how to wrap automotive wire harness with cloth tape?

To wrap automotive wire harnesses with cloth tape, follow these key techniques and considerations:

‌1. Preparation & Material Selection‌

• Choose polyester fabric cloth tape with pressure-sensitive adhesive, available in common widths like 9mm, 19mm, or 25mm. Prioritize tape with noise reduction, wear resistance (E-grade), and flame retardancy for critical areas like engine compartments or high-voltage wiring‌.

‌2. Core Wrapping Methods‌

• ‌Point Wrapping (点缠)‌: Secure branch points by overlapping tape tightly twice at specific locations, ensuring no twisting and direct adhesion to wires‌.
• ‌Interval Wrapping (间隔缠绕)‌: Wrap tape with exposed gaps between segments. Start/end with one full wrap, maintaining consistent spacing (gap ≈ tape width)‌.
• ‌Full Coverage (密缠)‌: Overlap tape by 1/2 or 1/4 width for complete insulation. Avoid gaps or adhesive reversal; ensure ends are firmly pressed to prevent peeling‌12.
• ‌Branch Handling‌: At wire junctions, cross-wrap tape twice internally and externally to fix branches securely‌.

‌3. Application by Vehicle Zone‌

• ‌Engine Bay/High-Voltage Areas‌: Use flame-retardant tape (e.g., orange for EV high-voltage lines) with enhanced abrasion resistance. Avoid polyester tapes if temperatures exceed 150°C; switch to corrugated tubes where friction is high‌13.

• ‌Passenger Cabin‌: Employ hand-tearable, low-VOC tapes for manual wrapping. Ensure minimal odor and compliance with volatile organic compound standards‌.
• ‌Underbody/Exposed Areas‌: Combine cloth tape with corrugated tubes or PVC sleeves for abrasion and corrosion protection‌.

‌4. Critical Best Practices‌

• ‌Tension Control‌: Apply tape without excessive stretching to maintain adhesive integrity and conformability‌2.
• ‌Termination‌: Press tape ends firmly for 2–3 laps to prevent lifting. For multi-wire joints, wrap ≥10mm beyond the splice point‌.
• ‌Validation‌: Verify no wire exposure after bending, especially at 90° angles‌.

‌5. Evolving Standards‌

• ‌New Energy Vehicles (NEVs)‌: Upgrade to E-grade abrasion-resistant tape for main harnesses, and ensure flame retardancy aligns with larger battery capacities. Tesla recalls highlight critical wear/fire risks‌.
• ‌Material Innovation‌: UV-curable hot-melt adhesives now enable eco-friendly production while enhancing temperature/wear resistance‌4.

Adhering to these methods ensures durability, safety, and compliance with automotive industry standards.