wiring harness

Abstract

One embodiment of the present disclosure provides a wiring harness capable of ensuring miniaturization and a high electromagnetic shielding effect. The wiring harness (10) includes a central wiring harness (21), the central wiring harness (21) having: a core wire (31); an insulating sheath (32) covering the outer surface of the core wire (31); and an electromagnetic shielding member covering the insulating sheath (32). The electromagnetic shielding member is formed as a metal layer (33) that is tightly fitted to the outer surface of the insulating sheath (32) and is seamlessly formed.

Description

Technical Field

[0001] The present disclosure relates to a wire harness. Background Art

[0002] Conventional wiring harnesses used in hybrid vehicles, electric vehicles, and other vehicles have been routed under the vehicle's floor, for example. Such wiring harnesses, for example, include a plurality of wires and a metal exterior member serving as a plurality of electromagnetic shielding components, each configured to individually house the wires (see, for example, Patent Document 1). In such wiring harnesses, the metal exterior member provides a high electromagnetic shielding effect.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2005-44607 Summary of the Invention

[0006] Problems to be solved by the invention

[0007] However, in the aforementioned wiring harness, since the wires are housed within the exterior member with gaps therebetween, the overall cross-sectional area in the direction perpendicular to the extension direction increases. Furthermore, even when a braided member made of braided metal wires is used as an electromagnetic shielding member instead of a metal exterior member and fitted over the wires, the gaps between the metal wires forming the braided member create a problem: To ensure a high electromagnetic shielding effect, the thickness of the braided member increases, resulting in an overall increase in the cross-sectional area perpendicular to the extension direction.

[0008] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a wire harness capable of ensuring miniaturization and a high electromagnetic shielding effect.

[0009] Solutions to Problems

[0010] The wire harness of the present disclosure includes a shielded wire having: a core wire; an insulating sheath covering the outer surface of the core wire; and an electromagnetic shielding member covering the insulating sheath, the electromagnetic shielding member being a metal layer tightly adhered to the outer surface of the insulating sheath and seamlessly formed.

[0011] Effects of the Invention

[0012] According to the wire harness of the present disclosure, miniaturization and a high electromagnetic shielding effect can be ensured. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a schematic diagram of a vehicle in one embodiment.

[0014] Figure 2 This is a cross-sectional view of a wire harness in one embodiment.

[0015] Figure 3 It is a partially enlarged schematic diagram of a wiring harness in one embodiment. DETAILED DESCRIPTION

[0016] [Description of Embodiments of the Present Disclosure]

[0017] First, embodiments of the present disclosure will be described below.

[0018] The wiring harness disclosed herein,

[0019] [1] A shielded electric wire having: a core wire; an insulating sheath covering an outer surface of the core wire; and an electromagnetic shielding member covering the insulating sheath, the electromagnetic shielding member being a metal layer that is tightly adhered to the outer surface of the insulating sheath and formed seamlessly.

[0020] According to this structure, since the electromagnetic shielding component is a metal layer that is tightly fitted to the outer surface of the insulating covering and formed without seams, it is possible to reduce the cross-sectional area in the direction orthogonal to the extension direction while ensuring a high electromagnetic shielding effect, compared to the case where it is formed as a metal exterior component, a woven component, etc.

[0021] [2] Preferably, there is a metal member to which the shielded electric wire is connected, and the metal layer is formed up to the metal member.

[0022] According to this structure, since the metal layer is formed to extend across the metal member to which the shielded wire is connected, the metal layer and the metal member can be connected without using an additional connecting member such as a tightening tape, thereby establishing an electromagnetic shielding structure.

[0023] [3] Preferably, the insulating covering is made of enamel.

[0024] According to this structure, since the insulating coating is made of enamel, it can improve heat resistance compared to other conventional insulating coatings. Therefore, it is easy to adopt a manufacturing method in which heated metal powder is sprayed onto the outer surface of the insulating coating to form a metal layer.

[0025] [4] Preferably, the core wire is composed of a bus bar.

[0026] According to this structure, since the core wire is formed of a bus bar, the enamel does not seep into the insulation coating when the enamel is formed. In other words, when the core wire is formed of a stranded wire, the enamel may seep into the insulation coating when the enamel is formed, but this can be avoided.

[0027] [Details of the embodiments of the present disclosure]

[0028] Specific examples of the wire harness disclosed herein will be described below with reference to the accompanying drawings. It should be noted that the present invention is not limited to these examples, but is defined by the claims and encompasses all modifications within the meaning and scope of the claims.

[0029] like Figure 1 As shown, the wiring harness 10 electrically connects two or more electrical devices (equipment), for example, a battery 11 located at the rear of a vehicle V and electrical components 12 located at the front of the vehicle V. It should be noted that the battery 11 can be a high-voltage battery capable of supplying voltages exceeding 100 volts, or a low-voltage battery capable of supplying voltages such as 12 volts or 24 volts. Furthermore, when a high-voltage battery 11 is used, the electrical components 12 can be, for example, an inverter connected to the electric motor driving the wheels. Furthermore, when a low-voltage battery 11 is used, the electrical components 12 can be, for example, a distribution box connected to each small electric motor. This embodiment describes the case where a high-voltage battery 11 is used and a wiring harness 10 capable of handling large currents is employed. The wiring harness 10 is routed so that its central portion passes under the floor of the vehicle V, for example, and its two ends rise from under the floor and connect to the battery 11 and electrical components 12 on the floor.

[0030] The wire harness 10 includes a central wire harness 21 constituting wiring in the central portion under the floor, end wire harnesses 22 constituting wiring at both end portions, and a connecting member 23 as a metal member connecting the central wire harness 21 and the end wire harnesses 22 .

[0031] like Figure 2 As shown, the center wire harness 21 includes a core wire 31 and an insulating sheath 32 covering the outer surface of the core wire 31. The core wire 31 is made of a metal such as aluminum or copper and is formed from a rod-shaped bus bar. In this embodiment, the core wire 31 has a rectangular cross-section perpendicular to its extension direction. The core wire 31 is arranged so that its length in the width direction of the vehicle V is greater than its length in the vertical direction. The insulating sheath 32 is made of enamel.

[0032] Furthermore, the center harness 21 is formed as a shielded wire having a metal layer 33 as an electromagnetic shielding member covering the insulating sheath 32. The metal layer 33 is formed to be in close contact with the outer surface of the insulating sheath 32 and seamless. Specifically, the metal layer 33 is provided to cover the entire outer circumference of the insulating sheath 32, but without any seams such as those associated with metal foil. Furthermore, the metal layer 33 lacks the seams or gaps associated with braided metal wires. The metal layer 33 is formed by spraying heated metal powder onto the outer surface of the insulating sheath 32.

[0033] In addition, if Figure 3 As shown, the metal layer 33 is formed all the way to the connecting member 23. That is, the metal layer 33 is integrally formed from the outer surface of the insulating coating 32 to the outer surface of the connecting member 23 in a state where the electric wire 34 consisting of the core wire 31 and the insulating coating 32 is connected to the connecting member 23.

[0034] Next, a method for manufacturing the wire harness 10 configured as described above and its operation will be described.

[0035] The manufacturing method of the wire harness 10 includes: a connecting step of connecting the electric wire 34 consisting of the core wire 31 and the insulating covering 32 in the central wire harness 21 to the connecting member 23; and a forming step of spraying heated metal powder 35 onto the outer surface of the insulating covering 32 to form the metal layer 33 after the connecting step.

[0036] In detail, Figure 3 As shown, during the forming process, heated metal powder 35 is sprayed from nozzle 36 onto the outer surfaces of insulating coating 32 and connecting member 23, thereby forming metal layer 33 from the outer surface of insulating coating 32 to the outer surface of connecting member 23, closely adhering to those outer surfaces without any seams. As a result, the outer surface of electric wire 34, including core wire 31, is surrounded by metal layer 33, and metal layer 33 is electrically connected to connecting member 23, which is a metal member. This suppresses the radiation of electromagnetic noise from core wire 31 to the outside.

[0037] Next, the effects of the above-described embodiment will be described below.

[0038] (1) Because the electromagnetic shielding member is a metal layer 33 that is tightly fitted to the outer surface of the insulating covering portion 32 and is formed without a seam, it is possible to reduce the cross-sectional area in the direction orthogonal to the extension direction while ensuring a high electromagnetic shielding effect, compared to, for example, a metal exterior member, a woven member, or the like.

[0039] (2) Because the metal layer 33 is formed all the way to the connecting member 23 to which the center harness 21 is connected, the metal layer 33 can be connected to the connecting member 23 as a metal member without using an additional connecting member such as a fastening tape, thereby establishing an electromagnetic shielding structure. Specifically, when a braided member is used as the electromagnetic shielding member, for example, it is necessary to place the braided member outside the metal member and fasten it together with a fastening tape, etc., but this is not necessary.

[0040] (3) Since the insulating coating 32 is made of enamel, its heat resistance is improved compared to other conventional insulating coatings. Therefore, it is easy to adopt a manufacturing method in which heated metal powder 35 is sprayed onto the outer surface of the insulating coating 32 to form the metal layer 33. In other words, in order to spray heated metal powder 35 onto the outer surface of the insulating coating 32 to form the metal layer 33, the insulating coating 32 is made of a highly heat-resistant enamel. This not only achieves the above-mentioned effects, but also facilitates manufacturing.

[0041] (4) Since the core wire 31 is formed of a bus bar, the enamel will not penetrate into the insulation coating 32 when the enamel is formed. In other words, if the core wire 31 is formed of a stranded wire, the enamel may penetrate into the insulation coating 32 when the enamel is formed, but this can be avoided.

[0042] (5) Since the manufacturing method of the wire harness 10 includes a forming step in which the heated metal powder 35 is sprayed onto the outer surface of the insulating covering 32 to form the metal layer 33, the wire harness 10 can be manufactured more easily than, for example, a case in which an electromagnetic shielding member is manufactured separately and assembled with the electric wires.

[0043] This embodiment can be implemented with the following modifications: This embodiment and the following modifications can be implemented in combination with each other within a range that does not technically conflict.

[0044] ■In the above embodiment, it is assumed that the metal layer 33 is formed all the way to the connection member 23 connected to the central harness 21, but this is not limited to this. For example, the metal layer 33 may not be formed all the way to the connection member 23, but may be formed to be connected to the connection member using other structures.

[0045] ■ In the above embodiment, the insulating coating 32 is assumed to be made of enamel, but the present invention is not limited thereto and the insulating coating may be made of other materials.

[0046] ■ In the above embodiment, the core wire 31 is formed of a bus bar, but the present invention is not limited thereto and may be another type of core wire, for example, a core wire formed of a stranded wire.

[0047] Although not particularly mentioned in the above embodiment, the wire harness 10 may be formed such that, for example, a pair of wire harnesses are arranged side by side in one vehicle V, or three or more wire harnesses are arranged side by side.

[0048] Although not particularly mentioned in the above embodiment, the center harness 21 may be fixed to the vehicle V in a state of being housed and held by a resin exterior member that covers and holds the metal layer 33 , for example.

[0049] ■In the above-described embodiment, the wire harness 10 corresponding to a large current assuming the use of the high-voltage battery 11 is described, but it is not limited thereto, and it may also be formed as a wire harness for the case of using the low-voltage battery 11.

[0050] The technical ideas and their effects that can be grasped from the above-described embodiment and other examples are described below.

[0051] (i) A method for manufacturing a wire harness, the wire harness including a shielded wire, the shielded wire having: a core wire; an insulating coating portion that coats the outer surface of the core wire; and an electromagnetic shielding member that covers the insulating coating portion.

[0052] The electromagnetic shielding member is a metal layer that is formed in close contact with the outer surface of the insulating coating portion without seams, and the method for manufacturing the wire harness includes a forming step: spraying heated metal powder onto the outer surface of the insulating coating portion to form the metal layer.

[0053] According to this method, since the electromagnetic shielding member is a metal layer that is formed in close contact with the outer surface of the insulating coating portion without seams, for example, compared with the case where it is formed as a metal exterior member, a braided member, etc., the cross-sectional area in the direction orthogonal to the extending direction can be reduced while ensuring a high electromagnetic shielding effect. In addition, since it includes a forming step of spraying heated metal powder onto the outer surface of the insulating coating portion to form the metal layer, for example, compared with the case of separately manufacturing the electromagnetic shielding member and assembling it with the wire, the wire harness can be easily manufactured.

[0054] The wire harness 10 may also be, for example, a flat shape in which the dimension in the thickness direction is smaller than the dimension in the width direction. As Figure 2 in the example, the core wire 31 of the wire harness 10 may also be, for example, a bus bar having a flat shape in which the dimension in the thickness direction is smaller than the dimension in the width direction. It may also be that the core wire 31 has a flat upper surface, a flat lower surface, and two opposing side surfaces, and the cross-section in the direction orthogonal to the extending direction of the core wire 31 is rectangular. An insulating coating film 32 having a uniform thickness may be provided in close contact with the outer surface of the core wire 31 so as to cover the entire core wire 31. The insulating coating film 32 may also be a varnish that adheres to the surface of the core wire 31 without penetrating into the core wire 31. A metal layer 33 having a uniform thickness may be provided in close contact with the outer surface of the insulating coating film 32 so as to cover the entire insulating coating film 32. The metal layer 33 may also be the electromagnetic shielding member of the wire harness 10. The metal layer 33 (electromagnetic shielding member) may also be provided in a shape that is the same as the shape of the outer surface of the core wire 31. Figure 2 In the example, the shape of the metal layer 33 is a square tube having a certain shape throughout the entire length of the central wire harness 21.

[0055] The metal layer 33 may be formed in a state where the electric wire 34 and the connecting member 23 are connected so that the insulating coating 32 is attached to the core wire 31. The metal layer 33 may also be formed integrally with the outer surface of the insulating coating 32 and the outer surface of the connecting member 23 so as to be in close contact. Figure 3 As shown, a step or a radial gap sometimes occurs between the outer surface of the end of the connecting member 23 and the outer surface of the wire 34. However, since the metal layer 33 is formed by spraying the heated metal powder 35 from the nozzle 36 onto the outer surface of the insulating sheath 32 and the outer surface of the connecting member 23, the metal layer 33 can also be formed with a substantially constant thickness without any seams throughout the connecting portion having such a step.

[0056] The metal layer 33 in the illustrated example may be referred to as a seamless and gapless metal layer that continuously extends over the entire length and the entire circumference of the metal layer 33 .

[0057] like Figure 2 As in the example of , the center harness 21 may be an insulating resin enameled bus bar such as a polyurethane enameled copper bus bar.

[0058] Description of Reference Numerals

[0059] 10 Wiring Harness

[0060] 11 Batteries

[0061] 12 Electrical components

[0062] 21 Central wiring harness (shielded wire)

[0063] 22 End harness

[0064] 23. Connecting components (metal components)

[0065] 31 core wire

[0066] 32 Insulation coating

[0067] 33 Metal layer (electromagnetic shielding member)

[0068] 34 Wires

[0069] 35 Metal Powder

[0070] 36 nozzles

[0071] V Vehicle

Claims

1. A wire harness comprising a shielded electric wire, the shielded electric wire comprising: a core wire; an insulating coating covering an outer surface of the core wire; and an electromagnetic shielding member covering the insulating coating. The electromagnetic shielding member is a metal layer formed to be in close contact with the outer surface of the insulating covering without any seams. The wiring harness includes a metal member to which the shielded electric wires are connected. The outer diameter of the metal member is larger than the outer diameter of the core wire, the core wire and the insulating covering constitute an electric wire, and a step is formed at a connection portion where the outer surface of the metal member and the outer surface of the electric wire are connected. The metal layer is formed by spraying heated metal powder onto the outer surface of the insulating covering, covering the connecting portion having the step, and the metal layer is integrally formed from the outer surface of the insulating covering to the outer surface of the metal component in a tightly joined and seamless manner.

2. The wire harness according to claim 1, wherein The insulating covering is made of enamel.

3. The wire harness according to claim 2, wherein The core wire is formed by a bus bar.

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