Large-square flat flexible wire harness

Abstract

The invention provides a large-square flat flexible wire harness, which integrates wire harnesses in a carriage into flexible flat wire harnesses, effectively solves the problem that the large-square wire harnesses are difficult to arrange in a cockpit, saves space and improves driving experience. The flexible flat cable comprises a flexible flat wire group which comprises a flat or flat-like wire body and a flat sheath, and the periphery of the wire body is coated with the flat sheath; the flat wire connecting end of each group of terminals is used for being fixedly connected with one end of the flexible flat wire group in the length direction, and the guide output end of each group of terminals is used for being fixedly connected with an external input or output wire; each wire body fixing piece comprises a connecting end connected with the flexible flat wire group and a fixed connecting end used for being fixedly connected with the corresponding position of a vehicle body; the flexible flat wire group is provided with corresponding bending and length according to the carriage passing part of each vehicle type, and a plurality of wire body fixing pieces are arranged along the length direction of the flexible flat wire group.

Description

Technical Field

[0001] This invention relates to the technical field of wire harness structures, specifically a large-square flat flexible wire harness. Background Technology

[0002] For power harnesses used in automotive low-voltage power supply systems or high-voltage charging interfaces to battery packs, due to the large current carrying capacity of the harness, a large cross-sectional area is required to obtain good current carrying capacity in order to control the appropriate temperature rise.

[0003] Most existing wiring harnesses of this type use large-square-meter round wire harnesses, whose outer diameter is too large, resulting in a noticeable bulge on the passenger compartment floor, which is unsightly. Furthermore, when laying wiring harnesses inside the vehicle, the large outer diameter of the round structure makes it difficult to achieve a good fit at sheet metal corners, encroaching on passenger space and reducing occupant comfort. To address this, some manufacturers use conductive rigid busbars, but these are prone to insulation wrinkles and cracks during bending, requiring the use of special insulation, which significantly increases costs. Additionally, rigid busbars require specialized conforming tooling for packaging and transportation, further increasing packaging and transportation costs.

[0004] Therefore, there is an urgent need to develop a large, single-story wiring harness that can minimize the space occupied inside the vehicle while meeting functional requirements and reducing costs. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides a large-square-width flat flexible wiring harness that integrates wiring harnesses located within the vehicle compartment into a flexible flat wiring harness. This effectively solves the problem of difficult layout of large-square-width wiring harnesses in the driver's cabin, while also saving space and improving the driving experience.

[0006] A large-square-area flat flexible wire harness, characterized in that it comprises: A flexible flat line assembly includes a flat or near-flat line body and a flat sheath, wherein the flat sheath covers the outer periphery of the line body. Two sets of terminals, the flat wire connection end of each set of terminals is used to fix one end of the flexible flat wire group in the length direction, and the guide output end of each set of terminals is used to fix the external input or output line. And several line fixing components, including connecting ends for connecting flexible flat line groups and fixing ends for fixing to corresponding positions on the vehicle body; The flexible flat line group is configured with corresponding bends and lengths according to the passage of each vehicle body. Several line fixing members are arranged along the length direction of the flexible flat line group. The fixing ends of the line fixing members fix the flexible flat line group to the corresponding position of the vehicle body. The two ends of the flexible flat line group along the length direction are respectively connected to the flat wire connection ends of the corresponding terminals.

[0007] Its further features are: The flexible flat wire group consists of several circular metal wires arranged in the width direction, and a flat sheath covers the outer periphery of the overall flat wire formed by the arrangement of several circular metal wires. The circular metal wires that make up the flexible flat wire assembly all have the same diameter, ensuring uniform and reliable overall performance. The wire in the flexible flat wire group is a flat metal wire; The flat metal wire is specifically a rectangular cross-section structure, and its height does not exceed 30% of its width; The flat metal wire is specifically a waist-shaped cross-section structure, with semi-circular edges at both ends in the width direction. The semi-circular edges at both ends in the width direction are joined together to form a complete circle. The middle part in the width direction is a rectangular cross-section structure. The diameter of the semi-circular edge is the height of the rectangular cross-section, and the diameter of the semi-circular edge does not exceed 30% of the width of the flat metal wire. The terminal is a flat round butt plug. At this time, the flat wire connection end of the terminal is the female end, which is provided with a first concave positioning cavity that conforms to the shape of the wire. After the flat sheath of the corresponding end of the flexible flat wire group is stripped, it is inserted into the first concave positioning cavity and the connection is made stable and reliable by external force. The terminal guide output end is the female end, which has a second concave positioning cavity that conforms to the shape of the corresponding round wire. After the sheath of the external input or output wire is stripped, it is inserted into the second concave positioning cavity and the connection is made stable and reliable by external force. The entire terminal is covered with a conforming outer sheath. The flat wire connection end and the guide output end of the terminal are both metal leads and are integral metal connectors. After the flat sheath of the corresponding end of the flexible flat wire group is removed, the flat wire connection end is connected by welding or crimping. After the sheath of the external input or output wire is removed, the guide output end is connected by welding or crimping. The terminal and the corresponding connection area are sealed and insulated by heat shrink tubing to ensure the durability and reliability of the connection. The total cross-sectional area of ​​the metal core of all wires in the flexible flat wire group is greater than 25 mm². The line fixing components include through-hole rubber parts, positioning brackets, clips, and tapes. Depending on the vehicle assembly environment, the corresponding through-hole rubber parts, positioning brackets, clips, and tapes are installed on the pre-processed semi-finished flexible flat line assembly.

[0008] By adopting the above technical solutions, flexible flat wiring harnesses effectively solve the problem of difficult layout of large-square-meter wiring harnesses in the cockpit by increasing width and reducing thickness, while saving space and improving the driving experience. Furthermore, flexible flat wiring harnesses have a larger surface area, resulting in better heat dissipation, and can also utilize the skin effect to increase the current carrying capacity of the wiring harness. In addition, flexible flat wiring harnesses have excellent flexibility, allowing for bundling during packaging. Compared to the dedicated packaging fixtures and tooling of rigid wiring harnesses, flexible flat wiring harnesses offer a cost advantage. Large-square-meter flat flexible wiring harnesses are assembled from flexible flat wiring harnesses, two sets of terminals, and several wire fixing components. These three structures are transported independently and then assembled before wiring harness placement in the vehicle. The wiring harness is rationally assembled and arranged according to actual needs, which greatly reduces the transportation cost of the wiring harness and makes it highly adaptable. Attached Figure Description

[0009] Figure 1 This is a three-dimensional structural diagram of the invention (two large, flat, flexible wire harnesses are integrated and arranged through a wire fixing component). Figure 2 This is a cross-sectional view of a specific embodiment of the flexible flat wire assembly of the present invention; Figure 3 This is a cross-sectional view of a second specific embodiment of the flexible flat wire assembly of the present invention; Figure 4 This is a cross-sectional view of a specific embodiment three of the flexible flat wire assembly of the present invention; Figure 5 Left view of the flat-round connector for adapting to flexible flat wire assembly of the present invention; Figure 6 The right view of the flat round connector for adapting to flexible flat wire assembly of the present invention; The names corresponding to the serial numbers in the diagram are as follows: Flexible flat wire assembly 10, flat sheath 11, round metal wire 12, flat metal wire 13, semi-circular edge 131, terminal 20, flat wire connection end 21, first concave positioning cavity 211, guide output end 22, outer sheath with conformal shape 23, second concave positioning cavity 221, wire fixing component 30, connection end 31, and fixed connection end 32. Detailed Implementation

[0010] A large-square flat flexible wire harness, see Figures 1-6 It includes a flexible flat wire assembly 10, two sets of terminals 20, and several wire fixing components 30; The flexible flat line assembly 10 includes a flat or near-flat line body and a flat sheath, with the flat sheath 11 covering the outer periphery of the line body; The flat wire connection end 21 of each set of terminals 20 is used to fix one end of the flexible flat wire group 10 in the length direction, and the guide output end 22 of each set of terminals 20 is used to fix external input or output lines. Each set of wire fixing components 30 includes a connecting end 31 for connecting the flexible flat wire group and a fixing end 32 for fixing to the corresponding position of the vehicle body. The flexible flat wire assembly 10 is configured with corresponding bends and lengths according to the passage of each vehicle body. Several wire fixing members 30 are arranged along the length direction of the flexible flat wire assembly 10. The fixing end 32 of the wire fixing member 30 fixes the flexible flat wire assembly 10 to the corresponding position of the vehicle body. The two ends of the flexible flat wire assembly 10 along the length direction are respectively connected to the flat wire connection end 21 of the corresponding terminal 20.

[0011] In a specific embodiment of the flexible flat line assembly 10, the line body is composed of several circular metal wires 12 arranged in the width direction, and a flat sheath 11 covers the outer periphery of the overall flat line formed by the arrangement of several circular metal wires 12; the diameter of the circular metal wires 12 that make up the flexible flat line is the same, ensuring that the overall performance is uniform and reliable.

[0012] In a second or third embodiment of the flexible flat wire assembly 10, the wire body within the flexible flat wire assembly is a single flat metal wire 13.

[0013] In the second specific embodiment, the flat metal wire 13 has a rectangular cross-section structure, and its height does not exceed 30% of its width.

[0014] In the third specific embodiment, the flat metal wire 13 is specifically a waist-shaped cross-section structure, with semi-circular edges 131 at both ends in the width direction. The semi-circular edges 131 at both ends in the width direction are joined together to form a complete circle, and the middle part in the width direction is a rectangular cross-section structure. The diameter of the semi-circular edge 131 is the height of the rectangular cross-section, and the diameter of the semi-circular edge 131 does not exceed 30% of the width of the flat metal wire 13.

[0015] In specific implementation, terminal 20 is a flat round butt plug. At this time, the flat wire connection end 21 of terminal 20 is the female end, which is provided with a first concave positioning cavity 211 that conforms to the shape of the wire body. After the flat sheath of the corresponding end of the flexible flat wire group 10 is stripped, it is inserted into the first concave positioning cavity 211 and the connection is made stable and reliable by external force. Terminal guide output end 22 is the female end, which is built with a second concave positioning cavity 221 that conforms to the shape of the corresponding round wire body. After the sheath of the external input or output wire is stripped, it is inserted into the second concave positioning cavity 221 and the connection is made stable and reliable by external force. The entire terminal is covered with a conforming outer sheath 23. Then, the connection end is sealed and insulated by heat shrink tubing to ensure the durability and reliability of the connection.

[0016] In another embodiment of terminal 20, the flat wire connection end 21 and the guide output end 22 of terminal 20 are both metal leads, and it is an integral metal connector (see...). Figure 1After the flat sheath of the corresponding end of the flexible flat wire assembly 10 is removed, the flat wire connection end 21 is connected by welding or crimping. After the sheath of the external input or output wire is removed, the guide output end 22 is connected by welding or crimping. The terminal 20 and the corresponding connection area are sealed and insulated by heat shrink tubing to ensure the durability and reliability of the connection.

[0017] In a specific embodiment, the total cross-sectional area of ​​the metal core of all wires in the flexible flat wire group 10 is greater than 25 mm².

[0018] In a specific embodiment, the line fixing component 30 consists of a through-hole rubber component, a positioning bracket, a clip, and tape. Depending on the vehicle assembly environment, the corresponding through-hole rubber component, positioning bracket, clip, and tape are installed on the pre-processed semi-finished flexible flat line assembly.

[0019] In a specific embodiment, two large-square-width, flat, flexible wire harnesses are integrated and arranged via wire fixing component 30, as shown below. Figure 1 As shown.

[0020] Flexible flat wiring harnesses effectively solve the problem of difficult layout of large-square-meter wiring harnesses in the cockpit by increasing width and reducing thickness, while saving space and improving the driving experience. Furthermore, flexible flat wiring harnesses have a larger surface area, resulting in better heat dissipation and the ability to increase current carrying capacity by utilizing the skin effect. In addition, flexible flat wiring harnesses have excellent flexibility, allowing for bundling during packaging. Compared to the dedicated packaging fixtures and tooling of rigid wiring harnesses, flexible flat wiring harnesses offer a cost advantage. Large-square-meter flat flexible wiring harnesses are assembled from flexible flat wiring harnesses, two sets of terminals, and several wire fixing components. These three structures are transported independently and assembled before wiring harness placement in the vehicle. The wiring harness is rationally assembled and arranged according to actual needs, significantly reducing transportation costs and ensuring high adaptability.

[0021] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0022] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A large-square-width, flat, flexible wire harness, characterized in that, It includes: A flexible flat line assembly includes a flat or near-flat line body and a flat sheath, wherein the flat sheath covers the outer periphery of the line body. Two sets of terminals, the flat wire connection end of each set of terminals is used to fix one end of the flexible flat wire group in the length direction, and the guide output end of each set of terminals is used to fix the external input or output line. And several line fixing components, including connecting ends for connecting flexible flat line groups and fixing ends for fixing to corresponding positions on the vehicle body; The flexible flat line group is configured with corresponding bends and lengths according to the passage of each vehicle body. Several line fixing members are arranged along the length direction of the flexible flat line group. The fixing ends of the line fixing members fix the flexible flat line group to the corresponding position of the vehicle body. The two ends of the flexible flat line group along the length direction are respectively connected to the flat wire connection ends of the corresponding terminals.

2. The large-square flat flexible wire harness according to claim 1, characterized in that: The flexible flat wire assembly consists of several circular metal wires arranged in the width direction, and a flat sheath covers the outer periphery of the overall flat wire formed by the arrangement of several circular metal wires.

3. The large-square flat flexible wire harness according to claim 2, characterized in that: The circular metal wires that make up the flexible flat wire assembly all have the same diameter.

4. The large-square flat flexible wire harness according to claim 1, characterized in that: The wire in the flexible flat wire assembly is a flat metal wire.

5. A large-square flat flexible wire harness according to claim 4, characterized in that: The flat metal wire is specifically a rectangular cross-section structure, and its height does not exceed 30% of its width.

6. The large-square flat flexible wire harness according to claim 4, characterized in that: The flat metal wire is specifically a waist-shaped cross-section structure, with semi-circular edges at both ends in the width direction. The semi-circular edges at both ends in the width direction are joined together to form a complete circle. The middle part in the width direction is a rectangular cross-section structure. The diameter of the semi-circular edge is the height of the rectangular cross-section. The diameter of the semi-circular edge does not exceed 30% of the width of the flat metal wire.

7. The large-square flat flexible wire harness according to claim 1, characterized in that: The terminal is a flat-round butt plug. In this case, the flat wire connection end of the terminal is the female end, which is provided with a first concave positioning cavity that conforms to the shape of the wire. After the flat sheath of the corresponding end of the flexible flat wire group is removed, it is inserted into the first concave positioning cavity and pressed by external force to make the connection stable and reliable. The terminal guide output end is the female end, which has a second concave positioning cavity that conforms to the shape of the corresponding round wire. After the sheath of the external input or output wire is removed, it is inserted into the second concave positioning cavity and pressed by external force to make the connection stable and reliable. The entire terminal is covered with a conforming outer sheath.

8. A large-square flat flexible wire harness according to claim 1, characterized in that: The flat wire connection end and the guide output end of the terminal are both metal leads and are integral metal connectors. After the flat sheath of the corresponding end of the flexible flat wire group is removed, the flat wire connection end is connected by welding or crimping. After the sheath of the external input or output line is removed, the guide output end is connected by welding or crimping. The terminal and the corresponding connection area are sealed and insulated by heat shrink tubing.

9. A large-square flat flexible wire harness according to claim 1, characterized in that: The total cross-sectional area of ​​the metal core of all wires in the flexible flat wire group is greater than 25 mm².

10. A large-square flat flexible wire harness according to claim 1, characterized in that: The line fixing components include through-hole rubber parts, positioning brackets, clips, and tapes. Depending on the vehicle assembly environment, the corresponding through-hole rubber parts, positioning brackets, clips, and tapes are installed on the pre-processed semi-finished flexible flat line assembly.

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