Wiring harness

Abstract

The invention relates to a conductor assembly with a conductor arrangement having at least two conductors (3; 5; 7; 9) and a conductor support (21), wherein the conductor assembly (1; 101; 303; 403) has a support section (TA) in which the conductors (3; 5; 7; 9) run within the conductor support (21), and wherein the conductors (3; 5; 7; 9) run at least sectionally next to each other in the support section (TA).

Description

Technical field

[0001] The present invention relates to a wiring harness. State of the art

[0002] It is generally known that electrical and electronic components of a vehicle, such as power sources, switches, electrical consumers, and control units, are electrically connected to one another by means of a functionally or customer-specific configured wiring harness to form an electrical network in which information is exchanged between the various network components or which are supplied with electrical energy. Such a wiring harness, also known as a cable harness, consists of a multitude of electrical conductors or wires (hereinafter referred to simply as electrical conductors) bundled together and a covering that encloses the conductor bundle. Electrical connectors or similar connection elements may be attached to the ends of the conductors.

[0003] However, this wiring harness has the disadvantage that the bundled wiring harness can only be attached to a component in a space-saving manner with increased effort. Description of the invention

[0004] The object of the invention is therefore to provide a wiring harness that can be attached to a component in a simple and space-saving manner.

[0005] This problem is solved by the features of the independent claims. Advantageous embodiments of the invention are specified in the dependent claims, the following description, and the figures.

[0006] The invention proposes a cable assembly with a conductor arrangement comprising at least two conductors and a conductor support, wherein the cable assembly has a support section in which the conductors run within the conductor support, and wherein the conductors run side by side at least partially in the support section. Because the conductors run side by side at least partially in the support section and are not bundled together, the cable assembly has a low profile in the support section and can therefore be attached to a component in a space-saving manner in the area of ​​the support section.

[0007] It should be explicitly noted here that the conductors of a wiring harness are not limited to electrical conductors, but can also be any other type of conductor that can be part of a wiring harness. This includes, for example, optical conductors such as fiber optic cables, pneumatic or hydraulic lines for transporting liquids or gases, as well as data or communication lines for transmitting signals. Mechanical conductors, such as push or pull rods, and heat transfer conductors, such as thermal lines or refrigerant lines, also fall under this definition. Therefore, the term "conductor" or "electrical conductor" is used here explicitly as a synonym for any type of conductor and not just electrical conductors alone.

[0008] In order to freely define the routing of the conductors within the conductor carrier and to be able to manufacture the conductor set in a simple manner, an exemplary embodiment provides that the conductor carrier has a carrier layer and a cover layer that is materially bonded to the carrier layer in sections, wherein it is provided that two or more conductors of the conductor arrangement run in the carrier section between the carrier layer and the cover layer.

[0009] Preferably, the top layer is joined to the carrier layer section by section by gluing and / or fusing and / or welding.

[0010] In order to allow the conductors of the conductor arrangement to be guided not only parallel to each other within the support section, but also crossed while maintaining an equally flat design of the conductor set, an exemplary embodiment provides that two or more conductor passages extend within the conductor support, wherein it is provided that a first conductor runs in a first conductor passage of the conductor passages and a second conductor runs in a second conductor passage of the conductor passages, and wherein it is provided that the first conductor passage and the second conductor passage intersect in a crossing area of ​​the support section, in which the first conductor runs over or under or alongside the second conductor.

[0011] Of course, it is also possible that, for example, the first conductor passage crosses two or more of the other conductor passages of the cable set.

[0012] It is preferred that the first conductor and the second conductor are in contact with the system at the intersection.

[0013] In order to make the conductor set particularly space-saving in sections and to be able to attach it to a component in a process-reliable manner, it is preferably provided that at least two of the conductor passages, preferably the first conductor passage and the second conductor passage, run parallel to each other in the support section and / or the conductors run at least sectionally, preferably at least substantially, in the support section.

[0014] Preferably, one or two or more or all of the conductor passages are each, preferably completely on the outer circumference, bounded to the outside by a section of the carrier layer and a section of the cover layer.

[0015] For example, it is provided that in the first conductor opening, preferably in addition to the first conductor, further conductors of the conductor arrangement run, and / or that in the second conductor opening, preferably in addition to the second conductor, further conductors of the conductor arrangement run. It is preferably provided that the conductors running in the first conductor opening pass over, under, or alongside the conductors running in the second conductor opening at the intersection.

[0016] In order to manufacture the conductor carrier with low weight and in a process-technically simple manner, an exemplary embodiment provides that the support layer is formed by a first planar structure, and / or that the cover layer is formed by a second planar structure. preferably, the material of the first surface structure is identical to the material of the second surface structure.

[0017] In order to manufacture the ladder support as cost-effectively as possible, in an exemplary embodiment it is provided that the first surface structure is formed by a textile surface structure, preferably by a nonwoven fabric or a woven fabric, and that the second surface structure is formed by a film, preferably by a film made of plastic.

[0018] In order to adapt the wiring harness section by section to the respective installation situation, a preferred embodiment provides that the wiring harness has a starting section and / or an end section, wherein it is provided that the conductors of the conductor arrangement run outside the conductor carrier in the starting section and / or in the end section, wherein it is preferably provided that two or more of the conductors run parallel to each other in the starting section and / or the end section and / or are grouped together to form a conductor bundle.

[0019] Preferably, the conductor bundle is wrapped with a winding in the initial section and / or the final section.

[0020] In order to form a particularly mechanically stable connection between the conductor and the conductor support, an exemplary embodiment provides that one, two or more of the conductors each have a conductor sheath, wherein it is provided that one, two or more of the conductor sheaths are each materially bonded, preferably glued and / or fused and / or welded to the conductor support, preferably the support layer and / or the cover layer, and / or wherein it is provided that one, two or more of the conductor sheaths are each not materially bonded to the conductor support, preferably the support layer and / or the cover layer.

[0021] To create the most compact possible conductor assembly, a preferred embodiment provides that the conductor(s), each running in one of the receiving channels, bears against the carrier layer and / or the cover layer over its entire circumference, preferably fully or over a large area. In other words, the receiving channels are dimensioned, preferably with respect to their cross-sectional diameter, preferably precisely, such that the carrier layer and the cover layer bear against the conductor(s) without gaps and / or are connected to the conductor(s) without gaps and / or directly.

[0022] In order to reliably attach the wiring harness to a component, an exemplary embodiment provides that the wiring harness has at least one fastening element for attaching the wiring harness to a component, wherein the fastening element is designed and / or suitable for attaching the wiring harness to the component by means of the fastening element in a force-fit and / or form-fit manner, wherein it is preferably provided that the conductor carrier has an opening which is bounded to the outside by the conductor carrier, preferably the carrier layer and / or the cover layer, and into which the fastening element can be inserted or is inserted, and / or wherein it is preferably provided that the fastening element has an element head which is embedded between the carrier layer and the cover layer.

[0023] The invention further proposes an arrangement with a conductor assembly and a component as described above, wherein the conductor assembly is connected to the component via the conductor carrier, preferably the carrier layer and / or the cover layer, preferably by a material bond and / or by means of the fastening element. Because the conductors in the carrier section run at least partially side by side and are not bundled together, the conductor assembly has a low profile in the carrier section. The conductor assembly attached to the component is thus arranged flat against the component, resulting in a minimal overall height caused by the conductor assembly.

[0024] Preferably, the component to be joined is an electrical and / or electronic component, such as a DC / DC converter, or a body panel or vehicle door. By way of example, the material of a joining surface of the component to which the conductor carrier is connected is a metal, preferably aluminum or an aluminum alloy, or a textile fabric, preferably a nonwoven or woven fabric. However, the material of the joining surface can also be, for example, wood or a plastic.

[0025] Preferably, the conductor support, preferably the carrier layer or the cover layer, is connected to the component being joined, preferably over a surface and / or by means of a material bond, and / or the conductor support, preferably the carrier layer or the cover layer, is connected to the component being joined, preferably at points, by means of the fastening element(s) in a force-fit and / or form-fit manner. Character description

[0026] Advantageous embodiments of the invention are explained in more detail below with reference to the accompanying figures. These show: Fig. 1. In a top view, a first set of wires; Fig. 2 in a side section view along the, in which Fig. 1. In the drawn section plane AA, the first set of lines; Fig. 3. In a top view, a second set of wires; Fig. 4 in a side view showing a first arrangement comprising the first conductor set and a first joining component; Fig. 5 in a side section view the first arrangement in a specific installation situation; Fig. 6 in a side section view a second arrangement, and Fig. 7 in a side section view a third arrangement.

[0027] In the Fig. Figure 1 shows a wiring harness 1. The wiring harness 1 has a conductor arrangement with a conductor 3, a conductor 5, a conductor 7, and a conductor 9. In this or another embodiment of the wiring harness 1, the wiring harness can, of course, also have more or fewer than four conductors. The wiring harness 1 has a starting section AA, a support section TA, and a ending section EA. The support section TA is arranged between the starting section AA and the ending section EA.

[0028] The wiring harness 1 has a connector 11. Each of the conductors 3, 5, 7, and 9 is connected to the connector 11 at its first end. The wiring harness 1 can be electrically connected to an electrical and / or electronic component or to another wiring harness via the connector 11. At the second end of each conductor 3, 5, 7, and 9, opposite the first end of the respective conductor 3, 5, 7, or 9, an electrical connector is arranged and connected to the respective conductor 3, 5, 7, or 9. Conductor 3 is connected to connector 13, conductor 5 to connector 15, conductor 7 to connector 17, and conductor 9 to connector 19. The electrical connectors 13, 15, 17, and 19 are each represented here by a cable lug. Alternatively, the connecting elements 13, 15, 17 and 19 can also be used, for example, as follows:Each connection is formed by a wire end ferrule or a connector. The wiring harness 1 can be connected to an electrical and / or electronic component or to another wiring harness via the connecting elements 13, 15, 17 and 19.

[0029] The conductor assembly 1 further comprises a conductor support 21, which mechanically connects the conductors 3, 5, 7, and 9 parallel to each other and spaced apart. The conductor support 21 extends only along support section TA and serves to shape and hold the conductor assembly 1 and to attach the conductor assembly 1 to a component. Within the conductor support 21 and within support section TA, the conductors 3, 5, 7, and 9 therefore extend within the conductor support 21. Outside support section TA, and thus along the initial section AA and along the final section EA, the conductors 3, 5, 7, and 9 are free of the conductor support 21 and are not directly connected to each other in the initial section AA and the final section EA, but only indirectly via the conductor support 21 in support section TA.

[0030] As this is shown in the Fig. As shown in Figure 2, the conductor carrier 21 has a support layer 23 and a cover layer 25. The support layer 23 and the cover layer 25 are, here only by way of example, each formed by a plastic film. In this or another embodiment of the conductor assembly 1, the support layer 23 can also be formed, for example, by a textile fabric, preferably a nonwoven, instead of the plastic film.

[0031] Several conductor openings, four of which are shown here as examples, are assigned to the conductor carrier 21. Each opening is bounded externally, preferably completely, by both the support layer 23 and the cover layer 25. Conductor 3 extends through a first conductor opening, conductor 5 through a second conductor opening, conductor 7 through a third conductor opening, and conductor 5 through a fourth conductor opening. In conductor set 1, the conductor openings extend side by side, with directly adjacent openings spaced parallel to each other. Furthermore, the first, second, third, and fourth conductor openings extend essentially in a common plane.

[0032] Between the conductor openings, the cover layer 25 is bonded to the carrier layer 23. In the edge regions of the conductor carrier 21, adjacent to the conductor arrangement and / or the conductor openings, the cover layer 25 is also bonded to the carrier layer 23. The conductor openings are also dimensioned such that the carrier layer 23 and the cover layer 25 are in close contact with the conductor 3, 5, 7, or 9 running through the respective conductor opening. To achieve this, the conductor assembly 1 is manufactured by thermoforming under vacuum.

[0033] In the Fig. Figure 3 shows a cable assembly 101. Parts of the cable assembly 101 that are structurally and / or functionally identical to the parts of the cable assembly 1 are designated with the same reference numerals. Unless explicitly stated otherwise, the descriptions for cable assembly 1 also apply to cable assembly 101. The cable assembly 101 is essentially identical to the cable assembly 1 and differs from the cable assembly 1, preferably exclusively, in that the first cable passage and the second cable passage intersect in a crossing area KB within the support section TA. Fig. In the intersection area KB, the first conductor 3 runs behind the plane of the drawing and thus under the second conductor 5. In the intersection area KB, the first conductor opening and the second conductor opening intersect such that the first conductor 3 extends coaxially to the second conductor 5 in the initial section, and the second conductor 5 extends coaxially to the first conductor 3 in the final section. This allows the positions of the connecting elements 13, 15, 17, and 19 to be interchanged for different applications of the cable assembly 101. In the intersection area KB, the first conductor 3, preferably a conductor sheath of the first conductor 3, and the second conductor 5, preferably a conductor sheath of the second conductor 5, are in contact with each other.

[0034] In the Fig. Figure 4 shows an arrangement 201. Parts of arrangement 201 that are structurally and / or functionally identical to the parts of arrangement 101 are designated with the same reference numerals. Unless explicitly stated otherwise, the descriptions for arrangement 101 may also apply to arrangement 201. Arrangement 201 comprises the wiring harness 1 and a joining component 203 formed by a DC / DC converter. In this or another embodiment of arrangement 201, the joining component 203 may also be formed, for example, by a body panel or a door trim. The wiring harness 1, specifically the carrier layer 23, is bonded over its entire surface to the joining component 203, specifically to a joining surface of the joining component 203. In this or another embodiment of arrangement 201, the carrier layer 23 may also be welded or fused to the joining surface, for example.In the initial section AA, conductors 3, 5, 7, and 9 are grouped together as a conductor bundle (here only as an example). Conductors 3, 5, 7, and 9 are in the... Fig. 4. For clarity, these are only illustrated as lines. In the Fig. Figure 5 shows the arrangement 201 in a side section view, with the low-profile wiring harness 1 arranged in a narrow gap 205 extending between the joining component 203 and another component 207. In this or another embodiment of the arrangement 201, the wiring harness 1 can also be replaced, for example, by the wiring harness 101. All descriptions of the arrangement 201 with the wiring harness 1 then apply analogously to the arrangement 201 with the wiring harness 101.

[0035] In the Fig. Figure 6 shows an arrangement 301. Parts of arrangement 301 that are structurally and / or functionally identical to the parts of arrangement 101 are designated with the same reference numerals. Unless explicitly stated otherwise, the descriptions for arrangement 101 may also apply to arrangement 301. Arrangement 301 comprises a conductor assembly 303 and an connecting element 305. The conductor assembly 303 is essentially identical to conductor assembly 1 and differs from conductor assembly 1, preferably exclusively, in that the conductor carrier 21 has an opening that is radially outwardly bounded by the support layer 23 and the cover layer 25. The opening is located approximately midway between conductor 5 and conductor 7.The joining component 305 is essentially identical to the joining component 203 and differs from the joining component 203, preferably exclusively, in that the joining component 305 has a recess 307 which is bounded externally by the joining component 305 and is open in the direction of the wiring harness 303. The arrangement 301 also differs from the arrangement 101 in that the wiring harness 303 is not bonded to the joining component 305, but is positively and / or force-fit connected to the joining component 305 by means of at least one fastening element 311 of the arrangement 301. The fastening element 311 has an element head 313, an element shaft 315, and, preferably, elastically compliant clamping elements 317 that project radially outwards from the element shaft 315.To connect the wiring harness 303 to the joining component 305, the fastening element 311 with its element shaft 315 is guided through the opening to such an extent that the element head 313 rests flat against the cover layer 25. The support layer 23 faces the joining component 305, and the element shaft 315 projects partially into the recess 307, with the clamping elements 317 being clamped, preferably radially to the element shaft 315, between the element shaft 315 and the recess wall of the joining component 305, which defines the recess 307 radially outwards.

[0036] In the Fig.Figure 7 shows an arrangement 401. Parts of arrangement 401 that are structurally and / or functionally identical to the parts of arrangement 301 are designated with the same reference numerals. Unless explicitly stated otherwise, the descriptions for arrangement 301 may also apply to arrangement 401. Arrangement 401 is essentially identical to arrangement 301 and differs from arrangement 301, preferably exclusively, in that the conductor assembly 303 is replaced by a conductor assembly 403. Unless explicitly stated otherwise, the descriptions for conductor assembly 303 may also apply to conductor assembly 403. Conductor assembly 403 differs from conductor assembly 303, preferably exclusively, in that the opening is only associated with the carrier layer 23 and not with the cover layer 25, and is therefore only bounded externally by the carrier layer 23.Furthermore, the cable assembly 403 differs from the cable assembly 303 in that the element head 313 rests flat on the carrier layer 23 and is completely covered by the cover layer 25 on its side opposite the element shaft 315 and the joining part 305. In the cable assembly 403, the element head 313 of the fastening element 311 is embedded between the carrier layer 23 and the cover layer 25.

[0037] It should be expressly noted here that in this or another embodiment of arrangement 201, the wiring harness 1 can also be replaced, for example, by wiring harnesses 301 or 401. Naturally, all described wiring harnesses 1, 101, 303, and 403 can be materially bonded, preferably glued, to one of the joining components 203 and 305, and / or force-fit and / or form-fit connected to one of the joining components 203 and 305 by means of the fastening element 311. It is also self-evident that the conductor carrier 21 in the wiring harnesses 1, 101, 303 and 403 extends completely or largely or mostly between the plug 11 and the connecting elements 13, 15, 17 and 19, so that the initial section AA and / or the final section EA are correspondingly small, or that the initial section AA and / or the final section EA are not present at all. REFERENCE MARK LIST 1 wiring harness 3 conductors 5 ladders 7 ladders 9 ladders 11 plugs 13 Connecting element 15 Connecting element 17 Connecting element 19 Connecting element 21 ladder carriers 23 Carrier layer 25 Top layer 101 Wiring harness 201 Order 203 Joining component 205 gap 207 further components 301 Order 303 Wiring harness 305 Joining component 307 Exclusion 311 Fastening element 313 Element head 315 Element shaft 317 Clamping element 401 Arrangement 403 Wiring harness AA Initial Section TA Carrier Section EA End Section KB intersection area

Claims

Conductor set comprising: a conductor arrangement with at least two conductors (3; 5; 7; 9), and a conductor support (21), wherein the conductor set (1; 101; 303; 403) has a support section (TA) in which the conductors (3; 5; 7; 9) run within the conductor support (21), and wherein the conductors (3; 5; 7; 9) run at least sectionally next to each other in the support section (TA). Conductor assembly according to claim 1, characterized in that the conductor carrier (21) has a carrier layer (23) and a cover layer (25) which is partially bonded to the carrier layer (23) in a materially bonded manner, wherein it is provided that two or more conductors (3; 5; 7; 9) of the conductor arrangement run in the carrier section (TA) between the carrier layer (23) and the cover layer (25). Conductor assembly according to claim 1 or 2, characterized in that two or more conductor passages extend within the conductor carrier (21), wherein it is provided that a first conductor (3) runs in a first conductor passage of the conductor passages and a second conductor (5) runs in a second conductor passage of the conductor passages, and wherein it is provided that the first conductor passage and the second conductor passage intersect in a crossing area (KB) of the carrier section (TA), in which the first conductor (3) runs over or under or next to the second conductor (5) past the second conductor (5). Conductor assembly according to claim 2 or 3, characterized in that the carrier layer (23) is formed by a first planar structure, and / or that the cover layer (25) is formed by a second planar structure, wherein it is preferably provided that the material of the first planar structure is identical to the material of the second planar structure. Wiring set according to claim 4, characterized in that the first surface structure is formed by a textile surface structure, preferably by a nonwoven fabric or a woven fabric, and that the second surface structure is formed by a film, preferably by a film made of plastic. A conductor assembly according to one of the preceding claims, characterized in that the conductor assembly (1; 101; 303; 403) has a starting section (AA) and / or an end section (EA), wherein it is provided that the conductors (3; 5; 7; 9) of the conductor arrangement run outside the conductor carrier (21) in the starting section (AA) and / or in the end section (EA), wherein it is preferably provided that two or more of the conductors (3; 5; 7; 9) run parallel to each other at a distance from each other in the starting section (AA) and / or the end section (EA) and / or are combined to form a conductor bundle. A conductor assembly according to one of the preceding claims, characterized in that one, two or more of the conductors (3; 5; 7; 9) each have a conductor sheath, wherein it is provided that one, two or more of the conductor sheaths are each materially bonded, preferably glued and / or fused and / or welded to the conductor carrier (21), preferably the carrier layer (23) and / or the cover layer (25), and / or wherein it is provided that one, two or more of the conductor sheaths are each not materially bonded to the conductor carrier (21), preferably the carrier layer (23) and / or the cover layer (25). A wiring harness according to one of the preceding claims, characterized in that the wiring harness (1; 101; 303; 403) has at least one fastening element (311) for fastening the wiring harness (1; 101; 303; 403) to a component (203; 305), wherein the fastening element (311) is designed and / or suitable for fastening the wiring harness (1; 101; 303; 403) to the component (203; 305) by means of the fastening element (311) in a force-fit and / or form-fit manner, wherein it is preferably provided that the conductor carrier (21) has an opening which is bounded to the outside by the conductor carrier (21), preferably by the support layer (23) and / or the cover layer (25), and into which the fastening element (311) can be inserted or is inserted is, and / or wherein it is preferably provided that the fastening element (311) has an element head (313) which is embedded between the support layer (23) and the cover layer (25). Arrangement comprising a conductor set (1; 101; 303; 403) according to one of the preceding claims and a joining component (203; 305), wherein the conductor set (1; 101; 303; 403) is connected to the joining component (203; 305) via the conductor carrier (21), preferably the carrier layer (23) and / or the cover layer (25), preferably by means of a material bond and / or by means of the fastening element (311). Arrangement according to claim 9, characterized in that the conductor carrier (21), preferably the support layer (23) or the cover layer (25), is preferably connected to the joining part (203; 305) in a planar and / or material-bonded manner, and / or that the conductor carrier (21), preferably the support layer (23) or the cover layer (25), is preferably connected to the joining part (203; 305) by means of the fastening element(s) (311) in a force-fit and / or form-fit manner.

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