Cable harness and method of manufacturing the same
By setting protrusions on the conductive plate and surrounding it with a plastic body, combined with fixing devices, the complexities of cable bundle manufacturing and installation are solved, achieving simplified and efficient electrical connections, reducing costs, and ensuring the conduction of shielded current.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- AUDI AG
- Filing Date
- 2026-01-28
- Publication Date
- 2026-07-31
AI Technical Summary
The manufacturing and installation process of existing cable harnesses is complex and costly, making it difficult to achieve simplified and efficient electrical connections.
The innovative design employs a conductive plate and a conductor shield. By setting first and second protrusions on the conductive plate and surrounding the conductive plate with a plastic body to form a fixed and electrical connection, the manufacturing process is simplified and efficient installation is achieved through fixing devices.
It simplifies the manufacturing and enables efficient installation of cable bundles, reduces costs, and ensures effective discharge of shielded current through conductive connections.
Smart Images
Figure CN122495110A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to cable harnesses and methods for manufacturing the same. Background Technology
[0002] A cable bundle is typically a bundle of multiple individual cables or wires that transmit signals (information) or operating current (energy).
[0003] Depending on structural requirements, multiple cables can be combined into cable bundles and laid out as cable harnesses, held together for example by sheaths, clamps, cable ties, binding wires, or flexible conduits. These bundles, with their limited flexibility, are then subsequently installed, for example, in vehicles.
[0004] Cable bundles are typically assembled according to geometric and electrical requirements.
[0005] In electrical engineering, various cables or wires are shielded in a known manner. The shielding current generated in the conductor shield can be transmitted, for example, through the cable plug to the housing connected to the cable plug.
[0006] For example, US 2021 / 0125742 A1 discloses a cable bundle having multiple shielded wires, the conductor shields of which are connected to a common metal plate of a plug. This metal plate can be threaded to a housing via a mounting hole.
[0007] US 2023 / 0022337 A1 also disclosed cable bundles with a similar structure. Summary of the Invention
[0008] In this context, the object of the present invention is to provide a cable harness and a method for manufacturing the same, which enables simplified, efficient and cost-effective manufacturing and installation.
[0009] This objective is achieved by the cable bundle having the features of claim 1 and the method of manufacturing the cable bundle having the features of claim 7. Other particularly advantageous embodiments of the invention are disclosed in the corresponding dependent claims.
[0010] It should be noted that the features listed in the claims can be combined with each other in any technically reasonable manner (and can also be combined across categories, such as between methods and apparatus), and constitute other design schemes of the present invention. The specification, in particular, describes the features of the present invention and limits the invention in conjunction with the accompanying drawings.
[0011] It should also be noted that the conjunction “and / or” used herein, which connects two features to each other, should always be interpreted as follows: in a first embodiment of the subject matter of the invention, only the first feature may exist; in a second embodiment, only the second feature may exist; and in a third embodiment, both the first and second features may exist.
[0012] The subject of this invention is a cable bundle having at least one electrical conductor, which in turn has a conductive core wire, a non-conductive sheath surrounding the corresponding conductive core wire, and a conductive conductor shield surrounding the non-conductive sheath. Furthermore, the cable bundle has at least one conductive plate having: at least one insertion hole through which a power supply conductor passes; a first protrusion projecting from the edge of the insertion hole; at least one fixing hole for receiving a fixing device by which the plate can be fixed to an object (e.g., a housing); and a second protrusion projecting from the edge of the fixing hole.
[0013] It should be understood that the fixing device and the object on which the cable bundle is to be fixed are not part of the cable bundle according to the invention, nor are they a limitation of the cable bundle according to the invention.
[0014] The cable bundle also has at least one fixing element that secures the section of the conductor shield folded to the outer peripheral surface of the first protrusion at the first protrusion. Furthermore, the cable bundle has a plastic body that surrounds at least one conductive plate on its outer side, wherein the outer peripheral surface of the first protrusion and the area of the second protrusion extend from the plastic body.
[0015] In other words, the conductive plate is embedded (e.g., infused) into the plastic body, meaning that the narrow and wide faces of the plate are adaptively surrounded by the plastic body. Conversely, portions of the first and second protrusions are not surrounded by the plastic body. In the sense of the invention, they therefore protrude from the plastic body. However, spatial protrusion relative to the surface of the plastic body is not necessary.
[0016] It should be understood that the first and second protrusions are conductive and electrically connected to the plate. In this way, the conductor shield is electrically connected to the conductive plate via the first protrusion. Since the second protrusion, projecting from the edge of the mounting hole, is not surrounded by the plastic body, it provides a contact surface for the fixing device that can be received in the mounting hole. If the fixing device is conductive, it automatically establishes a conductive connection with the object (which may be, for example, a housing, cable bundle, or the conductive plate to which the fixing device is attached) upon fixing. The object can be conductive to receive the shielding current conducted in the conductor shield and, if necessary, to conduct it away (e.g., grounding).
[0017] Except for the outer periphery of the first protrusion and the area of the second protrusion, the conductive plate can be substantially completely surrounded by a plastic body, thus protecting it from external influences (e.g., corrosion). This simplifies the manufacturing of the cable harness. The conductive plate surrounded by the plastic body can be provided as a prefabricated component, with at least one conductor and its conductor shielding fixed to this prefabricated component during the installation process as described herein. The manufacturing of the cable harness can be carried out efficiently and cost-effectively. Cable harnesses assembled in this way enable efficient installation, such as in vehicles.
[0018] In an advantageous embodiment, the first protrusion is designed as a single piece with the conductive plate.
[0019] In another preferred embodiment, the second protrusion is designed as a single piece with the conductive plate.
[0020] In both of the above embodiments, the conductive plate can be provided as a single structural unit with the first protrusion and / or the second protrusion, thereby further simplifying the manufacturing and installation of the cable bundle.
[0021] Other embodiments specify that the cable bundle has multiple conductive plates. That is, each individual plate has at least one insertion hole with a first protrusion and at least one fixing hole with a second protrusion. In this case, a plastic body surrounds all the conductive plates, wherein the corresponding outer peripheral surface of the first protrusion and the corresponding area of the second protrusion extend from the plastic body. The plastic body holds the conductive plates in a desired arrangement.
[0022] If the plastic body is non-conductive, then the conductive plates are arranged electrically insulated from each other within the plastic body. This can be advantageously used to achieve specific shielding schemes.
[0023] Alternatively, the plastic body can be constructed to be conductive. In the case of multiple conductive plates, the plastic body establishes conductive connections between the plates.
[0024] In another advantageous embodiment, the second protrusion is constructed in a sleeve shape. The second protrusion can act as a support sleeve to support the conductive plate between a fixing device (e.g., a screw or rivet) and an object on which the cable bundle is to be fixed, while establishing a conductive connection with the object.
[0025] Other preferred embodiments specify that the end face of the sleeve-shaped second protrusion is flush with the surface of the plastic body, which makes the cable bundle structure more compact.
[0026] Furthermore, the subject of this invention is a method for manufacturing a cable harness, comprising the following steps:
[0027] - Provide at least one electrical conductor having a conductive core wire, a non-conductive sheath surrounding the corresponding conductive core wire on its outer periphery, and a conductive conductor shield surrounding the non-conductive sheath on its outer periphery.
[0028] - Provide at least one conductive plate having at least one insertion hole, a first protrusion protruding from the edge of the insertion hole, a fixing hole for receiving a fixing device for fixing the conductive plate to an object, and a second protrusion protruding from the edge of the fixing hole;
[0029] - At least one conductive plate is surrounded from the outside by a plastic material to form a plastic body, such that the outer peripheral surface of the first protrusion and the area of the second protrusion extend from the plastic body;
[0030] - Insert the electrical conductor into the insertion hole;
[0031] - Fold the section of the conductor shield to the outer periphery of the first protrusion; and
[0032] - Provide at least one fixing element and fix the section of the conductor shield folded to the outer peripheral surface of the first protrusion at the first protrusion.
[0033] It should be understood that the definitions of terms related to the method, as well as the functions and advantages of the method features, can be fully referenced to the corresponding definitions, functions, and advantages of the cable harness according to the present invention, and vice versa. Therefore, for the sake of brevity, repeated descriptions of features with the same meaning and their functions and advantages may be omitted, and such omissions should not be construed as limiting the disclosed inventive subject matter.
[0034] In a preferred embodiment, surrounding at least one conductive plate with a plastic body includes injection molding the plate with a plastic material.
[0035] In another embodiment, the conductor shield is secured to the first protrusion by crimping. Crimping should be understood as a connection method in which the conductor shield is secured to the fixing element and / or the first protrusion by plastic deformation of the outer peripheral surface of the fixing element, for example by rolling, pressing, or folding.
[0036] Other advantageous embodiments provide multiple electrical conductors, multiple fixing elements, and multiple conductive plates, wherein the multiple plates are collectively surrounded from the outside by a plastic material to form a plastic body, wherein one of the multiple conductors is inserted into at least one insertion hole in each plate, and the conductor shield of the respective conductor is fixed to a corresponding first protrusion of the respective plate by at least one fixing element. All conductive plates are thus arranged and held in a single plastic body. Attached Figure Description
[0037] Other features and advantages of the invention will become apparent from the following description of embodiments of the invention, which should not be construed as limiting, and which will be described in detail below in conjunction with the accompanying drawings. The drawings schematically illustrate:
[0038] Figure 1 A perspective view showing a portion of a cable bundle according to an embodiment of the present invention;
[0039] Figure 2 Show Figure 1 A perspective sectional view of the components of the cable bundle;
[0040] Figure 3 A perspective cross-sectional view showing components of a cable harness according to another embodiment of the present invention;
[0041] Figure 4 The following is shown after the first step of the method according to an embodiment of the present invention. Figure 1 A perspective view of the components of the cable bundle;
[0042] Figure 5 This is shown after another step in the method. Figure 4 A perspective view of the components;
[0043] Figure 6 This is shown after yet another step in the method. Figure 5 A perspective view of the components;
[0044] Figure 7 This is shown after another step in the method. Figure 6 A perspective longitudinal section of the component; and
[0045] Figure 8 This is shown after another step in the method. Figure 7 A perspective longitudinal section of the component. Detailed Implementation
[0046] In different accompanying drawings, parts that are functionally identical are always labeled with the same reference numerals, so these parts are usually described only once.
[0047] The following will also refer to Figure 1 , Figure 2 , Figure 4 and Figure 5 ,in, Figure 1 A perspective view of a portion of a cable bundle 10 according to an embodiment of the present invention is shown schematically. Figure 2 Show Figure 1 A perspective sectional view of the components of the cable harness 10. Figure 4 The following is shown after the first step of the method according to an embodiment of the present invention. Figure 1 A perspective view of the components of cable bundle 10. Figure 5 This is shown after another step in the method. Figure 4 A perspective view of the component.
[0048] In this example, the cable bundle 10 has three electrical conductors 11.1, 11.2, and 11.3. Of course, the invention is not limited to the number of conductors shown. The cable bundle may have more or fewer than the three conductors 11.1, 11.2, and 11.3 shown.
[0049] Each conductor 11.1, 11.2 and 11.3 has conductive cores 12.1, 12.2 and 12.3, non-conductive sheaths 13.1, 13.2 and 13.3 surrounding the corresponding conductive cores 12.1, 12.2 and 12.3, and conductive conductor shields 14.1, 14.2 and 14.3 surrounding the non-conductive sheaths 13.1, 13.2 and 13.3.
[0050] The cable harness 10 also has a conductive plate 15 (e.g., a metal plate). This plate 15, in turn, has insertion holes 16.1, 16.2, and 16.3 for each of the conductors 11.1, 11.2, and 11.3. (As shown in the example...) Figure 1 As can be seen, conductors 11.1, 11.2, and 11.3 pass through the corresponding insertion holes 16.1, 16.2, and 16.3. Furthermore, in this example, plate 15 has three first protrusions 17.1, 17.2, and 17.3, which extend beyond the edges of the corresponding insertion holes 16.1, 16.2, and 16.3, respectively. Additionally, in this example, plate 15 has three fixing holes 18.1, 18.2, and 18.3. These fixing holes are used to receive fixing devices (not shown) (e.g., screws, rivets, etc.), by which plate 15 can be fixed to an object (e.g., a housing, also not shown). Finally, in this example, plate 15 has three second protrusions 19.1, 19.2, and 19.3, which extend beyond the edges of the corresponding fixing holes 18.1, 18.2, and 18.3, respectively.
[0051] In this example, the cable bundle 10 also has three fixing elements 20.1, 20.2 and 20.3, which respectively fix the sections of the conductor shields 14.1, 14.2 and 14.3 folded to the outer peripheral surfaces of the corresponding first protrusions 17.1, 17.2 and 17.3 onto the corresponding first protrusions 17.1, 17.2 and 17.3.
[0052] Furthermore, the cable bundle 10 has a plastic body 21 that surrounds at least one conductive plate 15 on its outer side. Figure 5 It can be clearly seen that the outer peripheral surfaces of the corresponding first protrusions 17.1, 17.2 and 17.3 and the regions of the second protrusions 19.1, 19.2 and 19.3 extend from the plastic body 21, that is, they are not surrounded by the plastic body 21 like the rest of the conductive plate 15.
[0053] Conductor shields 14.1, 14.2, and 14.3 are electrically connected together via the conductive plate 15 of the exemplary cable bundle 10. Through mounting devices (not shown) that can be received in the respective mounting holes 19.1, 19.2, and 19.3—which may also be conductive and capable of being connected to an object (not shown, such as a housing, which may also be conductive)—the shielding current conducted through the respective conductor shields 14.1, 14.2, and 14.3 can be directed to that object, which itself may be grounded, for example, thereby ultimately grounding the conductor shields 14.1, 14.2, and 14.3 as well.
[0054] Figure 4 and Figure 5 The diagram also shows that the first protrusions 17.1, 17.2, and 17.3 are designed as a single piece with the conductive plate 15. Furthermore, in this example, the second protrusions 19.1, 19.2, and 19.3 are also designed as a single piece with the conductive plate 15. Specifically, in this example, the second protrusions 19.1, 19.2, and 19.3 are each constructed in a sleeve shape, but are not limited to this. In this example, they form a support sleeve that engages between the corresponding fixing device and the object after the conductive plate 15 is fixed to the object, simultaneously establishing electrical contact between the conductive shielding elements 14.1, 14.2, and 14.3 and the object through the conductive plate 15, as... Figure 2 The shielding current 24 through conductor 11.1 is illustrated by way of example.
[0055] In the embodiment of the cable bundle 10 shown here, the end faces of the corresponding sleeve-shaped second protrusions 19.1, 19.2 and 19.3 are substantially flush with the surface of the plastic body 21, and in the example shown, flush with the front 22 and back 23 of the plastic body 21.
[0056] Figure 3 A perspective cross-sectional view schematically illustrating components of a cable bundle 30 according to another embodiment of the present invention is shown. Figure 1 The main difference in the cable bundle 10 is that, instead of a single conductive plate 15 for collecting the shielding current of all conductors 11.1, 11.2, and 11.3, the cable bundle 30 has three conductive plates 15.1, 15.2, and 15.3. Each conductive plate has an insertion hole 16.1, 16.2, and 16.3 along with a corresponding first protrusion 17.1, 17.2, or 17.3, and a fixing hole 18.1, 18.2, and 18.3 along with a corresponding second protrusion 19.1, 19.2, or 19.3. In this case, the individual shielding current 24 of conductors 11.1, 11.2, and 11.3 is guided to the object through the corresponding plates 15.1, 15.2, and 15.3 and the corresponding second protrusions 19.1, 19.2, and 19.3.
[0057] In all other respects, cable bundle 30 may be constructed similarly or identically to cable bundle 10, but is not limited thereto. Other combinations of the features disclosed herein are conceivable.
[0058] The following will combine Figures 4 to 8 A method for manufacturing a cable harness (e.g., cable harness 10) according to an embodiment of the present invention is described. Figures 4 to 8 Different method steps are shown in the figures.
[0059] In particular, Figure 4 A conductive plate 15 is shown that provides the cable bundle 10. It should be understood that, in the case of manufacturing the cable bundle 30, three separate conductive plates 15.1, 15.2 and 15.3 are provided at this time.
[0060] Figure 5 The state is shown after another step of the method, wherein plate 15 (or multiple plates 15.1, 15.2, 15.3) is surrounded on the outside by plastic material to form plastic body 21, wherein the outer peripheral surfaces of the corresponding first protrusions 17.1, 17.2 and 17.3 and the regions of the corresponding second protrusions 19.1, 19.2 and 19.3 extend from plastic body 21.
[0061] In the illustrated embodiment of the method, plate 15 is injection molded over a plastic material to form a plastic body 21. However, the invention is not limited to injection molding over a plastic material. Other techniques for surrounding a plate 15 or multiple plates 15.1, 15.2, and 15.3 with the plastic body 21 (e.g., placing the plate in a liquid plastic material and subsequently curing it) are also included within the scope of the invention.
[0062] Figure 6 The manufacturing state is shown, in which electrical conductors 11.1, 11.2 and 11.3 are provided and inserted into the corresponding insertion holes 16.1, 16.2 and 16.3 of the plate 15.
[0063] Figure 7 A perspective cross-sectional view along the first conductor 11.1 is shown, with an enlarged view illustrating how a section of the conductor shield 14.1 is folded over to the outer peripheral surface of the first protrusion 17.1. For example, the conductor shield 14.1 (e.g., a braided metal mesh) is folded approximately 180° around the first protrusion 17.1. This step is performed in the same manner for the other conductors 11.2 and 11.3.
[0064] Figure 8 This is shown after yet another step in the method. Figure 7A longitudinal sectional view of the component shows that a fixing element 20.1 is provided, and the section of the conductor shield 14.1 folded to the outer peripheral surface of the first protrusion 17.1 is fixed at the first protrusion 17.1 to establish electrical contact between the conductor shield 14.1 and the conductive plate 15. In particular, in the illustrated embodiment, the conductor shield 14.1 is fixed by crimping, but is not necessarily limited to crimping.
[0065] In principle, the conductive plate 15 or conductive plates 15.1, 15.2, and 15.3 can be made of any conductive material. This material is not limited to metals. The specific electrical properties of the selected material allow for the targeted design of the electrical contact characteristics.
[0066] Furthermore, the diameters of the fixing holes 18.1, 18.2, 18.3 and the second protrusions 19.1, 19.2, 19.3 (e.g., support sleeves) can be adjusted according to desired electrical contact characteristics and / or mechanical and / or geometric requirements.
[0067] List of reference numerals
[0068] 10 Cable bundles
[0069] 11.1-11.3 Electrical conductors
[0070] 12.1-12.3 Core wires
[0071] 13.1-13.3 Sheath
[0072] 14.1-14.3 Conductor shielding
[0073] 15. Conductive plate
[0074] 15.1-15.3 Conductive plates
[0075] 16.1-16.3 Insertion Holes
[0076] 17.1-17.3 First protrusion
[0077] 18.1-18.3 Fixing holes
[0078] 19.1-19.3 Second protrusion
[0079] 20.1-20.3 Fixing Components
[0080] 21 Plastic body
[0081] 22 Front
[0082] 23 Back
[0083] 24 Shielding Current
[0084] 30 Cable bundles
Claims
1. A cable harness (10, 30), comprising: - At least one electrical conductor (11.1, 11.2, 11.3) having a conductive core (12.1, 12.2, 12.3), a non-conductive sheath (13.1, 13.2, 13.3) surrounding the respective conductive core (12.1, 12.2, 12.3) on its outer periphery, and a conductive conductor shield (14.1, 14.2, 14.3) surrounding the non-conductive sheath (13.1, 13.2, 13.3) on its outer periphery. - At least one conductive plate (15, 15.1, 15.2, 15.3) having: at least one insertion hole (16.1, 16.2, 16.3) through which the electrical conductor (11.1, 11.2, 11.3) passes; a first protrusion (17.1, 17.2, 17.3) protruding from the edge of the insertion hole (16.1, 16.2, 16.3); at least one fixing hole (18.1, 18.2, 18.3) for receiving a fixing device by which the plate (15, 15.1, 15.2, 15.3) can be fixed to an object; and a second protrusion (19.1, 19.2, 19.3) protruding from the edge of the fixing hole (18.1, 18.2, 18.3). - At least one fixing element (20.1, 20.2, 20.3) that fixes the section of the conductor shield (14.1, 14.2, 14.3) folded over to the outer peripheral surface of the first protrusion (17.1, 17.2, 17.3) at the first protrusion (17.1, 17.2, 17.3); and - A plastic body (21) that surrounds the at least one conductive plate (15, 15.1, 15.2, 15.3) from the outside. The outer peripheral surfaces of the first protrusion (17.1, 17.2, 17.3) and the regions of the second protrusion (19.1, 19.2, 19.3) extend from the plastic body (21).
2. The cable bundle of claim 1, wherein, The first protrusion (17.1, 17.2, 17.3) and the conductive plate (15, 15.1, 15.2, 15.3) are designed as a single piece.
3. The cable bundle of claim 1 or 2, wherein, The second protrusion (19.1, 19.2, 19.3) and the conductive plate (15, 15.1, 15.2, 15.3) are designed as a single piece.
4. The cable bundle according to any of the preceding claims, wherein, The cable bundle has multiple conductive plates (15.1, 15.2, 15.3).
5. The cable bundle according to any of the preceding claims, wherein, The second protrusion (19.1, 19.2, 19.3) is constructed in a sleeve shape.
6. The cable bundle of claim 5, wherein, The end face of the sleeve-shaped second protrusion (19.1, 19.2, 19.3) is flush with the surface (22, 23) of the plastic body (21).
7. A method for manufacturing a cable harness (10, 30), comprising the following steps: - Provide at least one electrical conductor (11.1, 11.2, 11.3) having a conductive core wire (12.1, 12.2, 12.3), a non-conductive sheath (13.1, 13.2, 13.3) surrounding the respective conductive core wire (12.1, 12.2, 12.3) on its outer periphery, and a conductive conductor shield (14.1, 14.2, 14.3) surrounding the non-conductive sheath (13.1, 13.2, 13.3) on its outer periphery. - Provide at least one conductive plate (15, 15.1, 15.2, 15.3) having: at least one insertion hole (16.1, 16.2, 16.3); a first protrusion (17.1, 17.2, 17.3) projecting from the edge of the insertion hole (16.1, 16.2, 16.3); at least one fixing hole (18.1, 18.2, 18.3) for receiving a fixing device by means of which the plate (15, 15.1, 15.2, 15.3) can be fixed to an object; and a second protrusion (19.1, 19.2, 19.3) projecting from the edge of the fixing hole (18.1, 18.2, 18.3). - The at least one conductive plate (15, 15.1, 15.2, 15.3) is surrounded from the outside by a plastic material to form a plastic body (21) such that the outer peripheral surface of the first protrusion (17.1, 17.2, 17.3) and the area of the second protrusion (19.1, 19.2, 19.3) protrude from the plastic body (21); - Insert the electrical conductors (11.1, 11.2, 11.3) into the insertion holes (16.1, 16.2, 16.3); - Fold the sections of the conductor shielding (14.1, 14.2, 14.3) onto the outer peripheral surface of the first protrusion (17.1, 17.2, 17.3); and - Provide at least one fixing element (20.1, 20.2, 20.3) and fix the section of the conductor shield (14.1, 14.2, 14.3) folded to the outer peripheral surface of the first protrusion (17.1, 17.2, 17.3) at the first protrusion (17.1, 17.2, 17.3).
8. The method of claim 7, wherein, Enclosing the at least one conductive plate (15, 15.1, 15.2, 15.3) with the plastic body (21) includes: injection molding the plate (15, 15.1, 15.2, 15.3) with plastic material.
9. The method of claim 7 or 8, wherein, The conductor shielding (14.1, 14.2, 14.3) is fixed to the first protrusion (17.1, 17.2, 17.3) by crimping.
10. The method of any one of claims 7 to 9, wherein, Provided are multiple electrical conductors (11.1, 11.2, 11.3), multiple fixing elements (20.1, 20.2, 20.3), and multiple conductive plates (15.1, 15.2, 15.3), wherein the multiple plates (15.1, 15.2, 15.3) are collectively surrounded from the outside by a plastic material to form the plastic body (21), wherein each plate (15.1, 15.2, 15.3) has at least one insertion hole (16.1, 16.3). 2, 16.3) Insert one of the plurality of conductors (11.1, 11.2, 11.3), and the conductor shield (14.1, 14.2, 14.3) of the corresponding conductor (11.1, 11.2, 11.3) is fixed to the corresponding first protrusion (17.1, 17.2, 17.3) of the corresponding plate (15.1, 15.2, 15.3) by at least one fixing element (20.1, 20.2, 20.3).