Wire harness

Abstract

The present disclosure provides a wire harness capable of improving the fixing workability of a terminal portion while suppressing buckling of the terminal portion. A wire harness (11) according to one embodiment of the present disclosure is provided with: a solid conductor (15); and a terminal part (16) provided at an end of the solid conductor (15). The terminal part (16) is made of a second metal material that is harder than the first metal material constituting the solid conductor (15), and is connected to the solid conductor (15).

Description

wire harness Technical Field

[0001] This disclosure relates to a wire harness. Background Technology

[0002] Conventionally, there exists a type of wiring harness that includes a solid conductor connecting a vehicle's charging interface connector and a battery (see, for example, Patent Document 1). This wiring harness includes a terminal portion located at the end of the solid conductor. The terminal portion is forged from the solid conductor. The terminal portion has a flat portion and a bolt fastening hole extending through the flat portion, and is bolted to the connected object by inserting a bolt into the bolt fastening hole.

[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, in such wiring harnesses, to prevent buckling of the bolted terminals, a relatively rigid metal material is required to construct the solid conductor itself. Furthermore, especially when the solid conductor connects to the vehicle's charging port connector and battery, tolerances tend to increase as the solid conductor becomes longer. Additionally, due to the long distance between the vehicle's charging port connector and battery, their positional relationship is prone to misalignment. For these reasons, the bolts at the terminals are tightened while the rigid metal solid conductor is bent with considerable force. Therefore, the terminal's secure fastening performance suffers.

[0008] The purpose of this disclosure is to provide a wire harness that can both suppress buckling of the terminal portion and improve the fixation workability of the terminal portion.

[0009] Solution for solving the problem

[0010] The wire harness disclosed herein comprises: a solid conductor; and a terminal portion disposed at the end of the solid conductor, the terminal portion being made of a second metal material harder than a first metal material constituting the solid conductor, and being connected to the solid conductor.

[0011] Invention Effects

[0012] According to the wire harness disclosed herein, it is possible to suppress buckling of the terminal portion while improving the fixation workability of the terminal portion. Attached Figure Description

[0013] Figure 1 is a schematic perspective view of the wiring harness, charging interface connector, and battery in one embodiment.

[0014] Figure 2 is a partial cross-sectional view of the wire harness in one embodiment. Detailed Implementation

[0015] (Description of embodiments of this disclosure)

[0016] The embodiments of this disclosure are first described in detail.

[0017] The wire harness disclosed herein is the following type of wire harness:

[0018] (1) It comprises: a solid conductor; and a terminal portion disposed at the end of the solid conductor, the terminal portion being made of a second metal material harder than the first metal material constituting the solid conductor, and being connected to the solid conductor.

[0019] According to this configuration, since the terminal portion is made of a second metal material that is harder than the first metal material constituting the solid conductor, buckling during bolt tightening can be suppressed, for example. Furthermore, since the solid conductor is made of a first metal material that is softer than the second metal material constituting the terminal portion, it can be easily flexed, for example, making bolt tightening of the terminal portion easier.

[0020] (2) In (1) above, the main components of the first metal material and the second metal material may be the same.

[0021] According to this structure, since the main components of the first metal material and the second metal material are the same, galvanic corrosion can be suppressed.

[0022] (3) In either (1) or (2) above, the first metal material may be aluminum from the 1000 series.

[0023] According to this composition, since the first metallic material is 1000 series aluminum, it is relatively soft, and, for example, compared with metals whose main component is copper, it can achieve weight reduction. In addition, it can also improve electrical conductivity.

[0024] (4) In any of the above (1) to (3), the second metal material may be a 6000 series aluminum alloy.

[0025] According to this composition, since the second metal material is a 6000 series aluminum alloy, it is harder and, for example, lighter than metals with copper as the main component.

[0026] (5) In any of the above (1) to (4), the terminal portion may have a bolt fastening hole.

[0027] According to this configuration, since the terminal part has a bolt fastening hole, the bolt can be inserted into the bolt fastening hole, thereby making the bolt fastening operation easy.

[0028] (6) In any of (1) to (5) above, the solid conductor may connect the vehicle’s charging interface connector and the battery.

[0029] With this configuration, since the solid conductor connects the vehicle's charging interface connector and the battery, its length increases and tolerances tend to become larger. Furthermore, the positional relationship between the vehicle's charging interface connector and the battery is prone to misalignment. For these reasons, it becomes easy to flex the solid conductor significantly while simultaneously bolting the terminal section. Because the solid conductor is made of a soft first metallic material, it can be easily flexed, thus facilitating the bolting operation at the terminal section.

[0030] (Details of the embodiments disclosed herein)

[0031] Specific examples of the wire harnesses disclosed herein are described below with reference to the accompanying drawings. In the figures, for ease of explanation, some components are sometimes exaggerated or simplified. Furthermore, the dimensional proportions of the components may differ in each figure. The terms "parallel," "orthogonal," or "true circle" in this specification are not limited to parallel, orthogonal, or true circle in a strict sense, but also include generally parallel, orthogonal, or true circle within the range that can function effectively in this embodiment. Moreover, the invention is not limited to these examples, but is shown by the claims and is intended to include all variations within the scope and meaning of the claims.

[0032] (Composition of wire harness 11)

[0033] As shown in Figure 1, wiring harness 11 is used to connect the vehicle's charging interface connector 12 and battery 13. Additionally, an external charging cable (not shown) is connected to the charging interface connector 12. Wiring harness 11 has two shielded busbars 14.

[0034] (Composition of shielded busbar 14)

[0035] As shown in Figure 2, the shielded busbar 14 has a solid conductor 15, a terminal portion 16, an insulation layer 17, and a shielding layer 18.

[0036] (The structure of solid conductor 15)

[0037] The solid conductor 15 is a single-core wire. The solid conductor 15 is formed into a long strip with a circular cross-sectional shape. Also, in Figure 2, only the first end of the shielding busbar 14 in the length direction is shown. The second end, which is opposite to the first end, is omitted from the figure because it has the same structure as the first end.

[0038] (The structure of terminal 16)

[0039] A terminal portion 16 is provided at the end of the solid conductor 15. The terminal portion 16 has: a cylindrical engagement portion 16a with an end face shape identical to the end face of the solid conductor 15; a flat portion 16b extending from the engagement portion 16a; and a bolt fastening hole 16c penetrating the flat portion 16b. The terminal portion 16 is connected to the solid conductor 15 by engaging the end face of the engagement portion 16a with the end face of the solid conductor 15. Furthermore, the engagement portion 16a is engaged with the solid conductor 15, for example, by FSW (Friction Stir Welding) or electromagnetic pulse engagement. The flat portion 16b of the terminal portion 16 overlaps with a connection object (not shown) and is bolted to the connection object by inserting a bolt (not shown) into the bolt fastening hole 16c. In this embodiment, the connection object is a connection terminal provided on the charging interface connector 12 or the battery 13.

[0040] (Composition of insulating layer 17)

[0041] The insulating layer 17 covers the entire outer periphery of the solid conductor 15. The insulating layer 17 covers almost the entire length of the solid conductor 15. The insulating layer 17 is made of an insulating resin material.

[0042] (Composition of shielding layer 18)

[0043] The shielding layer 18 covers the entire outer periphery of the insulating layer 17. The shielding layer 18 covers the entire length of the insulating layer 17. The shielding layer 18 is made of a metallic material with electromagnetic shielding properties. For example, the shielding layer 18 is made of a metal tube or braided wire.

[0044] Furthermore, the shielding busbar 14 is bent according to the shape of the vehicle body to connect the charging interface connector 12 and the battery 13. Also, Figure 1 schematically illustrates a simple shape where the shielding busbar 14 is bent at a right angle in only one location, but it is not limited to this; the shielding busbar 14 can be bent in multiple locations or at different angles. The charging interface connector 12 and the battery 13 are connected by bolts to the connected object via the terminal portion 16, and the solid conductor 15 connects them.

[0045] Here, the terminal portion 16 is made of a second metal material that is harder than the first metal material constituting the solid conductor 15. In other words, the terminal portion 16 is made of a second metal material that is stronger than the first metal material constituting the solid conductor 15. Furthermore, the strength mentioned here refers to a numerical value indicating the amount of force that can be withstood per unit area without deformation. Additionally, the material and shape of the terminal portion 16 are designed to prevent buckling during bolt tightening. Conversely, the solid conductor 15 is made of a first metal material that is softer than the second metal material constituting the terminal portion 16. In other words, the solid conductor 15 is made of a first metal material that is weaker than the second metal material constituting the terminal portion 16.

[0046] In this embodiment, the first metal material constituting the solid conductor 15 and the second metal material constituting the terminal portion 16 have the same main composition. Specifically, the main composition of both the first metal material constituting the solid conductor 15 and the second metal material constituting the terminal portion 16 is aluminum. More specifically, the first metal material is 1000 series aluminum. The second metal material is a 6000 series aluminum alloy.

[0047] Next, the function of the wire harness 11 constructed as described above will be explained.

[0048] For example, when bolting the terminal portion 16 to the connected object, due to the tolerance of the solid conductor 15 or the misalignment of the charging interface connector 12 and the battery 13, sometimes the terminal portion 16 is bolted while the solid conductor 15 is bent. In this case, if the first metal material constituting the solid conductor 15 is hard, the terminal portion 16 will be bolted while being bent with a large force. However, since it is made of a soft first metal material, it can be bent easily, thus making the bolting operation easier.

[0049] The effects of the above implementation methods will be described below.

[0050] (1) Since the terminal portion 16 is made of a second metal material that is harder than the first metal material constituting the solid conductor 15, buckling during bolt tightening can be suppressed, for example. Furthermore, since the solid conductor 15 is made of a first metal material that is softer than the second metal material constituting the terminal portion 16, it can be easily flexed, for example, making bolt tightening of the terminal portion 16 easier. Additionally, since the solid conductor 15 is made of a soft first metal material, the stress applied to the terminal portion 16 can be suppressed to a smaller extent when the terminal portion 16 is in a bolt-tightened state.

[0051] (2) Since the main components of the first metal material constituting the solid conductor 15 and the second metal material constituting the terminal portion 16 are the same (aluminum), galvanic corrosion can be suppressed.

[0052] (3) Since the first metal material constituting the solid conductor 15 is 1000 series aluminum, it is soft and, for example, lightweight compared to metals with copper as the main component. In addition, it can also improve conductivity.

[0053] (4) Since the second metal material constituting the terminal part 16 is a 6000 series aluminum alloy, it is hard and, for example, can be lightweight compared with metals with copper as the main component.

[0054] (5) Since the terminal part 16 has a bolt fastening hole 16c, the bolt can be inserted into the bolt fastening hole 16c, thereby making the bolt fastening operation easy.

[0055] (6) Since the solid conductor 15 connects the charging interface connector 12 and the battery 13, its length increases and the tolerance is prone to become larger. In addition, the positional relationship between the charging interface connector 12 and the battery 13 is also prone to shift. For these reasons, it is easy to find a situation where the solid conductor 15 is bent considerably while the terminal portion 16 is bolted. Since the solid conductor 15 is made of a soft first metal material, it can be easily bent, making the bolting operation of the terminal portion 16 easier.

[0056] This embodiment can be implemented by modifications as shown below. This embodiment and the following modifications can be combined with each other within the scope of technical inconsistency.

[0057] In the above embodiment, the first metal material constituting the solid conductor 15 and the second metal material constituting the terminal portion 16 have the same main component (aluminum), but this is not a limitation, and the main components may be different. For example, the first metal material may have aluminum as its main component, while the second metal material may have copper as its main component.

[0058] In the above embodiment, the first metal material constituting the solid conductor 15 is 1000 series aluminum, but it is not limited to this, and may be changed to other first metal materials that are softer than the second metal material constituting the terminal portion 16.

[0059] In the above embodiment, the second metal material constituting the terminal portion 16 is a 6000 series aluminum alloy, but it is not limited to this and may be changed to other second metal materials that are harder than the first metal material constituting the solid conductor 15.

[0060] In the above embodiment, the terminal portion 16 has a flat portion 16b and a bolt fastening hole 16c, but it is not limited to this. For example, the terminal portion 16 may also have other shapes without the bolt fastening hole 16c.

[0061] In the above embodiment, the solid conductor 15 is used to connect the charging interface connector 12 and the battery 13, but it is not limited to this and can also be a solid conductor 15 used to connect other electrical devices to each other.

[0062] In the above embodiment, the wire harness 11 has two shielded busbars 14, each having a solid conductor 15, a terminal portion 16, an insulating layer 17, and a shielding layer 18, but is not limited thereto. For example, the wire harness 11 may also be configured without the shielding layer 18. Alternatively, for example, the wire harness 11 may also be configured with an outer insulating layer that further covers the periphery of the shielding layer 18.

[0063] In the above embodiment, the first end and the second end of the shielding busbar 14 are made to have the same configuration in the length direction, but it is not limited to this, and the first end and the second end may also have different configurations.

[0064] In the above embodiment, the cross-sectional shape of the solid conductor 15 is circular, but it is not limited to this as long as it is a single-core wire. For example, the cross-sectional shape can also be quadrilateral or elliptical.

[0065] In the above embodiments, the joint 16a is joined to the solid conductor 15, for example by FSW or electromagnetic pulse joining, but is not limited thereto. For example, it can also be connected to the solid conductor 15 by other structures or methods such as riveting or welding.

[0066] Before connecting and / or joining the terminal portion 16 to the solid conductor 15, the end face of the joint portion 16a of the terminal portion 16 and the end face of the solid conductor 15 can be flat surfaces that can fit tightly without gaps or allow for surface contact. In the example shown in FIG. 2, the solid conductor 15 can contact and be joined with the terminal portion 16 by the entire end face of the solid conductor 15, i.e., by the conductor cross-sectional area of ​​the solid conductor 15. Thus, when electrically connecting the solid conductor 15 and the terminal portion 16, the conductor cross-sectional area of ​​the solid conductor 15 (i.e., the thickness of the solid conductor 15 or the shielding bus 14) can be utilized to the maximum extent, thereby improving the mechanical strength of the connection between the terminal portion 16 and the solid conductor 15 and the reliability of the electrical connection. The joining of flat surfaces is beneficial for the uniform distribution of stress or for avoiding localized stress concentration. The end face of the joint portion 16a of the terminal portion 16 and the end face of the solid conductor 15 can each be composed of only one or more flat surface regions.

[0067] As shown in FIG2, the end face of the joint portion 16a of the terminal portion 16 and the end face of the solid conductor 15 can be directly joined between these two end faces without the intervention of solder or adhesive or other intervening substances different from the first metal material and the second metal material. For example, when both the solid conductor 15 and the terminal portion 16 have aluminum metal atoms, after joining the solid conductor 15 to the terminal portion 16, a joint area in which the aluminum metal atoms of the solid conductor 15 and the aluminum metal atoms of the terminal portion 16 coexist can be formed with a predetermined axial length or thickness.

[0068] Explanation of reference numerals in the attached figures

[0069] 11. Wiring Harness

[0070] 12 Charging Interface Connector

[0071] 13 batteries

[0072] 14 Shielded busbars

[0073] 15 Solid conductor

[0074] 16 Terminal Section

[0075] 16a Joint

[0076] 16b Flat section

[0077] 16c bolt fastening hole

[0078] 17 Insulation layer

[0079] 18. Shielding layer.

Claims

1. A wire harness comprising: a solid conductor; and a terminal portion disposed at an end of the solid conductor, the terminal portion being made of a second metal material harder than a first metal material constituting the solid conductor and connected to the solid conductor.

2. The wire harness according to claim 1, wherein, The first metallic material and the second metallic material have the same main components.

3. The wire harness according to claim 1, wherein, The first metallic material is 1000 series aluminum.

4. The wire harness according to claim 1, wherein, The second metal material is a 6000 series aluminum alloy.

5. The wire harness according to claim 1, wherein, The terminal portion has bolt fastening holes.

6. The wire harness according to claim 1, wherein, The solid conductor connects the vehicle's charging interface connector and the battery.

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