Vehicle wiring harness system and method of connecting a vehicle wiring harness

Abstract

The application relates to a vehicle wire harness system and a connecting method of the vehicle wire harness, and relates to the technical field of vehicles. The vehicle wire harness system comprises a female bus, a flexible cable, a wire and a support. The flexible cable is arranged on the surface of the female bus and fixedly connected with the female bus, and the length direction of the flexible cable is consistent with the length direction of the female bus. The support comprises a first mounting part connected with the female bus and a second mounting part connected with the wire.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and more specifically to a vehicle wiring harness system and a method for connecting vehicle wiring harnesses. Background Technology

[0002] As vehicles become increasingly electronically and electrically integrated, the number of electrical components in a vehicle continues to rise. As the carrier of electrical and signal transmission, the number, size, and complexity of vehicle wiring harnesses also increase. Traditional vehicle wiring harnesses primarily use wires as the main connection element. When the number of circuits increases, this easily leads to larger harness size, more complex layout, and lower assembly efficiency.

[0003] To meet the demands for lightweight and integrated wiring harnesses in vehicles, vehicle wiring harness structures are constantly evolving. However, existing wiring harness structures still struggle to simultaneously satisfy the requirements for high integration and flexible wiring. Summary of the Invention

[0004] One objective of this invention is to provide a vehicle wiring harness system that meets the requirements for high integration and flexible wiring; another objective is to provide a method for connecting vehicle wiring harnesses.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, this application provides a vehicle wiring harness system, which includes a busbar, a flexible cable, a conductor, and a support member; the flexible cable is disposed on the surface of the busbar and fixedly connected to the busbar, and the length direction of the flexible cable is consistent with the length direction of the busbar; the support member includes a first mounting part connected to the busbar and a second mounting part connected to the conductor.

[0006] Through the above setup, the busbar acts as a rigid carrier, providing basic support for the wiring harness arrangement. Flexible cables are placed on the surface of the busbar and fixedly connected to it, forming an integrated structure. This leverages the high loop density and small space requirements of flexible cables to improve the integration of the wiring harness, while the busbar provides support and protection for the flexible cables, reducing their susceptibility to bending and damage. The length direction of the flexible cables is consistent with the length direction of the busbar, allowing them to be neatly arranged along the main direction of the busbar, reducing crossings and bends, and improving the orderliness of the wiring.

[0007] The support includes a first mounting part that connects to the busbar and a second mounting part that connects to the conductor, enabling the busbar or the combined structure formed by the busbar and the flexible cable to be installed in a unified manner with the conductor, thereby improving the overall integration while retaining the flexibility of the conductor layout.

[0008] Therefore, this application achieves both wire harness integration and flexible wiring through the above-mentioned structural combination.

[0009] Furthermore, the support member includes a first part and a second part, which together form a first wiring channel. Busbars and flexible cables pass through the first wiring channel, which forms a first mounting part. The second part has a second wiring channel, through which conductors pass, which forms a second mounting part.

[0010] According to the aforementioned technical means, the support component forms a layered wiring structure through a first part and a second part. The first part and the second part enclose a first wiring channel, allowing the busbar and flexible cable to be installed as a combined structure within the same channel. This integrates the busbar and flexible cable into the same installation interface. On the one hand, it facilitates the use of the busbar to provide support, fixation, and protection for the flexible cable, reducing the problems of easy bending and damage when the flexible cable is arranged separately. On the other hand, it helps to improve the integration of the busbar and flexible cable, reducing the space occupied by scattered wiring. At the same time, the second part is provided with a second wiring channel, allowing the conductors to be installed and fixed in an independent channel. Thus, without affecting the adaptability of the conductors themselves, the conductors, busbar, and flexible cable combined structure are integrated into the same support component for unified installation. Therefore, this support component can not only achieve the classification constraint and stable fixation of different conductors, but also allow the busbar system and conductor system to be arranged along a common path, reducing the use of additional clips and installation parts, saving layout space, and improving the integration, installation convenience, and assembly efficiency of the wiring harness assembly.

[0011] Furthermore, the second wiring channel includes a groove that is recessed in the direction from the second part to the first part, and the groove extends through the second part along the length of the wire; and / or, the first part and the second part are detachably connected.

[0012] Based on the aforementioned technical means, the second wiring channel adopts a groove structure that is recessed from the second part towards the first part, and the groove extends through the second part along the length of the wire, facilitating wire insertion and limiting and fixing of the wire, which helps improve the regularity of wire arrangement and assembly efficiency. The first and second parts are detachably connected, which facilitates the installation, disassembly, and maintenance of the busbar and flexible cables, improves the flexibility and adaptability of the support components, and thus helps improve the overall integration effect and installation convenience of the vehicle wiring harness system.

[0013] Furthermore, the first mounting part is snapped into the busbar, and / or the second mounting part is snapped into the wire.

[0014] Based on the aforementioned technical means, the second wiring channel adopts a groove structure that is recessed from the second part towards the first part, and the groove extends through the second part along the length of the wire, facilitating wire insertion and limiting and fixing of the wire, which helps improve the regularity of wire arrangement and assembly efficiency. The first and second parts are detachably connected, which facilitates the installation, disassembly, and maintenance of the busbar and flexible cables, improves the flexibility and adaptability of the support components, and thus helps improve the overall integration effect and installation convenience of the vehicle wiring harness system.

[0015] Furthermore, the vehicle wiring harness system includes multiple support members spaced apart along the length of the flexible cable.

[0016] Based on the aforementioned technical means, the vehicle wiring harness system includes multiple support members spaced apart along the length of the flexible cable. These support members are installed at locations where the busbar, flexible cable, and conductors need to be integrated and fixed to achieve local connection and stable support. In areas without support members, the conductors can be flexibly arranged. This approach helps to improve the flexibility of conductor arrangement while ensuring the overall integration effect of the wiring harness system, thus balancing the integration level and wiring adaptability of the vehicle wiring harness system.

[0017] Furthermore, the vehicle wiring harness system also includes fasteners that are connected to both the busbar and the flexible cable, with at least a portion of the fasteners connected to the surface of the flexible cable facing away from the busbar.

[0018] According to the above technical means, the fasteners are connected to both the busbar and the flexible cable, and at least some of the fasteners are set on the surface of the flexible cable away from the busbar. This is conducive to the stable fixing of the flexible cable to the busbar, improving the reliability of the connection between the two, reducing the possibility of the flexible cable lifting, shifting or falling off, and further enhancing the support and protection of the busbar for the flexible cable. This is conducive to improving the overall integration effect and structural stability of the vehicle wiring harness system.

[0019] Furthermore, the fastener includes tape wrapped around the surface of at least a portion of the busbar and at least a portion of the flexible cable, and the tape is connected to both the busbar and the flexible cable.

[0020] According to the above technical means, the tape is wrapped around the surface of at least part of the busbar and at least part of the flexible cable, and is connected to both the busbar and the flexible cable. This helps to stably fix the flexible cable to the busbar, improve the reliability of the connection between the two, enhance the support and protection of the busbar for the flexible cable, and reduce the setting of additional fixing structures. This helps to improve the overall integration effect and assembly convenience of the vehicle wiring harness system.

[0021] Furthermore, the vehicle wiring harness system also includes a connector, which includes a housing and a plurality of terminals housed within the housing. Each terminal includes a first connection structure and a second connection structure for connecting to a flexible cable. The first connection structure is used for electrical connection to a mating terminal in an external connection component.

[0022] According to the above technical means, the connector also includes a compression structure, which is disposed inside the housing. Along the first direction, the compression structure and the flexible cable are respectively located on both sides of the second connection structure. The compression structure is used to compress the second connection structure so that the flexible cable is connected to the second connection structure. The first direction intersects with the length direction of the flexible cable.

[0023] Furthermore, the connector also includes a compression structure, which is disposed inside the housing. Along the first direction, the compression structure and the flexible cable are respectively located on both sides of the second connecting structure. The compression structure is used to compress the second connecting structure so that the flexible cable is connected to the second connecting structure. The first direction intersects with the length direction of the flexible cable.

[0024] According to the above-mentioned technical means, the extrusion structure is located inside the housing and is located on both sides of the second connection structure, respectively, with the flexible cable. It can extrude the second connection structure in a direction that intersects with the length direction of the flexible cable, so as to make the flexible cable and the second connection structure stably connected. This is beneficial to improving the reliability and stability of the connection between the two, and also beneficial to improving the assembly efficiency of the connector and the connection reliability of the vehicle wiring harness system.

[0025] Furthermore, the flexible cable includes a conductor portion and an insulation portion. The insulation portion is provided with a first limiting portion, and the housing is provided with a second limiting portion that cooperates and connects with the first limiting portion. The conductor portion is electrically connected to the second connection structure.

[0026] Based on the above-mentioned technical means, this application is able to install flexible cables at accurate positions within the connector through the first limiting part and the second limiting part.

[0027] Secondly, this application provides a method for connecting vehicle wiring harnesses. The method is applied to a vehicle wiring harness system, which includes a busbar, flexible cables, conductors, and a support member. The flexible cables are disposed on the surface of the busbar and fixedly connected to it, with the length direction of the flexible cables aligned with the length direction of the busbar. The support member includes a first mounting portion connected to the busbar and a second mounting portion connected to the conductors. The method includes: dividing the vehicle current loop into a first current loop, a second current loop, and a third current loop according to the magnitude of the current in the vehicle current loop, wherein the current in the first current loop is less than the current in the second current loop, and the current in the second current loop is less than the current in the third current loop; arranging the busbar between two ports of the third current loop and electrically connecting the busbar to the third current loop; arranging the flexible cables according to the arrangement path of the busbar and fixing them to the busbar, with the length direction of the flexible cables aligned with the length direction of the busbar; placing the flexible cables between two ports of the first current loop and electrically connecting them to the first current loop; arranging the conductors between two ports of the second current loop and electrically connecting them to the second current loop; and fixing the busbar and conductors using the support member.

[0028] Based on the aforementioned technical means, busbars, flexible cables, and conductors are used to connect the different current circuits according to their current magnitudes. This facilitates matching different conductors with circuits of different current levels. Among these, the flexible cables are fixed to the busbars along their arrangement path and are installed in the same direction as the busbars, which helps improve the regularity and integration of the wiring harness arrangement and enhances the support and protection provided by the busbars for the flexible cables. At the same time, using support components to fix the busbars and conductors improves the coordinated arrangement of different conductors and ease of installation, thus taking into account both the integration and flexible wiring requirements of the vehicle wiring harness system.

[0029] The beneficial effects of this invention are: This application utilizes the coordinated arrangement of busbars, flexible cables, conductors, and support components to create an integrated layout structure for the flexible cables. The support components further secure the flexible cables to the conductors, thereby improving the integration, layout regularity, and space utilization of the vehicle wiring harness system while retaining the flexibility of the conductors. Simultaneously, the busbars provide support, fixation, and protection for the flexible cables, reducing their susceptibility to bending and damage, and enhancing the feasibility of engineering applications. Furthermore, the combination of equal-sequence and equidistant interface design, multi-circuit parallel connection, and connector extrusion connection structure further improves connection reliability, assembly convenience, and manufacturing efficiency, while reducing connection costs.

[0030] It should be noted that the technical effects of any implementation method in the second aspect can be found in the technical effects of the corresponding implementation method in the first aspect, and will not be repeated here.

[0031] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0032] Figure 1 This invention provides a structural schematic diagram of a vehicle wiring harness system; Figure 2 This invention provides an assembly diagram of a vehicle wiring harness system; Figure 3 A schematic diagram of the connection structure between a busbar and a flexible cable provided by the present invention; Figure 4 A schematic diagram of the structure of a support member provided by the present invention; Figure 5 A schematic diagram of an interface connection for a flexible cable provided by the present invention; Figure 6 A schematic diagram of the structure of a connector provided by the present invention; Figure 7 This is a schematic diagram of a vehicle wiring harness connection method provided by the present invention.

[0033] Among them, 100-vehicle wiring harness system; 101-busbar; 102-flexible cable; 1021-conductor part; 1022-insulation part; 1022a-first limiting part; 103-wire; 104-support member; 1041-first part; 1041a-first wiring channel; 1042-second part; 1042a-second wiring channel; 105-fixing member; 106-connector; 1061-housing; 1062-first connection structure; 1063-second connection structure; 1064-extruded structure. Detailed Implementation

[0034] The embodiments of the present invention will be described below with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be understood that the preferred embodiments are only for illustrating the present invention and not for limiting the scope of protection of the present invention.

[0035] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the drawings only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0036] In some embodiments, see Figure 1 This application provides a vehicle. The vehicle includes multiple connectors electrically connected to each other via a vehicle wiring harness system 100. Each connector serves as a port for electrical equipment or communication equipment on the vehicle. The electrical equipment can be lamps, actuators, controllers, sensors, or other electrical components on the vehicle, and the communication equipment can be an interface component for signal exchange between on-board control units. Each connector is respectively located at the corresponding electrical equipment or communication equipment to realize power transmission and signal transmission between different devices within the vehicle.

[0037] In some embodiments, see Figure 1 and Figure 2 This application provides a vehicle wiring system. The vehicle wiring harness system 100 includes a busbar 101, a flexible cable 102, a conductor 103, and a support member 104. The flexible cable 102 is disposed on the surface of the busbar 101 and fixedly connected to the busbar 101, and the length direction of the flexible cable 102 is consistent with the length direction of the busbar 101. The support member 104 includes a first mounting part connected to the busbar 101 and a second mounting part connected to the conductor 103.

[0038] For example, the busbar 101 and the flexible cable 102 form an integrated arrangement structure. The busbar 101 is arranged at the bottom and the flexible cable 102 is arranged at the top. The flexible cable 102 is disposed on the surface of the busbar 101 and fixedly connected to the busbar 101, and the length direction of the flexible cable 102 is consistent with the length direction of the busbar 101.

[0039] The busbar 101 can be a metal busbar conductor. For example, the busbar 101 can be an aluminum busbar, a copper busbar, or a combination of copper and aluminum busbars. That is, the busbar 101 in this embodiment is not limited to a single material, as long as it can be used for current transmission in the vehicle wiring harness system 100 and can provide support for the flexible cable 102.

[0040] The flexible cable 102 can be a flat, flexible conductor. For example, the flexible cable 102 can be a flexible flat cable (FFC) or a flexible printed circuit (FPC). The flexible cable 102 is disposed on the surface of the busbar 101, and the length direction of the flexible cable 102 is consistent with the length direction of the busbar 101; that is, the flexible cable 102 is arranged along the extension direction of the busbar 101. In this way, the busbar 101 can serve as a supporting foundation for the flexible cable 102, providing support and protection for the flexible cable 102 as it is arranged along with the busbar 101, thereby improving the stability of the flexible cable 102 arrangement.

[0041] It should be noted that the "flexibility" in flexible cable 102 refers to the flexibility of the conductor part during wiring, rather than a description of the connection ports at both ends.

[0042] The conductor 103 can be a linear conductor commonly used in vehicle wiring harnesses, used to cooperate with the busbar 101 and flexible cable 102 in the arrangement. The conductor 103 can be set according to the actual wiring requirements. In this embodiment, the specific material, wire diameter and insulation structure of the conductor 103 are not limited, as long as they can meet the connection requirements of the corresponding circuit.

[0043] The support member 104 includes a first mounting portion connected to the busbar 101 and a second mounting portion connected to the conductor 103. The first mounting portion can be connected to the busbar 101 for installation and positioning of the busbar 101; the second mounting portion can be connected to the conductor 103 for installation and positioning of the conductor 103. In this way, the support member 104 can simultaneously accommodate both the busbar 101 and the conductor 103, thereby realizing the combined arrangement of the busbar 101 and the conductor 103.

[0044] For example, the support member 104 can be provided with a snap-fit ​​structure to form a first mounting portion and a second mounting portion. The first mounting portion can be a snap-fit ​​portion, clamping portion, or limiting portion that cooperates with the busbar 101, and the second mounting portion can be a snap-fit ​​portion, clamping portion, or limiting portion that cooperates with the wire 103. That is, as long as the support member 104 can form a first mounting portion connected to the busbar 101 and a second mounting portion connected to the wire 103 to achieve support and fixation of the busbar 101 and the wire 103, the specific structural form of the support member 104 is not limited in the embodiments of this application.

[0045] In this embodiment, the busbar 101 and the flexible cable 102 form a combined arrangement structure, and the conductor 103 is arranged in conjunction with the busbar 101 through the support member 104. In this way, on the one hand, the busbar 101 can play a rigid supporting role, supporting and protecting the flexible cable 102, reducing the risk of the flexible cable 102 being bent and damaged; on the other hand, the support member 104 can simultaneously install and fix the busbar 101 and the conductor 103, which is conducive to realizing the integrated arrangement between different conductors and improving the arrangement stability and structural compactness of the vehicle wiring harness system 100.

[0046] In some embodiments, see Figure 2 , Figure 3 and Figure 4The support member 104 includes a first part 1041 and a second part 1042. The first part 1041 and the second part 1042 form a first wiring channel 1041a. The busbar 101 and the flexible cable 102 pass through the first wiring channel 1041a, and the first wiring channel 1041a forms a first mounting part. The second part 1042 is provided with a second wiring channel 1042a. The conductor 103 passes through the second wiring channel 1042a, and the second wiring channel 1042a forms a second mounting part.

[0047] For example, the first part 1041 and the second part 1042 cooperate to form a first wiring channel 1041a for accommodating the busbar 101 and the flexible cable 102. The busbar 101 and the flexible cable 102 can be jointly installed within the first wiring channel 1041a, thereby forming a combined arrangement structure. The first wiring channel 1041a forms a first mounting part, that is, the first mounting part limits, supports, and installs the busbar 101 and the flexible cable 102 through the first wiring channel 1041a. In this way, the busbar 101 and the flexible cable 102 can be arranged through the same wiring channel, which is beneficial to improving the stability when the two are combined and facilitates the arrangement of the flexible cable 102 attached to the busbar 101.

[0048] The second part 1042 is provided with a second wiring channel 1042a, through which the wire 103 passes, forming a second mounting part. That is, the second mounting part limits, supports, and mounts the wire 103 via the second wiring channel 1042a, allowing the wire 103 to be arranged collaboratively with the busbar 101 and the flexible cable 102 through the support member 104. In this way, the wire 103 does not require a separate mounting component and can be used in conjunction with the busbar 101 and the flexible cable 102, thereby improving the overall integration of the vehicle wiring harness system 100.

[0049] For example, the first wiring channel 1041a and the second wiring channel 1042a can be arranged along the direction of the busbar 101 (flexible cable 102) and the conductor 103 to respectively adapt to the wiring requirements of the busbar 101, the flexible cable 102 and the conductor 103. After the busbar 101 and the flexible cable 102 are passed through the first wiring channel 1041a, the conductor 103 is passed through the second wiring channel 1042a, so that the busbar 101, the flexible cable 102 and the conductor 103 can be combined and installed through the same support member 104. Through the above settings, on the one hand, the first wiring channel 1041a can constrain the busbar 101 and the flexible cable 102, making the combined arrangement of the busbar 101 and the flexible cable 102 more stable; on the other hand, the second wiring channel 1042a can constrain the conductor 103, making the conductor 103 maintain a predetermined direction when arranged in conjunction with the busbar 101, thereby helping to improve the layout regularity and installation stability of the vehicle wiring harness system 100.

[0050] The support member 104 forms two cooperating wiring channels through a first part 1041 and a second part 1042. The first wiring channel 1041a is used for the installation of the busbar 101 and the flexible cable 102, and the second wiring channel 1042a is used for the installation of the conductor 103. In this way, the busbar 101 and the flexible cable 102 can be arranged as a combined structure, and the conductor 103 can be arranged in coordination with this combined structure through the second wiring channel 1042a. This facilitates the integrated arrangement of different conductors and improves the structural compactness, layout stability, and installation convenience of the vehicle wiring harness system 100.

[0051] In addition, the second part 1042 can also be connected to components on the vehicle body to secure the support 104.

[0052] In some embodiments, see Figure 2 , Figure 3 and Figure 4 The second wiring channel 1042a includes a groove, which is recessed in the direction from the second part 1042 to the first part 1041, and extends through the second part 1042 along the length of the wire 103.

[0053] That is, the second wiring channel 1042a can adopt an open groove structure, with the groove recessed from the second part 1042 toward the first part 1041 and continuously arranged along the length of the conductor 103.

[0054] The wire 103 can be inserted radially into the groove and arranged axially along the groove. This arrangement allows the groove to guide, limit, and support the wire 103, ensuring that the wire 103 maintains its predetermined direction after installation. This improves the regularity of the wire 103 arrangement, simplifies the insertion process, and enhances assembly convenience.

[0055] Since the groove extends through the second part 1042 along the length of the wire 103, the wire 103 can be extended along the groove according to the actual wiring requirements, so that the support member 104 can not only install and fix the wire 103, but also take into account the continuity of the wire 103 arrangement.

[0056] In some embodiments, see Figure 2 , Figure 3 and Figure 4 The first part 1041 and the second part 1042 are detachably connected.

[0057] That is, the first part 1041 and the second part 1042 can be connected to each other in the assembled state and can be separated from each other when needed.

[0058] In this way, when the busbar 101 and the flexible cable 102 are installed into the first wiring channel 1041a, the first part 1041 and the second part 1042 can be separated first to facilitate the placement of the busbar 101 and the flexible cable 102; after the busbar 101 and the flexible cable 102 are placed in place, the first part 1041 and the second part 1042 are connected to form a limit and fixation on the busbar 101 and the flexible cable 102.

[0059] This design improves the ease of installing the busbar 101 and flexible cable 102 into the support 104, and also facilitates subsequent disassembly, maintenance and replacement, thereby increasing the flexibility of the support 104.

[0060] The second wiring channel 1042a adopts a groove structure, which facilitates the insertion of the wire 103 and limits and fixes the wire 103. The first part 1041 and the second part 1042 are detachably connected, which facilitates the assembly and disassembly of the busbar 101 and the flexible cable 102. Thus, the support member 104 can not only realize the coordinated arrangement of the busbar 101, the flexible cable 102 and the wire 103, but also take into account the convenience of assembly and structural stability, thereby improving the layout regularity, installation convenience and overall integration effect of the vehicle wiring harness system 100.

[0061] In some embodiments, see Figure 2 , Figure 3 and Figure 4 The first mounting part is snapped into the busbar 101, and / or the second mounting part is snapped into the wire 103.

[0062] The first mounting part is snapped into the busbar 101. That is, the first mounting part usually has a snap-fit ​​structure that matches the busbar 101. Through mechanical snap-fit ​​or limiting, the busbar 101 is stably fixed in the first mounting part and is not easy to slide or fall out.

[0063] Similarly, the second mounting part is snapped into the wire 103, which means that the second mounting part is also provided with a snapping structure that matches the wire 103, which can reliably clamp and limit the wire 103.

[0064] This snap-fit ​​connection eliminates the need for additional fasteners, enabling quick and secure installation. Therefore, the busbar 101 and wire 103 are connected to the support 104 via a snap-fit ​​connection, simplifying the installation of the vehicle wiring harness system 100 while ensuring the overall stability and reliability of the layout.

[0065] In some embodiments, see Figure 2 , Figure 3 and Figure 4 The vehicle wiring harness system 100 includes a plurality of support members 104 spaced apart along the length of the flexible cable 102.

[0066] It should be noted that this application does not limit the location of the support member 104. The support member 104 can be set at the location where the busbar 101, flexible cable 102 and conductor 103 need to be fixed, and can be arranged at intervals at different locations along the cable route.

[0067] Each support member 104 includes a first part 1041 and a second part 1042. The first part 1041 and the second part 1042 form a first wiring channel 1041a, through which the busbar 101 and the flexible cable 102 pass, forming a first mounting part. The second part 1042 has a second wiring channel 1042a, through which the conductor 103 passes, forming a second mounting part. With this structure, the busbar 101 and the flexible cable 102 are fixed in the same channel, while the conductor 103 is fixed through an independent channel, thereby achieving a stable arrangement of each conductor.

[0068] By intermittently installing support members 104, the busbar 101 and flexible cable 102 are stably supported at critical locations, preventing displacement due to vibration or stress; on the other hand, please refer to... Figure 1 and Figure 2 The wire 103 can be flexibly routed in sections without the support 104 to adapt to different vehicle layout requirements. This implementation ensures the stability of the overall wiring harness layout while retaining the flexibility of the wire 103 during actual routing, thereby improving the ease of installation and overall reliability of the vehicle wiring harness system 100.

[0069] In some embodiments, see Figure 2 , Figure 3 and Figure 4 The vehicle wiring harness system 100 also includes a fastener 105, which is connected to both the busbar 101 and the flexible cable 102. At least a portion of the fastener 105 is connected to the surface of the flexible cable 102 facing away from the busbar 101.

[0070] It should be understood that the fastener 105 can apply a force to the flexible cable 102 toward the surface of the busbar 101 so that the flexible cable 102 can be securely disposed on the surface of the busbar 101.

[0071] It should be noted that this application does not limit the specific structure of the fastener 105. For example, the fastener 105 can be a structure such as tape, cable tie, or buckle, and can be continuously or intermittently arranged along the length of the flexible cable 102. As another example, the fastener 105 can also be an adhesive layer coated on the surface of the flexible cable 102, and can be fixed to the busbar 101 by adhesive bonding.

[0072] In some embodiments, see Figure 2 , Figure 3 and Figure 4 The fastener 105 includes tape wrapped around the surface of at least a portion of the busbar 101 and at least a portion of the flexible cable 102, and the tape is connected to both the busbar 101 and the flexible cable 102.

[0073] The tape is connected to both the busbar 101 and the flexible cable 102. By wrapping the tape around the busbar 101, a certain pressure is applied to ensure that the flexible cable 102 is tightly attached to the busbar 101. For example, the tape can be wrapped around the joint area between the busbar 101 and the flexible cable 102 as needed to ensure a stable fit between the two.

[0074] By using this tape wrapping method, the busbar 101 and the flexible cable 102 form an integrated structure. The flexibility of the tape makes installation convenient, and at the same time, it can buffer a certain amount of mechanical stress to reduce the loosening or displacement of the flexible cable 102 caused by vibration or bending, thereby improving the stability of the flexible cable 102 on the busbar 101.

[0075] It should be noted that the tape can be wrapped around the entire circumference and extension direction of the flexible cable 102 and the busbar 101, or it can be wrapped only in local positions. The specific wrapping position can be determined according to the actual fixing requirements, and this application does not limit it in this regard.

[0076] In some embodiments, see Figure 2 , Figure 5 and Figure 6When the vehicle wiring harness system 100 connects two connectors through the flexible cable 102, the ports of the two connectors corresponding to the flexible cable 102 need to match the conductor arrangement in the flexible cable 102, that is, to meet the requirements of equal sequence and equal spacing.

[0077] The term "equal sequence" refers to the corresponding arrangement of the connector ports at both ends (e.g., the same order or mirror symmetry); the term "equal spacing" refers to the equal spacing between adjacent terminals in the connectors at both ends, which is consistent with the spacing between adjacent conductors in the flexible cable 102.

[0078] For example, after determining the interface of connector A, the interface of connector B can be set in a manner that is arranged in the same order as connector A and with the same terminal spacing, so as to achieve direct connection of flexible cable 102.

[0079] For example, the interface of the B-end connector can also be set up in a manner that mirrors the A-end connector and has the same terminal spacing, so as to achieve a folded direct connection of the flexible cable 102.

[0080] This allows the conductors at both ends of the flexible cable 102 to quickly correspond one-to-one with the two connector ports, reducing the error rate. At the same time, it allows the flexible cable 102 to use a uniform conductor cutting size, simplifying the manufacturing process.

[0081] In some embodiments, see Figure 2 and Figure 6 The vehicle wiring harness system 100 also includes a connector 106, which includes a housing 1061 and a plurality of terminals housed within the housing 1061. Each terminal includes a first connection structure 1062 and a second connection structure 1063 connected to a flexible cable 102. The first connection structure 1062 is used for electrical connection to a mating terminal in an external connection component.

[0082] It should be understood that each terminal has two connection structures: a first connection structure 1062 located at the outer end of the terminal for electrical connection with a mating terminal in an external connection component; and a second connection structure 1063 located on the inner side of the terminal for connection with a flexible cable 102. The conductor portion 1021 of the flexible cable 102 is electrically connected via the second connection structure 1063. The conductor portion 1021 of the flexible cable 102 reliably contacts the second connection structure 1063 of the terminal through crimping, soldering, or plugging, ensuring stable signal or current transmission.

[0083] For example, during installation, the conductors at one end of the flexible cable 102 are connected one by one to the second connection structure 1063 of the terminal. On the other side, the first connection structure 1062 of the terminal is designed as a standardized interface to mate with mating terminals in external connection components (such as device ports or other wiring harness systems). When the mating terminals are inserted into the housing 1061 of the connector 106 and come into contact with the first connection structure 1062, the electrical connection is completed. The housing 1061 provides protection and positioning for the terminals, ensuring the overall robustness of the connector 106.

[0084] Therefore, this application ensures a standardized connection between the flexible cable 102 and external equipment, improves the ease of installation and maintenance, and is suitable for reliable connection and signal transmission of various vehicle electrical equipment.

[0085] In some embodiments, see Figure 2 , Figure 3 and Figure 6 The connector 106 also includes a compression structure 1064, which is disposed inside the housing 1061. Along the first direction, the compression structure 1064 and the flexible cable 102 are respectively located on both sides of the second connecting structure 1063. The compression structure 1064 is used to compress the second connecting structure 1063 so that the flexible cable 102 is connected to the second connecting structure 1063. The first direction intersects with the length direction of the flexible cable 102.

[0086] A compression structure 1064 is provided on both sides of the flexible cable 102 and the second connection structure 1063 of the terminal. During connection, the flexible cable 102 is placed above the second connection structure 1063 of the terminal, and the compression structure 1064 applies pressure between the second connection structure 1063 and the flexible cable 102. Through the action of the compression structure 1064, the second connection structure 1063 and the conductor portion 1021 of the flexible cable 102 are in close contact, thereby forming a stable electrical connection.

[0087] Because the first direction intersects the length direction of the flexible cable 102, the compressive force is applied perpendicularly, ensuring that the conductor will not slip during the connection process and that the contact is reliable. This simplifies the assembly process between the flexible cable 102 and the terminal, avoids complex welding or additional fasteners, and improves installation efficiency and connection stability.

[0088] Meanwhile, the extrusion structure 1064 inside the housing 1061 also helps to make the overall structure compact and maintain the reliability and durability of the wiring harness system.

[0089] This application does not limit the specific structure of the extrusion structure 1064. Exemplarily, the extrusion structure 1064 can be a spring-loaded pressure block. Specifically, the spring pressure block automatically applies constant pressure during assembly, pressing the flexible cable 102 firmly onto the second connection structure 1063 of the terminal. As another example, the extrusion structure 1064 can be a screw-type pressure plate. Specifically, the screw pressure plate presses against the flexible cable 102 by tightening the screw, forming reliable contact.

[0090] In this application, within the housing 1061, a compression structure 1064 is located on both sides of the second connection structure 1063 between the conductor portion 1021 of the flexible cable 102 and the terminal. When the flexible cable 102 is inserted from the rear end of the housing 1061, its conductor portion 1021 aligns with the second connection structure 1063. By applying the compression structure 1064 (e.g., a compression module), the second connection structure 1063 is brought into close contact with the conductor portion 1021 of the flexible cable 102, thereby achieving a solderless and crimp-free connection between the conductor and the terminal. This compression method allows for the provision of multiple compression modules to accommodate different numbers of conductors. This compression structure 1064 avoids traditional soldering or crimping processes, improves wire harness manufacturing efficiency, and provides a feasible solution for automated wire harness production.

[0091] In some embodiments, see Figure 3 and Figure 6 The flexible cable 102 includes a conductor portion 1021 and an insulation portion 1022. The insulation portion 1022 is provided with a first limiting portion 1022a. The housing 1061 is provided with a second limiting portion that cooperates with and connects to the first limiting portion 1022a. The conductor portion 1021 is electrically connected to the second connecting structure 1063.

[0092] The insulating portion 1022 is provided with a first limiting part 1022a, which is typically a hole, slot, or protrusion. A corresponding second limiting part is provided inside the connector housing 1061, such as a corresponding limiting protrusion, slot, or snap-fit ​​structure. When the flexible cable 102 is inserted into the housing 1061, the first limiting part 1022a and the second limiting part cooperate to precisely limit the position of the flexible cable 102, preventing it from shifting or misaligning within the housing 1061.

[0093] The conductor portion 1021 is electrically connected to the second connection structure 1063 of the terminal. Once the flexible cable 102 is accurately positioned, the conductor portion 1021 is tightly abutted against the second connection structure 1063 of the terminal, ensuring reliable contact through crimping, squeezing, or other methods. This implementation ensures accurate assembly of the flexible cable 102 through a limiting fit, preventing conductor misalignment or poor connection, thereby guaranteeing the stability and long-term reliability of the vehicle wiring harness system 100 connection.

[0094] In some embodiments, see Figure 6 The conductor portion 1021 of the flexible cable 102 includes multiple terminals, at least two of which can be connected in parallel to the same functional circuit.

[0095] Specifically, multiple terminals can be electrically connected in parallel through a short-circuit structure inside connector 106, a parallel connection method for external circuits, or a parallel design of the conductors inside flexible cable 102. Based on the current-sharing principle of parallel circuits, multiple terminals share the total current in the circuit, thereby improving the current-carrying capacity of the functional circuit; at the same time, parallel connection can form a redundant path, so that when one terminal or its connected conductor has poor contact or is disconnected, the current can still be transmitted normally through other parallel terminals, thereby enhancing the reliability and fault tolerance of the system.

[0096] This configuration can enhance the current-carrying capacity of the circuit connected to the flexible cable 102, or meet specific wiring and redundancy requirements, thereby expanding the application range of the flexible cable 102.

[0097] In some embodiments, see Figure 3 and Figure 7 This application provides a method for connecting vehicle wiring harnesses, applied to a vehicle wiring harness system 100, the method comprising: S100: Based on the magnitude of the current in the vehicle current loop, the vehicle current loop is divided into a first current loop, a second current loop, and a third current loop. The current in the first current loop is less than the current in the second current loop, and the current in the second current loop is less than the current in the third current loop.

[0098] Specifically, the current loops are first classified according to their current magnitude. The first current loop is the loop with the smaller current, the second current loop has a current greater than the first current loop but less than the third current loop, and the third current loop has the largest current.

[0099] For example, the first current loop is less than or equal to 10A, the second current loop is greater than 10A and less than or equal to 80A, and the third current loop is greater than 80A.

[0100] S200: Arrange busbar 101 between the two ports of the third current loop and electrically connect busbar 101 to the third current loop; arrange flexible cable 102 according to the arrangement path of busbar 101 and fix flexible cable 102 to busbar 101, with the length direction of flexible cable 102 consistent with the length direction of busbar 101; place flexible cable 102 between the two ports of the first current loop and electrically connect flexible cable 102 to the first current loop.

[0101] Busbar 101 is used for the third current loop because it is suitable for carrying larger currents. Specifically, busbar 101 is positioned between the two ports of the third current loop, electrically connecting it to the loop. Then, according to the arrangement path of busbar 101, a flexible cable 102 is arranged along the direction of busbar 101 and fixed to the surface of busbar 101, ensuring that the length direction of the flexible cable 102 is aligned with the length direction of busbar 101. Next, the flexible cable 102 is positioned between the two ports of the first current loop, electrically connecting it to the first current loop. The flexible cable 102 is suitable for small current loops, and its fixed arrangement on busbar 101 improves the neatness and stability of the circuit.

[0102] S300: Arrange the conductor 103 between the two ports of the second current loop and make the conductor 103 electrically connected to the second current loop; use the support member 104 to fix the busbar 101 and the conductor 103.

[0103] The conductor 103 is used for the second current loop (medium current). Specifically, the conductor 103 is positioned between the two ports of the second current loop and electrically connected to the loop. The conductor 103 offers good wiring flexibility, facilitating its placement in complex spaces. Finally, the busbar 101 and the conductor 103 are secured using the support member 104.

[0104] The support member 104 includes a first mounting part connected to the busbar 101 and a second mounting part connected to the conductor 103, ensuring that the busbar 101, flexible cable 102 and conductor 103 are installed securely as a whole.

[0105] Therefore, in this application, different current loops are arranged using appropriate conductors (busbar 101, flexible cable 102, wire 103), which not only ensures the current carrying requirements, but also achieves neat and reliable wire harness connection.

[0106] In this application, based on the current connection matching strategy, the conductor structure layout design is divided into two parts. For the third current loop, the busbar 101 and the flexible cable 102 form an integrated layout structure. Specifically, the busbar 101, as the main supporting structure, is arranged in the lower part, and the flexible cable 102 is arranged in the upper part, with the two forming an integrated structure by wrapping them together with tape.

[0107] Depending on the actual number of circuits, multiple flexible cables 102 can be overlapped to meet the requirements. For example, one flexible cable 102 can carry 12 to 20 circuits. When more circuits are needed, multiple flexible cables 102 can be stacked to facilitate overall assembly and reduce labor costs.

[0108] Flexible cable 102 has advantages in low-current circuits. Since low-current circuits account for a large proportion of the entire vehicle circuit, using flexible cable 102 to replace traditional wire 103 not only saves space and improves the efficiency of mechanized welding, but also optimizes the design cost of wire harness.

[0109] Furthermore, the busbar 101 acts as a support, protecting the flexible cable 102 and preventing it from bending or being damaged during installation, thus overcoming the disadvantage of the individual flexible cable 102 being easily damaged. In summary, this integrated arrangement not only improves the overall mechanical strength of the wiring harness but also optimizes installation efficiency and the performance of the vehicle's electrical system.

[0110] The above embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention.

Claims

1. A vehicle wiring harness system, characterized in that, It includes a busbar (101), a flexible cable (102), a conductor (103), and a support member (104); the flexible cable (102) is disposed on the surface of the busbar (101) and fixedly connected to the busbar (101), and the length direction of the flexible cable (102) is consistent with the length direction of the busbar (101); the support member (104) includes a first mounting part connected to the busbar (101) and a second mounting part connected to the conductor (103).

2. The vehicle wiring harness system according to claim 1, characterized in that, The support member (104) includes a first part (1041) and a second part (1042), the first part (1041) and the second part (1042) forming a first wiring channel (1041a), the busbar (101) and the flexible cable (102) passing through the first wiring channel (1041a), and the first wiring channel (1041a) forming the first mounting part; The second part (1042) is provided with a second wiring channel (1042a), and the wire (103) passes through the second wiring channel (1042a), which forms the second mounting part.

3. The vehicle wiring harness system according to claim 2, characterized in that, The second wiring channel (1042a) includes a groove that is recessed in the direction from the second portion (1042) to the first portion (1041), and the groove extends through the second portion (1042) along the length of the conductor (103); and / or, the first portion (1041) and the second portion (1042) are detachably connected.

4. The vehicle wiring harness system according to any one of claims 1-3, characterized in that, The first mounting part is engaged with the busbar (101), and / or the second mounting part is engaged with the conductor (103); and / or the vehicle wiring harness system includes a plurality of support members (104) spaced apart along the length direction of the flexible cable (102).

5. The vehicle wiring harness system according to any one of claims 1-3, characterized in that, It also includes a fastener (105) that is connected to both the busbar (101) and the flexible cable (102), and at least a portion of the fastener (105) is connected to the surface of the flexible cable (102) facing away from the busbar (101).

6. The vehicle wiring harness system according to claim 5, characterized in that, The fastener (105) includes tape wrapped around at least a portion of the surface of the busbar (101) and at least a portion of the flexible cable (102), and the tape is connected to both the busbar (101) and the flexible cable (102).

7. The vehicle wiring harness system according to any one of claims 1-3, characterized in that, It also includes a connector (106), which includes a housing (1061) and a plurality of terminals housed within the housing (1061). Each terminal includes a first connection structure (1062) and a second connection structure (1063) connected to the flexible cable (102). The first connection structure (1062) is used for electrical connection with a mating terminal in an external connection component.

8. The vehicle wiring harness system according to claim 7, characterized in that, The connector (106) further includes a compression structure (1064), which is disposed inside the housing (1061). Along the first direction, the compression structure (1064) and the flexible cable (102) are respectively located on both sides of the second connecting structure (1063). The compression structure (1064) is used to compress the second connecting structure (1063) so that the flexible cable (102) is connected to the second connecting structure (1063). The first direction intersects with the length direction of the flexible cable (102).

9. The vehicle wiring harness system according to claim 7, characterized in that, The flexible cable (102) includes a conductor portion (1021) and an insulation portion (1022). The insulation portion (1022) is provided with a first limiting portion (1022a). The housing (1061) is provided with a second limiting portion that cooperates with and connects to the first limiting portion (1022a). The conductor portion (1021) is electrically connected to the second connection structure (1063).

10. A method for connecting vehicle wiring harnesses, characterized in that, The method is applied to a vehicle wiring harness system (100), which includes a busbar (101), a flexible cable (102), a conductor (103), and a support member (104). The flexible cable (102) is disposed on the surface of the busbar (101) and fixedly connected to the busbar (101), and the length direction of the flexible cable (102) is consistent with the length direction of the busbar (101). The support member (104) includes a first mounting portion connected to the busbar (101) and a second mounting portion connected to the conductor (103). The method includes: Based on the magnitude of the current in the vehicle current loop, the vehicle current loop is divided into a first current loop, a second current loop, and a third current loop. The current in the first current loop is less than the current in the second current loop, and the current in the second current loop is less than the current in the third current loop. The busbar (101) is arranged between the two ports of the third current loop, and the busbar (101) is electrically connected to the third current loop; A flexible cable (102) is arranged according to the arrangement path of the busbar (101), and the flexible cable (102) is fixed to the busbar (101). The length direction of the flexible cable (102) is consistent with the length direction of the busbar (101). The flexible cable (102) is placed between the two ports of the first current loop and is electrically connected to the first current loop. The wire (103) is arranged between the two ports of the second current loop and is electrically connected to the second current loop; The busbar (101) and the conductor (103) are fixed by the support member (104).

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