiple wire harness conductors are arranged at intervals.

10 . A wire harness produced by the method for producing the wire harness according to claim 1 , wherein the wire harness comprises the wire harness conductors and the insulator, the gaps are disposed between the wire harness conductors, and the insulator wraps the wire harness conductors and is filled in the gaps, supporting pieces are provided in the insulator at intervals along an axial direction of the wire harness conductors for supporting the wire harness conductors, each of the supporting piece comprises a side surface and a peripheral surface, wherein the side surface and the peripheral surface are connected to the insulator, the wire harness conductors pass through the side surface or contact the peripheral surface, the insulator forms an integrated structure with the supporting pieces, the supporting pieces serve as a part of the produced wire harness, and the supporting pieces and the insulator are made of a same material; and

at least two of the wire harness conductors are electrically connected to each other to enable the plurality of wire harness conductors in the wire harness to realize a function of complex circuits.

11 . The wire harness according to claim 10 , wherein:

a molding housing is provided with a mold cavity;

the wire harness conductors are arranged in the mold cavity;

and

the wire harness conductors, the insulator and the molding housing form an integrated structure.

12 . The wire harness according to claim 10 , wherein each of the wire harness conductors is extended along a straight line or a curved line.

13 . The wire harness according to claim 10 , wherein the plurality of wire harness conductors are distributed in a same plane, or distributed and extended in a space.

14 . The wire harness according to claim 10 , wherein a material of the wire harness conductors comprises a non-metal material, and wherein the non-metal material is selected from the group consisting of one or more of a conductive ceramic, a carbon-containing conductor, a solid electrolyte, a mixed conductor and a conductive polymer material.

15 . The wire harness according to claim 14 , wherein the carbon-containing conductor is selected from the group consisting of one or more of graphite powder, a carbon nanotube material and a graphene material.

16 . The wire harness according to claim 10 , wherein the insulator has a breakdown strength of 0.3 KV/mm to 35 KV/mm.

17 . The wire harness according to claim 10 , wherein the insulator has a thickness of 0.03 mm to 5 mm.

18 . The wire harness according to claim 10 , wherein there are a plurality of supporting pieces disposed at intervals along an axis direction of the wire harness conductors in the cavity, and each of the supporting pieces has multiple recesses along an arrangement direction in which the multiple wire harness conductors are arranged at intervals.