Wire harness

By using a segmented wire harness design and flexible wires to absorb processing tolerances and positional deviations, the assembly difficulties of high-rigidity busbars during bending and assembly processes are solved, improving workability and durability while meeting heat dissipation requirements.

CN121666673APending Publication Date: 2026-03-13SUMITOMO WIRING SYSTEMS LTD
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Patent Information

Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
Filing Date
2024-08-09
Publication Date
2026-03-13

AI Technical Summary

Technical Problem

High-rigidity, high-power shielded busbars are prone to increased processing tolerances during bending and assembly, resulting in time-consuming and labor-intensive assembly operations, and subjecting the receiver to greater stress, which affects durability.

Method used

The wire harness design employs a segmented structure, including multiple flexible wires extending from a first connector and a second connector where the end of each flexible wire is electrically connected to the other end of a solid wire. The flexibility of the flexible wires absorbs manufacturing tolerances, and positional deviations are absorbed by fastening mechanisms and protectors.

Benefits of technology

It improves the ease of assembly of the wire harness, reduces stress on the receiver, enhances durability, and provides adequate heat dissipation.

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Abstract

A wire harness (1) is provided with: a first wire unit (4) in which a plurality of flexible wires (3) extend from a first connector (2); and a second electric wire unit (6) having a plurality of solid electric wires (5), the solid electric wires (5) being formed as a single wire for each of the plurality of flexible electric wires (3), and a second connector (10) being provided at one end of each solid electric wire (5). Each of the plurality of flexible wires (3) is electrically connected by assembling a first connection section (9) provided at the tip of the plurality of flexible wires (3) to a second connection section (11) provided at the other end of each of the solid wires (5).
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Description

Technical Field

[0001] This invention relates to wire harnesses. Background Technology

[0002] Conventionally, as disclosed in Patent Document 1, it is known to have a pair of high-power shielded buses. These high-power shielded buses are, for example, rigid, solid extruded products made of aluminum or copper. Receivers for electrical connection are provided at each end of the pair of high-power shielded buses. Thus, each end of the pair of high-power shielded buses is held by a receiver that secures both sets of buses together.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Publication No. 2023-517714 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] However, these high-rigidity, high-power shielded busbars are bent along the wiring path of the vehicle body. However, depending on the bending shape, the machining tolerances can sometimes become larger. Therefore, when assembling the high-power shielded busbars into the vehicle body, considerable force is required to align the high-rigidity busbars. Consequently, the assembly process can be labor-intensive and time-consuming.

[0008] Furthermore, if the high-rigidity, high-power shielded busbars are forcibly aligned with machining tolerances and assembled to the vehicle body, the receiver of the high-power shielded busbars will be subjected to significant stress. Therefore, there are concerns about the receiver's durability. Moreover, if a single receiver is used to hold the ends of a pair of high-power shielded buses, a single receiver is needed to support the machining tolerances of each high-power shielded busbar. Therefore, significant stress is applied to the receiver from the pair of high-power shielded buses, raising concerns about the receiver's durability from this perspective as well.

[0009] The purpose of this invention is to provide a wire harness that improves the workability of assembly.

[0010] Solution for solving the problem

[0011] The wiring harness that solves the aforementioned problem comprises: a first wire unit extending from a first connector with a plurality of flexible wires; and a second wire unit having a plurality of solid wires, each of the plurality of flexible wires being formed as a single wire, and a second connector being provided at one end of each of the solid wires, wherein each of the plurality of flexible wires is electrically connected by assembling a first connecting portion provided at one end of the plurality of flexible wires to a second connecting portion provided at the other end of each of the solid wires.

[0012] Invention Effects

[0013] This invention improves the workability of assembly. Attached Figure Description

[0014] Figure 1 This is a perspective view showing the appearance of a wire harness according to one embodiment.

[0015] Figure 2 This is a perspective view showing a structural example of the first connecting part and the second connecting part.

[0016] Figure 3 This is a perspective view showing a structural example of the first connecting part and the second connecting part.

[0017] Figures 4(a) and 4(b) are sequence diagrams showing the assembly outline of the protector.

[0018] Figure 5 This is a process diagram showing the assembly sequence of the wire harness.

[0019] Figure 6 This is an explanatory diagram showing an example of a combination of the first wire unit and the second wire unit. Detailed Implementation

[0020] First, embodiments of the present invention will be described.

[0021] (1) The wire harness of the present invention comprises: a first wire unit extending a plurality of flexible wires from a first connector; and a second wire unit having a plurality of solid wires, the solid wires being formed as single wires for each of the plurality of flexible wires, and a second connector being provided at one end of each of the solid wires, the plurality of flexible wires being electrically connected by assembling a first connecting portion provided at one end of the plurality of flexible wires to a second connecting portion provided at the other end of each of the solid wires.

[0022] According to this configuration, because the wire harness has a segmented structure consisting of flexible wires and solid wires, when assembling the wire harness to an assembly object, the bending of the flexible wires can absorb the processing tolerances and manufacturing tolerances of the solid wires. Therefore, when assembling the wire harness to an assembly object, it is not necessary to use greater force to position the solid wires, thus making the wire harness easier to assemble. This improves the workability of the assembly process.

[0023] (2) In (1) above, the plurality of flexible wires are stranded wires. According to this configuration, because easily bendable stranded wires are used as flexible wires, positional deviations when assembling solid wires to the assembly object are easily absorbed. Therefore, positioning of the solid wires is further facilitated. Therefore, this further contributes to improving the workability of the assembly.

[0024] (3) In (1) or (2) above, the assembly of the first connecting part and the second connecting part uses a structure that is fixed by a fastening mechanism. According to this configuration, the first connecting part and the second connecting part can be firmly fixed by the fastening mechanism.

[0025] (4) In (1) or (2) above, the first connecting part and the second connecting part are assembled using a male and female connector pair. According to this configuration, the first connecting part and the second connecting part can be connected by a simple operation of fitting the male and female connector pair.

[0026] (5) In any of (1) to (4) above, the wire harness includes a protector that protects the first connecting portion and the second connecting portion by housing them inside. According to this configuration, the connection portion of the first connecting portion and the second connecting portion can be protected from damage or water droplets.

[0027] (6) In (5) above, the protector has a position adjustment mechanism that absorbs positional deviations when assembled to the assembly object. According to this configuration, the position adjustment mechanism of the protector can absorb positional deviations when assembling the protector to the assembly object. Therefore, the protector can also absorb the processing tolerances, manufacturing tolerances, etc., inherent in solid wires.

[0028] (7) In any of (1) to (6) above, the diameter of the solid wire is made larger than the diameter of the flexible wire. According to this configuration, even if the flexible wire cannot be made to have a large diameter, sufficient heat dissipation effect in the wire harness is achieved by making the solid wire to have a large diameter.

[0029] (8) In any of (1) to (7) above, the first connector is a charging socket connector for connecting an external charging cable, the first connecting portion of the flexible wire of the charging socket connector is connected to the second connecting portion of the solid wire, and the second connector of the solid wire is connected to a battery disposed on the assembly object. According to this configuration, the workability of the assembly can be improved in the wiring harness connecting the charging socket connector and the battery.

[0030] (Details of embodiments of the present invention)

[0031] Specific examples of the invention are described below with reference to the accompanying drawings. It should be noted that the invention is not limited to these examples, but is shown through the claims and is intended to include all modifications within the meaning and scope equivalent to the claims. In the drawings, for ease of description, parts of the structure are sometimes exaggerated or simplified. Furthermore, the dimensional ratios of the various parts sometimes differ from the actual values.

[0032] (Wire harness 1)

[0033] like Figure 1As shown, the wiring harness 1 includes: a first wire unit 4, from which multiple flexible wires 3 extend; and a second wire unit 6, having multiple solid wires 5. The wiring harness 1 is used, for example, in a vehicle. The first connector 2, located at one end of the wiring harness 1, is, for example, a charging socket connector for connecting to an external charging cable (not shown). The other end of the wiring harness 1 is electrically connected to a vehicle battery (not shown). Thus, the wiring harness 1 is a charging wiring harness for a vehicle.

[0034] (Electrical Unit 4)

[0035] like Figure 1 As shown, the first wire unit 4 has a first connector 2 at one end of the flexible wire 3 and a first connecting portion 9 at the other end of the flexible wire 3. In this example, the first wire unit 4 has two flexible wires 3. The first wire unit 4 has a total of two first connecting portions 9 by providing the first connecting portions 9 at the ends of each flexible wire 3. A positive voltage is applied to one side of the flexible wire 3, and a negative voltage is applied to the other side of the flexible wire 3. The first wire unit 4 is, for example, a socket harness that connects to a charging cable and carries charging current.

[0036] (3 flexible wires)

[0037] like Figure 1 As shown, the flexible wire 3 is, for example, a stranded wire. The material of the flexible wire 3 is, for example, copper or aluminum. The flexible wire 3 has the characteristic of being easily bent, and in the case of stranded wire, its bending flexibility is particularly high. It should be noted that the flexible wire 3 can be either a wire with an insulating sheath covering the surface of the stranded wire or a wire with no insulating sheath covering the surface of the stranded wire.

[0038] (Second wire unit 6)

[0039] like Figure 1 As shown, the second wire unit 6 has a solid wire 5 formed by making each of the multiple flexible wires 3 into a single wire. Multiple solid wires 5 are arranged in pairs with the flexible wires 3 (two in this example). A positive voltage is applied to one side of the solid wire 5, and a negative voltage is applied to the other side. That is, the second wire unit 6 is individually configured by the solid wires 5 to which positive and negative poles are applied, thereby unipolarizing the two solid wires 5. The second wire unit 6 is, for example, a rigid wire harness with high rigidity.

[0040] (Solid wire 5)

[0041] The solid wire 5 has a second connector 10 at one end and a second connecting portion 11 at the other end. The solid wire 5 is, for example, a single-core wire, and more preferably, an aluminum single-core wire. The solid wire 5 is a wire with high rigidity. The solid wire 5 is electrically connected to the flexible wire 3 via the second connecting portion 11. The solid wire 5 is electrically connected to a battery (not shown) via the second connector 10. It should be noted that the solid wire 5 can, for example, be a cylindrical busbar.

[0042] As the second connector 10, a connector that connects via a male-female mating mechanism can be cited as an example. It should be noted that the second connector 10 can also be fixed to the other terminal by bolts, for example. Furthermore, in the case of a male-female mating connector, the second connector 10 can have a structure that positions and fixes it to the other terminal by bolts, screws, or the like.

[0043] (First connecting part 9, second connecting part 11)

[0044] like Figure 2 As shown, the assembly of the first connecting part 9 and the second connecting part 11 can, for example, be achieved using a structure secured by a fastening mechanism 13. The fastening mechanism 13 includes, for example, a bolt 14 and a nut 15. It should be noted that the bolt 14 is not limited to the nut 15; it can be used on any part that engages the threaded portion of the bolt 14.

[0045] like Figure 3 As shown, the assembly of the first connecting part 9 and the second connecting part 11 can, for example, use a male and female connector pair (male connector 16, female connector 17). For example, the first connecting part 9 can be a male connector 16 or include a male connector 16, and the second connecting part 11 can be a female connector 17 or include a female connector 17, and vice versa.

[0046] (Protector 19)

[0047] As shown in Figures 4(a) and (b), the wire harness 1 includes a protector 19 that protects the first connecting portion 9 and the second connecting portion 11 by housing them inside. In this example, the protector 19 positions the wire harness 1 at the connection portion of the first wire unit 4 and the second wire unit 6 by fixing it to the assembly object 18.

[0048] The protector 19 has: a protector body 20 that houses the first connecting portion 9 and the second connecting portion 11; and a pair of covers 21 that close the openings on both sides of the protector body 20. The covers 21 include: a first cover 21a that closes the opening in the protector body 20 for inserting a flexible wire 3; and a second cover 21b that closes the opening in the protector body 20 for inserting a solid wire 5. The protector 19 is fixed to the assembly object 18, for example, by a fastening part 22. The fastening part 22 is, for example, a bolt.

[0049] The protector 19 includes a position adjustment mechanism 23 that absorbs positional deviations when assembling to the assembly object 18. Thus, when assembling the wire harness 1 to the assembly object 18, the protector 19 can be assembled to the assembly object 18 by absorbing positional deviations at the connection portion between the first connection portion 9 and the second connection portion 11.

[0050] The position adjustment mechanism 23 includes, for example, a locking tab 24 formed in the protector body 20 for engaging the fastening part 22; and an elongated hole 26 provided in the locking tab 24 for inserting the shaft portion 25 of the fastening part 22. The locking tab 24 is, for example, formed in a plate shape. The fastening part 22 is fastened to a fastened portion 27 formed in the assembly object 18. The fastened portion 27 is, for example, a threaded hole formed in the assembly object 18. In this way, the protector 19 retains the connection portion of the flexible wire 3 and the solid wire 5 and absorbs positional deviations when assembling them into the assembly object 18.

[0051] Next, the function of the wire harness 1 in this embodiment will be explained.

[0052] (Assembly sequence of wire harness 1)

[0053] like Figure 5 As shown, in step 101, the second wire unit 6 is prepared first. That is, a pair of solid wires 5 to be assembled to the vehicle body are prepared. It should be noted that the solid wires 5 are formed into the desired bent shape, for example, by pre-bending a high-rigidity single-core wire along the wiring path. Thus, each solid wire 5 is sometimes a component formed by bending a high-rigidity single-core wire, and therefore there is a situation where the processing tolerances caused by the bending process are relatively large.

[0054] In step 102, after preparing the second wire unit 6, the second connector 10 of the solid wire 5 is connected to the battery (not shown).

[0055] In step 103, after connecting the second connector 10 of the solid wire 5, the solid wire 5 is secured to the vehicle body using clamps (not shown). For example, it is preferable to use multiple clamps to secure the solid wire 5 to the vehicle body. In addition, clamps of various structures can be used, such as those that insert protrusions into holes or those that are fixed with bolts.

[0056] In step 104, the first wire unit 4 is secured to the assembly object 18 (e.g., the vehicle body). The installation of the first wire unit 4 is preferably performed in a separate process from the installation of the second wire unit 6. Specifically, for example, in the case of assembly into a vehicle, the first connector 2 of the first wire unit 4 is secured to a power supply port on the vehicle body (not shown).

[0057] In step 105, after installing the first wire unit 4 and the second wire unit 6, the second connecting portion 11 of the solid wire 5 and the first connecting portion 9 of the flexible wire 3 of the first wire unit 4 are connected, and this connection is fixed to the assembly object 18 (e.g., the vehicle body) via the protector 19. In this example, the protector 19 is fixed to the assembly object 18 by the fastening portion 22. At this time, the fastening portion 22 is inserted into the elongated hole 26 of the protector 19, so when fixing the solid wire 5 to the assembly object 18, the position of the fastening portion 22 in the elongated hole 26 can be adjusted to absorb the processing tolerance of the bending process of the solid wire 5. In addition, the manufacturing tolerance of the solid wire 5 can also be absorbed.

[0058] (Advantages of harness 1)

[0059] like Figure 1 As shown, in this example, the wire harness 1 is divided into flexible wire 3 and solid wire 5. Therefore, during assembly, the flexible wire 3 can absorb deviations caused by bending of the solid wire 5. Thus, it is unnecessary to forcefully align the highly rigid solid wire 5 with the target position, thereby improving the workability of assembling the wire harness 1. In particular, when the flexible wire 3 is stranded, it is easy to bend, thus effectively absorbing deviations caused by bending.

[0060] Furthermore, because each of the multiple solid wires 5 is made into a single wire (single polarization), deviations from bending processes that occur within each wire can be absorbed individually. Therefore, this also helps improve the assembly workability of the wiring harness 1. Additionally, since a single connector structure that concentrates multiple solid wires 5 into a single connector component and electrically connects them to the vehicle body is not used, the stress of each solid wire 5 is not concentrated on the connector.

[0061] Furthermore, the wire harness 1 includes a protector 19 that protects the connection portion of the first connecting portion 9 and the second connecting portion 11. In particular, the protector 19 in this example has a structure in which the shaft portion 25 of the fastening portion 22 is inserted into the elongated hole 26, and the fastening portion 22 secures the protector 19 to the assembly object 18, thereby absorbing positional deviations when the protector 19 is fixed to the assembly object 18. Therefore, even if there are deviations due to bending processing in the solid wire 5, these deviations can be absorbed by adjusting the installation position of the protector 19. This further improves assembly workability.

[0062] Furthermore, the machining tolerances caused by the bending of the solid wire 5 can be absorbed by the alignment of the protector 19. Therefore, the solid wire 5 is not fixed to the assembly object 18 under forced force. Thus, excessive stress is not applied to the protector 19 from the solid wire 5, so there is no need to worry about the durability of the protector 19.

[0063] As shown in Figure 4(a), the diameter Wb of the solid wire 5 is preferably larger than the diameter Wa of the flexible wire 3. This is because, for example, considering the heat dissipation of the wire harness 1, even if the diameter Wa of the flexible wire 3 cannot be made large, the necessary heat dissipation is ensured by making the diameter Wb of the solid wire 5 large.

[0064] (The combination of wire unit 4 and wire unit 6)

[0065] like Figure 6 As shown, the first wire unit 4 and the second wire unit 6 can be freely combined. However, the shape of the first connector 2 varies depending on the specifications of the shipping destination. In this example, for instance, it is assumed that there are first wire units 4a of the first connector 2 with specification A, first wire units 4b of the first connector 2 with specification B, and first wire units 4c of the first connector 2 with specification C.

[0066] Furthermore, suppose that there are multiple second wire units 6, for example, depending on the type of vehicle to which assembly object 18 is assembled. In this example, suppose that, depending on the type of vehicle, there are, for example, second wire units 6a, 6b, and 6c. In this case, one of the three types of first wire units 4 and one of the three types of second wire units 6 can be freely combined. Therefore, compared to manufacturing wire harness types according to each specification, manufacturing costs can be kept low.

[0067] (Effects of the implementation method)

[0068] Based on the configuration of the above-described embodiments, the following effects can be obtained.

[0069] (1) The wire harness 1 includes: a first wire unit 4, from which a plurality of flexible wires 3 extend; and a second wire unit 6, having a solid wire 5, the solid wire 5 being formed as a single wire for each of the plurality of flexible wires 3, and a second connector 10 being provided at one end of each solid wire 5. The plurality of flexible wires 3 are electrically connected by assembling a first connecting portion 9 provided at one end of the plurality of flexible wires 3 to a second connecting portion 11 provided at the other end of each of the solid wires 5.

[0070] According to this configuration, because the wire harness 1 has a segmented structure consisting of a flexible wire 3 and a solid wire 5, when assembling the wire harness 1 to the assembly object 18, the bending of the flexible wire 3 can absorb the processing tolerances and manufacturing tolerances of the solid wire 5. Therefore, when assembling the wire harness 1 to the assembly object 18, it is not necessary to use considerable force to position the solid wire 5, thus making the assembly of the wire harness 1 easier. Therefore, the workability of the assembly is improved.

[0071] (2) The multiple flexible wires 3 are stranded wires. According to this configuration, because easily bendable stranded wires are used as flexible wires 3, positional deviations when assembling the solid wires 5 to the assembly object 18 are easily absorbed. Therefore, positioning of the solid wires 5 is further facilitated. This further contributes to improving the workability of the assembly.

[0072] (3) The first connecting part 9 and the second connecting part 11 are assembled using a structure that is fixed by a fastening mechanism 13. According to this configuration, the first connecting part 9 and the second connecting part 11 can be firmly fixed by the fastening mechanism 13.

[0073] (4) The first connecting part 9 and the second connecting part 11 are assembled using a male and female connector pair (male connector 16, female connector 17). According to this configuration, the first connecting part 9 and the second connecting part 11 can be connected by a simple operation of fitting the connectors together.

[0074] (5) The wire harness 1 is equipped with a protector 19 that protects the first connecting part 9 and the second connecting part 11 by housing them inside. According to this configuration, the connection portion of the first connecting part 9 and the second connecting part 11 can be protected from damage or water droplets.

[0075] (6) The protector 19 has a position adjustment mechanism 23 that absorbs positional deviations when assembling it to the assembly object 18. With this configuration, the position adjustment mechanism 23 of the protector 19 can absorb positional deviations when assembling the protector 19 to the assembly object 18. Therefore, the protection 19 can also absorb the processing tolerances, manufacturing tolerances, etc. of the solid wire 5.

[0076] (7) The diameter Wb of the solid wire 5 is made larger than the diameter Wa of the flexible wire 3. According to this configuration, even if the flexible wire 3 cannot be made to have a large diameter, the solid wire 5 can still be made to have a large diameter to achieve sufficient heat dissipation in the wire harness 11.

[0077] (8) The first connector 2 is a charging socket connector for connecting an external charging cable. The first connecting part 9 of the flexible wire 3 of the charging socket connector is connected to the second connecting part 11 of the solid wire 5. The second connector 10 of the solid wire 5 is connected to the battery provided on the assembly object 18. According to this configuration, the workability of the assembly can be improved in the wiring harness 1 that connects the charging socket connector and the battery.

[0078] (9) When the wire harness 1 is segmented, compared with the integrated type, we can expect to improve productivity, improve packaging appearance and improve transportation efficiency.

[0079] (Other implementation methods)

[0080] It should be noted that this embodiment can be implemented with the following modifications. This embodiment and the following variations can be combined with each other within the scope of technical inconsistency.

[0081] The number of flexible wires 3 extending from the first connector 2 is not limited to two, but can also be three or more. In this case, the second wire unit 6 has the same number of solid wires 5 as the flexible wires 3.

[0082] Connector 2 can also be changed to a connector other than the charging socket connector.

[0083] The first wire unit 4 is not limited to the charging socket harness; it can be any wire unit that is electrically connected to the second wire unit 6.

[0084] Flexible wires are not limited to stranded wires; any wire with high flexibility is acceptable.

[0085] Connector 1 2 and connector 2 10 can be various connectors, such as rectangular connectors, circular connectors, and ladder connectors.

[0086] The second wire unit 6 is not limited to rigid wire harnesses; any high-rigidity wire harness is acceptable.

[0087] Solid wire 5 can be any type of high-rigidity wire such as single-core wire or busbar mentioned above.

[0088] The connection method for the first connecting part 9 and the second connecting part 11 may include, for example, welding or crimping.

[0089] Flexible wire 3 and solid wire 5 can also have the same diameter.

[0090] The position adjustment mechanism 23 is not limited to a structure in which the hole through which the shaft portion 25 of the fastening portion 22 passes is an elongated hole 26. For example, a protrusion may be provided on the protector 19, and multiple engaging holes may be provided on the assembly object 18, and the position of the protector 19 may be optimized by engaging the protrusion with the hole in the multiple engaging holes in the most suitable position.

[0091] The protector 19 can be fixed to the assembly object 18, for example, by a strap. In this case, the installation position of the protector 19 can be flexible, so the processing tolerances and manufacturing tolerances of the solid wire 5 can also be absorbed in this structure.

[0092] The protector 19 can also be omitted from the wire harness 1. In this case, the processing tolerances and manufacturing tolerances of the solid wire 5 can be absorbed by the bending of the flexible wire 3.

[0093] Wiring harness 1 can also be used in machines other than vehicles.

[0094] The fastening mechanism 13 of the non-limiting embodiment shown in the figure ( Figure 2 ) and male and female connector pairs (male connector 16, female connector 17) Figure 3 These are examples of detachable wire couplers used to detachably connect flexible wires 3 and solid wires 5. For example, as illustrated in the non-limiting embodiment, the wire harness 1 may also include: a single first connector 2; a plurality of second connectors 10; a plurality of flexible wires 3 connected to the first connector 2; a plurality of solid wires 5 respectively connected to the plurality of second connectors 10; a plurality of first connecting portions 9 respectively disposed on the plurality of flexible wires 3; a plurality of second connecting portions 11 respectively disposed on the plurality of solid wires 5; and a plurality of detachable wire couplers (13, 14, 15, 16, 17) for detachably connecting the plurality of first connecting portions 9 and the plurality of second connecting portions 11 respectively. For example, as shown in the figure... Figure 6 As shown, the multiple detachable wire couplers improve the versatility of the wire harness.

[0095] While the invention has been described with reference to embodiments, it should be understood that this description is not limited to those embodiments or structures. This description also includes various modifications or equivalent variations. Furthermore, various combinations or methods, including only one element, or other combinations or methods above or below, also fall within the scope or spirit of this invention.

[0096] Explanation of reference numerals in the attached figures

[0097] 1. Wire harness; 2. First connector; 3. Flexible wire; 4. First wire unit; 4a. First wire unit; 4b. First wire unit; 4c. First wire unit; 5. Solid wire; 6. Second wire unit; 6a. Second wire unit; 6b. Second wire unit; 6c. Second wire unit; 9. First connection part; 10. Second connector; 11. Second connection part; 13. Fastening mechanism; 14. Bolt; 15. Nut; 16. Male connector; 17. Female connector; 18. Assembly object; 19. Protector; 20. Protector body; 21. Cover; 21a. First cover; 21b. Second cover; 22. Fastening part; 23. Position adjustment mechanism; 24. Clamping piece; 25. Shaft part; 26. Elongated hole; 27. Fastened part; Wa. Diameter; Wb. Diameter.

Claims

1. A wire harness, comprising: The first wiring unit extends multiple flexible wires from the first connector; and The second wire unit has multiple solid wires, each of which is formed as a single wire from the multiple flexible wires, and a second connector is provided at one end of each solid wire. The plurality of flexible wires are electrically connected by assembling a first connecting portion located at one end of the plurality of flexible wires to a second connecting portion located at the other end of each of the solid wires.

2. The wire harness according to claim 1, wherein, The multiple flexible wires are stranded wires.

3. The wire harness according to claim 1, wherein, The first connecting part and the second connecting part are assembled using a structure that is fixed by a fastening mechanism.

4. The wire harness according to claim 1, wherein, The first connecting part and the second connecting part are assembled using a male and female connector pair.

5. The wire harness according to claim 1, wherein, The wiring harness includes a protector that protects the first connector and the second connector by housing them inside.

6. The wire harness according to claim 5, wherein, The protector has a position adjustment mechanism that absorbs positional deviations when assembled onto the assembly object.

7. The wire harness according to claim 1, wherein, The diameter of the solid wire is larger than the diameter of the flexible wire.

8. The wire harness according to claim 1, wherein, The first connector is a charging socket connector for connecting an external charging cable. The first connecting portion of the flexible wire of the charging socket connector is connected to the second connecting portion of the solid wire. The second connector of the solid wire is connected to the battery disposed on the assembly object.

Citation Information

Patent Citations

  • High Power Shielded Busbars for Electric Vehicle Charging and Power Distribution

    JP2023517714A