Core unit and wiring harness

Abstract

A core unit (10) with: a core (11) made of magnetic material, which is formed in a ring shape, wherein electrical cables (21, 22, 23) of several phases are wound around the core (11) made of magnetic material at respective positions which differ from each other around the axial axis (X2) of the core (11) made of magnetic material in the circumferential direction; and a limiting element (12, 32, 42) configured to limit a displacement of the electrical cables (21, 22, 23) about the axial axis (X2) of the core (11) made of magnetic material, wherein the electrical cables (21, 22, 23) are wound around the core (11) made of magnetic material, wherein the limiting element (12, 32, 42) has a body (12a, 32a, 42a) which is attached to one end of the core (11) made of magnetic material in the axial direction (X2) of the core (11) made of magnetic material, and several cut-out areas (12b, 12c, 12d) are formed at the edge regions of the body (12a, 32a, 42a), wherein the cut-out areas (12b, 12c, 12d) are formed, which separately enclose the respective electrical cables (21, 22, 23) of each phase, which are wound around the core (11) of magnetic material, starting from the interior of the core (11) of magnetic material in a radial direction and restrict inwards in the radial direction, wherein the axial axis (X2) of the core (11) of magnetic material serves as a center point, characterized by the fact that the cut-out areas (12b, 12c, 12d) are each formed in a stepped shape, thereby suppressing the deformation of the winding shape and a displacement of each winding layer.

Description

1. Field of the invention

[0001] The present invention relates to a core unit and a cable harness. 2. Description of the state of the art

[0002] Conventionally, in a vehicle, such as a hybrid or electric vehicle, an inverter and a motor are connected via three-phase electrical cables to transfer power or energy from the inverter to the motor. In such a power supply from the inverter to the motor, a situation can arise where a rapidly rising voltage present in the inverter's output causes an excessive voltage spike in the wiring harness connecting the inverter and the motor, and this voltage spike is then supplied to the motor.

[0003] As a method for suppressing or damping such a voltage spike, it is effective to wrap an electrical cable around a core of magnetic material. Therefore, when multiple electrical cables are used, it is preferable, with regard to suppressing the increase in the number of parts, to wrap the multiple electrical cables around the core of magnetic material. The published Japanese patent application No. JP 2012-230851 A discloses a technique for a cable harness with a primary coil or primary winding constructed by wrapping multiple AC conductors around a ferrite core formed in a ring shape.

[0004] When electrical cables with different phases, wound around a magnetic core, are placed closer together, the electrostatic capacitance between them increases, thus reducing the cable impedance. This decrease in cable impedance can then lead to a spike in voltage due to an impedance mismatch within the overall circuit.

[0005] From JP 2010 - 199 413 A a core unit with the features of the introductory part of the main claim is known.

[0006] Further state of the art is known from documents DE 10 2015 107 605 A1 and DE 694 07 728 T2. OVERVIEW OF THE INVENTION

[0007] It is an object of the present invention to provide a core unit and a cable harness that are able to suppress the decrease in cable impedance.

[0008] To solve the aforementioned problem, a core unit according to one aspect of the present invention has the features of claim 1.

[0009] According to a further aspect of the present invention, it is preferred in the core unit that the shapes of the cut-out areas correspond to the winding shapes of the electrical cables in relation to the core made of magnetic material when viewed from the axial direction of the core made of magnetic material.

[0010] According to a further aspect of the present invention, it is preferred in the core unit that each of the cut-out areas holds the corresponding electrical cable, which is guided around the core made of magnetic material, from both sides around the axial axis of the core made of magnetic material.

[0011] According to a further aspect of the present invention, it is preferred in the core unit that the limiting element further comprises several webs that protrude upwards.

[0012] According to a further aspect of the present invention, a cable harness comprises the features of claim 5.

[0013] According to a further aspect of the present invention, it is preferred that the cable harness further comprises a holding unit which can be attached to a vehicle body or vehicle chassis and is designed to hold the core made of magnetic material and the limiting element, wherein the body of the limiting element is a conductive element with a connection area which is electrically connected to the holding unit, and the holding unit can electrically connect the connection area and the vehicle chassis.

[0014] These and other tasks, features, advantages and technical and industrial applications of this invention can be better understood by studying the following detailed description of currently preferred embodiments of the invention when viewed in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic view showing the construction of a connection between a motor and an inverter using a cable harness according to a first embodiment; Fig. Figure 2 is a perspective view of the wiring harness according to the first embodiment; Fig. Figure 3 is a cross-sectional view of a part of an electrical cable in the cable harness according to the first embodiment; Fig. Figure 4 is a top view of a core made of magnetic material according to the first embodiment; Fig. Figure 5 is a top view of a boundary element according to the first embodiment; Fig. 6 is a top view of a core unit according to the first embodiment; Fig. Figure 7 is a top view showing a state in which electrical cables are routed around the core unit according to the first embodiment; Fig. Figure 8 is a side view showing a state in which the electrical cables are routed or wound around the core unit according to the first embodiment; Fig. Figure 9 is a perspective view showing a state in which the electrical cables are routed around the core unit according to the first embodiment; Fig. Figure 10 is a perspective view of a cable harness according to a second embodiment; Fig. Figure 11 is a perspective view showing a state in which electrical cables are routed around a core unit according to the second embodiment; Fig. Figure 12 is a perspective view of the core unit, which is housed in a holding unit; Fig. Figure 13 is a cross-sectional view showing a state in which the core unit is attached to a vehicle body or vehicle chassis; and Fig. 14 is a front view showing a core unit according to a third embodiment; DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0015] In the following, a core unit and a wiring harness according to embodiments of the present invention are explained, particularly with reference to the drawings. The present invention is not limited to these embodiments. Furthermore, features belonging to the assembly in the following embodiments also include parts that are readily apparent to a person skilled in the art, or parts that are essentially identical to one another. First embodiment

[0016] A first embodiment is described with reference to Fig. 1 to Fig. 9 explained. The present embodiment relates to a core unit and a cable harness. Fig. Figure 1 is a schematic view showing the assembly of the connection between a motor and an inverter using the cable harness according to the first embodiment. Fig. Figure 2 is a perspective view of the wiring harness according to the first embodiment.

[0017] A 50-watt inverter and a 60-watt motor, which are in Fig. The components shown in Figure 1 are mounted in a vehicle, such as a hybrid or electric vehicle. The inverter 50 is a converter device that converts DC output power from a power source (not shown in the drawings) mounted in the vehicle into three-phase AC output power. The inverter 50 can output a PWM signal and can also output a sinusoidal signal. The motor 60 is a device that is driven by three-phase AC output power from the inverter 50; for example, the motor 60 is a three-phase motor in a Y configuration.

[0018] A cable harness 1 according to the first embodiment is used as a power supply line connecting the previously described three-phase AC inverter 50 and the motor 60. The cable harness 1 is routed such that it extends, for example, longitudinally along the underside of a floor panel that is part of the vehicle body. The cable harness 1 is, as shown in Fig. Figure 2 shows a three-phase electrical cable consisting of a three-phase type electrical cable group and three cables that supply three-phase AC power by using three electrical cables 21, 22 and 23.

[0019] As in Fig. As shown in Figure 2, the cable harness 1 in the first embodiment has an electrical cable section 2, an outer sheath section (housing) 3, an inverter-side connector 8, a motor-side connector 9, and a core unit 10. The electrical cable section 2 includes the electrical cables 21, 22, and 23 of the three phases, which are routed in the same direction. The inverter-side connector 8 is connected to one end of the electrical cable section 2 and connects the electrical cable section 2 to the inverter 50. The motor-side connector 9 is connected to the other end of the electrical cable section 2 and connects the electrical cable section 2 to the motor 60. As shown in Figure 2, the electrical cable section 2 is connected to the motor 60. Fig. As shown in Figure 3, the outer circumference of the electrical cable part 2 is covered with a cylindrical braided conductor 6 (shielding element) and a corrugated tube 7 (protective element).

[0020] As in Fig. As shown in Figure 3, the electrical cables 21, 22, and 23 of the three phases extend in the electrical cable section 2 along a predetermined axis X1 and are arranged at equal intervals around the axis X1. Each of the electrical cables 21, 22, and 23 of the three phases is an unshielded electrical cable and has a conductor section 4, which is circular in cross-section, and an insulating section 5 that covers the outer circumference of the conductor section 4. As shown in Fig. As shown in Figure 3, the cross-sectional shape of each electrical cable 21, 22, and 23, perpendicular to the axis X1, is essentially a round or circular shape. The conductor part 4 of all electrical cables 21, 22, and 23 is, for example, constructed from a stranded wire in which several strands of metal (aluminum alloy, copper alloy, or the like) are spirally twisted, or it is constructed from a single rod-shaped core conductor. The insulating part 5 of all electrical cables 21, 22, and 23 is, for example, made of synthetic resin.

[0021] The electrical cables 21, 22 and 23 of the electrical cable section 2 are in the cross-sectional layer which is in Fig. As shown in Figure 3, the electrical cables 21, 22, and 23 are arranged such that their respective central axes (centers of gravity) form a substantially equilateral triangle; that is, the electrical cables 21, 22, and 23 are arranged in a manner described as a type of stacked bale. Furthermore, the electrical cables 21, 22, and 23 of the three phases are arranged such that two electrical cables adjacent to each other circumferentially around axis X1 can come into contact with each other. Since both the conductor part 4 and the insulating part 5 of each electrical cable 21, 22, and 23 possess a certain degree of deformability, the electrical cable part 2 can be bent.

[0022] The braided conductor 6 is formed in a mesh shape by interlacing strands (thin metal wires) made of metal (for example, copper alloy) and is cylindrical in form. The braided conductor 6 completely surrounds the outer circumference of the electrical cable section 2 and thus serves as a shielding element that suppresses or attenuates noise. Due to the malleability of the strands, the braided conductor 6 is able to be freely stretched and deformed, conforming to the shape of the electrical cable section 2.

[0023] The corrugated tube 7 is a tube made of synthetic resin and shaped in a bellows-like form or similar. The corrugated tube 7 can be elastically deformed freely and maintains its cylindrical shape excellently due to its elastic restoring force. The corrugated tube 7 houses the electrical cable section 2 and the braided conductor 6 within its cylindrical shape and covers and protects the outer circumference of the electrical cable section 2.

[0024] As in Fig. As shown in Figure 2, the core unit 10 in the present embodiment is arranged at the intermediate position in the direction of extension of the electrical cable section 2. The core unit 10 has the function of reducing a voltage spike in the electrical cable section 2. The core unit 10 in the present embodiment has a core made of magnetic material 11 and a limiting element 12.

[0025] The core made of magnetic material 11 is a ring-shaped element made of magnetic material (ferromagnetic material, such as ferrite). In the present embodiment, the core made of magnetic material 11 is, as shown in Fig. Figure 4 shows a ring-shaped structure when viewed in cross-sectional view perpendicular to an axis X2. The core made of magnetic material 11 is a hollow, column-like element in which a through-bore 11a is formed, penetrating it in the axial direction. With respect to the core made of magnetic material 11, an "axial direction" denotes the direction of the axis X2, a "radial direction" denotes the radial direction perpendicular to the axis X2, and a "circumferential direction" denotes the direction of rotation around the axis X2.

[0026] The core made of magnetic material 11 has a pair of plate-like regions 11b and 11c and a pair of connecting regions 11d and 11e. The plate-like regions 11b and 11c are each flat, plate-like, constituent regions. The connecting regions 11d and 11e are each plate-like, constituent regions that are arc-shaped when viewed in the axial direction. The connecting region 11d joins one end of the plate-like regions 11b and 11c to each other, and the connecting region 11e joins the other ends of the plate-like regions 11b and 11c to each other. The plate-like regions 11b and 11c and the connecting regions 11d and 11e are formed together as a single unit.

[0027] The limiting element 12 in the present embodiment is an element made from a raw material, such as metal, that possesses conductivity. As in Fig. As shown in Figure 5, the limiting element 12 has a body 12a which is to be attached to one end of the core made of magnetic material 11 in the axial direction. The body 12a is brought into contact with an end face 11f of the core made of magnetic material 11, as shown in Figure 5. Fig. 4 is shown. As in Fig. As shown in Figure 5, the shape of body 12a, viewed from above, is a shape in which both ends of a rectangular form are formed into semicircles, and cut-out areas 12b, 12c, and 12d are formed in the remaining straight edge regions. Body 12a has a pair of straight sides 12e and 12f that are parallel to each other, and a pair of circular sides 12g and 12h that extend continuously between sides 12e and 12f. In the following explanation relating to body 12a, each of the respective directions of the straight sides 12e and 12f is referred to as a "longitudinal direction," and the direction perpendicular to the longitudinal direction when viewed from above is referred to as the "lateral direction."

[0028] The cut-out areas 12b, 12c, and 12d are formed at the edges of body 12a. More precisely, the second cut-out area 12c is formed in the middle of one side 12e, formed by the two straight sides 12e and 12f. The first cut-out area 12b and the third cut-out area 12d are formed at the corresponding end regions of the other side 12f. The first cut-out area 12b and the third cut-out area 12d are formed such that they enclose the second cut-out area 12c in the longitudinal direction between them.

[0029] Fig. Figure 6 is a front view showing the core unit 10 in a state where the limiting element 12 is attached to the core of magnetic material 11, viewed in the axial direction. In the present embodiment, the limiting element 12 has a projecting portion that fits onto the inner diameter of the core of magnetic material 11. The projecting portion is formed on the rear surface of the body 12a. The limiting element 12 is attached to the core of magnetic material 11 by fitting the projecting portion into the core of magnetic material 11. As shown in Figure 6, the limiting element 12 is attached to the core of magnetic material 11 by fitting the projecting portion into the core of magnetic material 11. Fig. As shown in Figure 6, the limiting element 12 is attached to the core of magnetic material 11 such that the body 12a covers the end face 11f of the core of magnetic material 11. More precisely, the limiting element 12 is attached to the core of magnetic material 11 such that each of the sides 12e, 12f, 12g, and 12h of the body 12a is arranged radially on the outside of an outer circumferential surface 11g of the core of magnetic material 11. In a state in which the limiting element 12 is attached to the core of magnetic material 11, each of the lower sides or bottom sides 12j, 12k, and 12m of the respective cut-out areas 12b, 12c, and 12d is also arranged radially on the inside of an inner circumferential surface 11h of the core of magnetic material 11.The bottom sides 12j, 12k, and 12m are located in the lowest regions of the cut-out areas 12b, 12c, and 12d, respectively. For example, the bottom side 12j of the first cut-out area 12b is located at the lowest point of side 12f. The cut-out areas 12b, 12c, and 12d, in conjunction with the inner circumferential surface 11h, form openings through which electrical cables 21, 22, and 23 can be passed when the cables are wound around the core of magnetic material 11.

[0030] The electrical cables 21, 22, and 23 are each guided around the core made of magnetic material 11 in a state in which the limiting element 12 is attached to the core made of magnetic material 11. As shown in Fig. 7 and Fig. As shown in Figure 8, the electrical cables 21, 22, and 23 of the multiple phases are guided around the core of magnetic material 11 at respective positions that differ around the axis of the core of magnetic material 11. The limiting element 12, as explained below, limits the displacement or displacement of each electrical cable 21, 22, and 23 that is guided around the core of magnetic material 11 about the axis of the core of magnetic material 11. In the cable harness 1 of the present embodiment, the electrical cable 22 of a second phase is wound or guided longitudinally around the central region of the plate-like area 11b, with the second cut-out area 12c serving as a guide.The electrical cable 22 of the second phase is wound several times around the plate-like area 11b, passing through an opening formed between the second cut-out area 12c and the plate-like area 11b.

[0031] The electrical cable 21 of a first phase is wound longitudinally around one end of the plate-like region 11c, with the first cut-out region 12b serving as a guide. The electrical cable 21 of the first phase is wound around the plate-like region 11c several times, passing through an opening formed between the first cut-out region 12b and the plate-like region 11c. The electrical cable 23 of a third phase is wound longitudinally around the other end of the plate-like region 11c, with the third cut-out region 12d serving as a guide. The electrical cable 23 of the third phase is wound around the plate-like region 11c several times, passing through an opening formed between the third cut-out region 12d and the plate-like region 11c.The electrical cable 21 of the first phase and the electrical cable 23 of the third phase are wound around the plate-like area 11c in such a way that the electrical cable 21 of the first phase and the electrical cable 23 of the third phase enclose the electrical cable 22 of the second phase in the longitudinal direction between them and are spaced apart from the electrical cable 22 of the second phase.

[0032] In this way, each of the cut-out areas 12b, 12c, and 12d of the limiting element 12 acts as a guide for the shape and position of a winding for all electrical cables 21, 22, and 23. For example, the first cut-out area 12b forms a guide when the electrical cable 21 of the first phase is wound around the plate-like area 11b of the core made of magnetic material 11. More precisely, the first cut-out area 12b determines the longitudinal position of the electrical cable 21 of the first phase when the electrical cable 21 of the first phase is wound around the plate-like area 11c. Furthermore, the bottom of the first cut-out area 12b is stepped and serves as a guide for the position of each layer in the longitudinal direction when the electrical cable 21 of the first phase is wound in multiple layers around the plate-like area 11c. That is to say,The shape of the first cut-out area 12b is predetermined based on the desired winding shape of the electrical cable 21 of the first phase in relation to the core of magnetic material 11, when viewed from the axial direction of the core of magnetic material 11. Consequently, the electrical cable 21 of the first phase is wound around the core of magnetic material 11, with the first cut-out area 12b serving as a guide, so that the winding around the core of magnetic material 11 takes place at a predetermined position, while a predetermined winding shape is produced.The shape of the first cut-out area 12b is formed in a stepped manner, in which the width of the first cut-out area 12b decreases in a stepped manner towards the bottom of the first cut-out area 12b, depending on each winding layer of the electrical cable 21 of the first phase, which is wound in multiple layers around the plate-like area 11c, thereby suppressing deformation of the winding shape due to the displacement of each winding layer. In the same way as before, the second cut-out area 12c serves as a guide when the electrical cable 22 of the second phase is wound around the plate-like area 11b, and the third cut-out area 12d serves as a guide when the electrical cable 23 of the third phase is wound around the plate-like area 11c.

[0033] The cut-out sections 12b, 12c, and 12d of the limiting element 12 enclose the respective phased electrical cables 21, 22, and 23 wound around the core of magnetic material 11, extending radially from the interior of the core. The first cut-out section 12b encloses the phased electrical cable 21 wound around the plate-like section 11c from the inside of the core of magnetic material 11 in the radial direction and limits the relative displacement of the phased electrical cable 21 with respect to the core of magnetic material 11. The first cut-out section 12b holds the phased electrical cable 21 wound around the core of magnetic material 11 from both sides around the axis of the core of magnetic material 11 (i.e., from both sides in the longitudinal direction).Due to this design, the first cut-out area 12b limits the longitudinal displacement (axial direction of the winding) of the electrical cable 21 of the first phase. Similarly, the second cut-out area 12c encloses the electrical cable 22 of the second phase, which is wound around the central area of ​​the plate-like region 11b, extending radially from the interior of the core made of magnetic material 11. The second cut-out area 12c restrains the electrical cable 22 of the second phase from both sides around the axis of the core made of magnetic material 11 and limits the relative displacement of the electrical cable 22 of the second phase with respect to the core made of magnetic material 11.The third cut-out area 12d encloses the electrical cable 23 of the third phase, which is wound around the other end of the plate-like area 11c, extending from the interior of the core of magnetic material 11 along the radial direction. The third cut-out area 12d holds the electrical cable 23 of the third phase from both sides around the axis of the core of magnetic material 11 and limits the relative displacement of the electrical cable 23 of the third phase with respect to the core of magnetic material 11.

[0034] In this way, a single cut-out area encloses a single-phase electrical cable, maintaining a condition in which the first-phase electrical cable 21, the second-phase electrical cable 22, and the third-phase electrical cable 23 are spaced apart from each other. Furthermore, in the body 12a of the limiting element 12, the cut-out areas 12b, 12c, and 12d are arranged at intervals such that a predetermined intermediate cable distance is maintained between the first-phase electrical cable 21, the second-phase electrical cable 22, and the third-phase electrical cable 23, which are spaced apart from each other. Therefore, the limiting element 12 is able to suppress the increase in electrostatic capacitance C due to the reduction of the intermediate cable distance between the phase-different electrical cables 21, 22, and 23.

[0035] In the cable harness 1 of the present embodiment, as explained below, each electrical cable 21, 22, and 23 of the respective phase is divided into two branch lines wound around the core made of magnetic material 11. Such a construction results in an improvement in form factor or the like. As in Fig. As shown in Figure 2, the electrical cable 21 of the first phase is divided into a branch line 21a and a branch line 21b by means of a branch connector 24 in the intermediate section of the cable harness 1. As shown in Fig. 7 and Fig. As shown in Figure 9, each of the branch lines 21a and 21b is wound around the core made of magnetic material 11. The electrical cable 21 of the first phase is divided into two thin branch lines 21a and 21b, and these branch lines are wound around the core made of magnetic material 11, thus achieving an improvement in the form factor and volume factor. Furthermore, the branch lines 21a and 21b, each of which is relatively thin, are wound around the core made of magnetic material 11, making it possible to increase the number of turns in the same cross-sectional area compared to a case in which the electrical cable 21 of the first phase itself is wound around the core made of magnetic material 11. A thin electrical cable also has the advantage that a wound section of the thin electrical cable is less prone to loosening compared to a thick electrical cable.

[0036] In the same way as for the electrical cable 21 of the first phase, the electrical cable 22 of the second phase is divided into a branch line 22a and a branch line 22b by means of the branch connector 24, and each of the branch lines 22a and 22b is wound around the core made of magnetic material 11. The electrical cable 23 of the third phase is divided into a branch line 23a and a branch line 23b by means of the branch connector 24, and each of the branch lines 23a and 23b is wound around the core made of magnetic material 11.

[0037] As previously explained, the core unit 10 according to the first embodiment comprises the core made of magnetic material 11 and the limiting element 12. Furthermore, the cable harness 1 according to the first embodiment comprises the core unit 10 and the electrical cables 21, 22, and 23. The limiting element 12 comprises the body 12a, which is attached to one end of the core made of magnetic material 11 in the axial direction. The edge regions of the body 12a, i.e., the cut-out regions 12b, 12c, and 12d, are formed thereon, with the cut-out regions 12b, 12c, and 12d separately enclosing the respective electrical cables 21, 22, and 23 of the respective phase, which extend from the interior of the core made of magnetic material 11 in the radial direction, the axis (axis line X2) of the core made of magnetic material 11 serving as a center point.The cut-out areas 12b, 12c, and 12d limit the respective relative displacements of the electrical cables 21, 22, and 23 (changes in the distance between one of the electrical cables 21, 22, and 23 and other electrical cables 21, 22, and 23). Therefore, according to the first embodiment, the core unit 10 is able to suppress the decrease in cable impedance due to the increase in electrostatic capacitance C between the electrical cables 21, 22, and 23. The core unit 10 reduces the deviation of the cable impedance of the cable harness 1 from a setpoint and reduces the impedance mismatch between the inverter 50, the cable harness 1, and the motor 60 in order to dampen the reflection of a voltage spike. Therefore, in the present embodiment, the core unit 10 and the cable harness 1 are able to reduce a voltage spike between the inverter 50, the cable harness 1 and the motor 60.

[0038] The shape and properties of the magnetic core 11 and the shape of the limiting element 12 are defined such that the cable impedance of the cable harness 1 corresponds to a target value. For example, the respective shapes and arrangements of the cut-out areas 12b, 12c, and 12d of the limiting element 12 are defined such that the spacing between the electrical cables 21, 22, and 23 corresponds to a target spacing. For example, the shape of the magnetic core 11 is not limited to the exemplary shape shown. Any shape of the magnetic core 11 can be used, provided that the magnetic core 11 is formed in a circumferentially closed shape when viewed from above. For example, the magnetic core 11 can be formed in a circular shape, a rectangular shape, or a substantially rectangular shape when viewed from above.The target value of the cable impedance of cable harness 1 is set so that it is maximally adapted to the impedance between the inverter 50, the cable harness 1 and the motor 60.

[0039] The shapes of the cut-out areas 12b, 12c, and 12d of the limiting element 12 correspond to the respective connection shapes of the electrical cables 21, 22, and 23 with respect to the core of magnetic material 11 when viewed in the axial direction of the core of magnetic material 11. That is, the shapes of the cut-out areas 12b, 12c, and 12d correspond to the respective outline shapes of the wound sections of the electrical cables 21, 22, and 23 in a cross-section taken along a plane that lies in the same plane as the end face 11f of the core of magnetic material 11. Therefore, the limiting element 12 is able to guide the winding positions and the shape of the windings of the electrical cables 21, 22, and 23 with respect to the core of magnetic material 11 in a suitable manner.

[0040] The cut-out areas 12b, 12c and 12d of the limiting element 12 hold the respective electrical cables 21, 22 and 23, which are wound around the core of magnetic material 11, from both sides of the respective electrical cables 21, 22 and 23 around the axis of the core of magnetic material 11. Therefore, the limiting element 12 is able to effectively limit the relative displacement (change in the distance between the cables) of each of the electrical cables 21, 22 and 23. Second embodiment

[0041] With reference to Fig. Sections 10 to 13 describe a core unit and a wiring harness of a second embodiment. In the second embodiment, the assembly features with the same function as those described in the first embodiment described above also have the same reference numerals, and their repeated description is omitted. Fig. Figure 10 is a perspective view of a cable harness according to the second embodiment. Fig. Figure 11 is a perspective view showing a state in which electrical cables are wound around a core unit according to the second embodiment. Fig. Figure 12 is a perspective view of the core unit, which is housed in a holding unit. Fig. 13 is a cross-sectional view, which runs along a line XIII-XIII in Fig. Figure 12 shows a cross-sectional view depicting a state in which the core unit is attached to a vehicle body. A core unit 30 in the second embodiment differs from the core unit 10 in the aforementioned first embodiment in that a limiting element 32 is conductive and the limiting element 32 is grounded on the side of the vehicle body.

[0042] The cable harness 1 in the second embodiment comprises the electrical cables 21, 22 and 23, the core unit 30 and a holding unit 33. As in Fig. As shown in Figure 11, the core unit 30 according to the second embodiment has the core made of magnetic material 11 and the limiting element 32. The core made of magnetic material 11 according to the second embodiment is identical to the core made of magnetic material 11 of the first embodiment. The limiting element 32 in the second embodiment has a body 32a. The planar shape of the body 32a is identical to the planar shape of the body 12a according to the aforementioned first embodiment. That is, the body 32a has a pair of straight sides 32e and 32f, which are parallel to each other, and a pair of round or circular sides 32g and 32h, which each extend continuously between the sides 32e and 32f. A second cut-out area 32c is formed in the central area of ​​the straight side 32e in the longitudinal direction.In the second embodiment, a first cut-out area 32b and a third cut-out area 32d are formed longitudinally at both ends of the other side 32f. The first cut-out area 32b and the third cut-out area 32d enclose the second cut-out area 32c between them longitudinally. The electrical cables 21, 22, and 23 are wound around the core of magnetic material 11 in the same manner as in the first embodiment described above.

[0043] The body 32a of the limiting element 32 according to the second embodiment is a conductive element with connection areas 32n, each of which is electrically connected to the holding unit 33. The connection area 32n is a plate-like, structurally forming area that is integrated with the body 32a and forms part of the body 32a. The connection area 32n projects axially from the edge region on side 32e of the body 32a towards the side of the core made of magnetic material 11. The connection areas 32n are formed longitudinally on both sides of the body 32a such that the connection areas 32n enclose the second cut-out area 32c between them. The body 32a is constructed of a conductive raw material, such as a metal (aluminum alloy, copper alloy, or the like).The connecting area 32n is electrically connected to a vehicle body via the holding unit 33, as explained below.

[0044] The in Fig. The holding unit 33 shown in Figure 12 is attached to a vehicle body, holding the core unit 30. In the present embodiment, the holding unit 33 is a housing in the form of a rectangular parallelepiped or cuboid, which accommodates the core unit 30 inside. As shown in Figure 12, the holding unit 33 is attached to a vehicle body, holding the core unit 30 inside. Fig. As shown in Figure 10, the holding unit 33 is covered from below by an outer sheath section 25. The outer sheath section 25 connects the corrugated tube 7 on the inverter 50 side and the corrugated tube 7 on the motor 60 side and covers the holding unit 33 and the electrical cable section 2. As shown in Fig. 12 and Fig. As shown in Figure 13, the holding unit 33 comprises a body 34, a shell 35, and a cover element 36. The body 34 is, for example, made of synthetic resin and has a base plate area 34a, side wall areas 34b, and mounting areas 34c. The base plate area 34a, the side wall areas 34b, and the mounting areas 34c are formed as a single unit. The base plate area 34a is a structural component, formed in a rectangular, plate-like shape. The base plate area 34a supports the core unit 30 from the underside of the vehicle. The respective side wall areas 34d are arranged at one end and the other end of the base plate area 34a in the width direction. The side wall area 34b projects from the edge region of the base plate area 34a in a side direction along the thickness direction of the base plate area 34a. The mounting area 34c is located at the upper end of the side wall area 34d; i.e.The fastening area 34c is located at the end region opposite the side of the base plate region 34a. The fastening area 34c projects outwards from an outer surface 34d of the side wall region 34b of the base plate region 34a in the width direction; that is, the fastening area 34c projects outwards from the surface opposite the side of the base plate region 34a of the side wall region 34b in the width direction. Two fastening areas 34c are formed in one side wall region 34b. A through-hole 34e is formed in the fastening area 34c. The cover 35 is a plate-like element made of metal. The cover 35 covers the body 34 on the outside of the body 34 to protect the body 34.

[0045] The cover element 36 is a plate-like conductive element made of metal or the like (aluminum alloy or copper alloy). The cover element 36 functions as a cover, covering the core unit 30, which is located on the body 34, from above, and as a grounding element, grounding the boundary element 32 on the side of the vehicle body. The cover element 36 has a body 36a, which is formed in a flat rectangular shape, and also has mounting areas 36b. The mounting area 36b projects outwards from the edge region of the body 36a in the width direction. The mounting area 36b is formed in a position corresponding to that of the mounting area 34c of the body 34. A through hole 36c, corresponding to the through hole 34e of the fastening area 34c, is formed in the fastening area 36b.

[0046] The cover element 36 is arranged on the upper end of the side wall region 34b of the body 34. As shown in Fig. As shown in Figure 13, a bottom surface 36d of the cover element 36 is brought into contact with the connection areas 32n of the core unit 30 in a state in which the cover element 36 is arranged on the side wall areas 34b. Therefore, the limiting element 32 and the cover element 36 are electrically connected to each other. The holding unit 33 is, as shown in Fig. As shown in Figure 13, the retaining unit 33 is attached to the side of the vehicle body using fasteners 37, such as screws. In the present embodiment, the retaining unit 33 is attached to a conductive base plate 38 from the underside of the vehicle. Threaded bores 38a are formed in the base plate 38. The fastener 37 is inserted into the through bore 34e of the mounting area 34c and into the through bore 36c of the mounting area 36b and is then screwed into the threaded bore 38a, thereby securing the retaining unit 33 to the base plate 38.

[0047] The cover element 36 is brought into contact with the base plate 38 at least at the mounting area 36b and is electrically connected to the base plate 38. Therefore, the body 32a of the limiting element 32 is electrically connected to the base plate 38 via the cover element 36 and is thus grounded. The limiting element 32 is electrically connected to the side of the vehicle body, and therefore the limiting element 32 interrupts the electrostatic capacitance C between the electrical cables 21, 22, and 23. Due to this configuration, according to the core unit 30 and the wiring harness 1 in the present embodiment, the cable impedance of the wiring harness 1 is increased to improve the impedance matching in the entire circuit (between the motor 60, the wiring harness 1, and the inverter 50), thus dampening the reflection of a voltage spike.

[0048] Furthermore, in the present embodiment, the limiting element 32 and the cover element 36 have high thermal conductivity. Therefore, it is possible to efficiently dissipate heat generated in the electrical cables 21, 22, and 23 and the magnetic core 11 to the side of the vehicle body. The heat generated in the magnetic core 11 and in the electrical cables 21, 22, and 23 is transferred to the base plate 38 via the limiting element 32 and the cover element 36. This reduces the temperature rise of the magnetic core 11, thereby lowering its temperature characteristics, increasing its magnetic conductivity, and enabling miniaturization of the magnetic core 11.Furthermore, the electrostatic capacitance C between the electrical cables 21, 22 and 23 in the core made of magnetic material 11 is reduced, thereby increasing the cable impedance of the cable harness 1.

[0049] As previously explained, the cable harness 1 according to the second embodiment comprises the holding unit 33, which is attached to the vehicle body and holds the core unit 30. The body 32a of the limiting element 32 is a conductive element with connection areas 32n that are electrically connected to the holding unit 33. The holding unit 33 connects the connection areas 32n and the vehicle body. Therefore, according to the cable harness 1 of the second embodiment, it is possible to achieve an increase in cable impedance. Third embodiment

[0050] With reference to Fig. Section 14 describes a third embodiment. Fig. Figure 14 is a front view depicting a core unit according to the third embodiment. A core unit 40 in the third embodiment differs from the core unit 10 in the aforementioned first embodiment and from the core unit 30 in the second embodiment in that a limiting element 42 has webs 42n for heat dissipation. The core unit 40 comprises the core made of magnetic material 11 and the limiting element 42. The core made of magnetic material 11 according to the third embodiment is identical to the core made of magnetic material 11 of the aforementioned first and second embodiments.

[0051] As in Fig. As shown in Figure 14, the limiting element 42 in the third embodiment has a body 42a. The planar shape of the body 42a is identical to the shape of the body 12a in the first embodiment and to the shape of the body 32a in the second embodiment, except that the body 42a has the webs 42n. The body 42a has a pair of straight sides 42e and 42f, which are parallel to each other, and a pair of round or circular sides 42g and 42h, which each extend continuously between the sides 42e and 42f. A second cutout area 42c is formed longitudinally in the central region of the straight side 42e. A first cutout area 42b and a third cutout area 42d are formed at the respective two end regions of the other side 42f.The first cut-out area 42b and the third cut-out area 42d enclose the second cut-out area 42c between them along the longitudinal direction. The electrical cables 21, 22, and 23 are wound around the core of magnetic material 11 in the same manner as in the aforementioned first and second embodiments.

[0052] The limiting element 42 according to the third embodiment has the webs 42n. The webs 42n are formed on the side 42e of the limiting element 42 and project towards a side opposite side 42f. The webs 42n are arranged at predetermined intervals along the longitudinal direction. The core unit 40 is, as shown in Fig.As shown in Figure 14, the core unit 40 is arranged such that the webs 42n are located on the upper side of the vehicle of the limiting element 42. The core unit 40 is attached to the base plate 38 or the like in the same manner as the core unit 30 in the aforementioned second embodiment, in a state in which the core unit 40 is housed inside the holding unit 33. The webs 42n are designed such that they are in contact with the cover element 36 in a state in which the core unit 40 is housed in the holding unit 33. If the limiting element 42 has the connecting areas 32n in the same manner as the limiting element 32 in the aforementioned second embodiment, the connecting areas 32n and the webs 42n are brought into contact with the cover element 36.

[0053] When heat is generated in the magnetic core 11 and in the electrical cables 21, 22, and 23, this heat is not dissipated directly into the air but is transferred to the body 42a of the boundary element 42, and the heat is also radiated from the body 42a and the webs 42n. Furthermore, the heat transferred to the webs 42n is transferred via the cover element 36 to the base plate 38. The temperature rise of the magnetic core 11 is thus dampened, thereby reducing the temperature characteristics of the magnetic core 11, increasing its magnetic conductivity, and thus miniaturizing the core 11. Additionally, the electrostatic capacitance C between the electrical cables 21, 22, and 23 in the magnetic core 11 is reduced, thereby increasing the cable impedance of the wiring harness 1. Modifications of all embodiments

[0054] The modifications of the first through third embodiments are explained. The limiting elements 12, 32, and 42 can be attached to the core of magnetic material 11 after the electrical cables 21, 22, and 23 have been wound around the core of magnetic material 11. The limiting elements 12, 32, and 42 can be attached to the core of magnetic material 11 by adhesion.

[0055] The cable harness 1 can have multiple core units 10, 30, and 40. For example, if the cable harness 1 in the first embodiment has multiple core units 10, the core units 10 are arranged at a predetermined distance along the axis X1. The number of core units 10 and the predetermined distance are optionally set such that the cable impedance of the cable harness 1 corresponds to a target value.

[0056] The content disclosed in the aforementioned embodiments and modifications can be practically implemented by optionally combining the embodiments and modifications with one another.

[0057] The core unit according to the embodiment comprises a core made of magnetic material, which is formed in a ring shape, and a limiting element that restricts the displacement of the electrical cable wound around the core about the core's axis. The limiting element has a body that is attached to one end of the core in the axial direction. At the edge of this body are several cut-out areas that separately surround the respective electrical cables of each phase wound around the core in the radial direction, starting from the interior of the core, with the core's axis serving as a center point.The cable harness according to the embodiment comprises the core made of magnetic material, the electrical cables of the multiple phases wound around the core made of magnetic material at corresponding positions that differ from one another around the axis of the core made of magnetic material, and the limiting element. The electrical cables of each phase are separately enclosed by the respective cut-out areas of the limiting element. The core unit and the cable harness according to the embodiment achieve the advantageous effect of reducing the decrease in cable impedance caused by electrical cables of different phases being located close to one another.

Claims

[1] A core unit (10) with: a core (11) made of magnetic material, which is formed in a ring shape, wherein electrical cables (21, 22, 23) of several phases are wound around the core (11) made of magnetic material at respective positions which differ from each other around the axial axis (X2) of the core (11) made of magnetic material in the circumferential direction; and a limiting element (12, 32, 42) configured to limit a displacement of the electrical cables (21, 22, 23) about the axial axis (X2) of the core (11) made of magnetic material, wherein the electrical cables (21, 22, 23) are wound around the core (11) made of magnetic material, wherein the limiting element (12, 32, 42) has a body (12a, 32a, 42a) which is attached to one end of the core (11) made of magnetic material in the axial direction (X2) of the core (11) made of magnetic material, and several cut-out areas (12b, 12c, 12d) are formed at the edge regions of the body (12a, 32a, 42a), wherein the cut-out areas (12b, 12c, 12d) are formed, which separately enclose the respective electrical cables (21, 22, 23) of each phase, which are wound around the core (11) of magnetic material, starting from the interior of the core (11) of magnetic material in a radial direction and restrict inwards in the radial direction, wherein the axial axis (X2) of the core (11) of magnetic material serves as a center point, characterized by , that the cut-out areas (12b, 12c, 12d) are each formed in a stepped shape, thereby suppressing the deformation of the winding shape and a displacement of each winding layer. [2] The core unit (10) according to claim 1, wherein the shapes of the cut-out areas (12b, 12c, 12d) correspond to the respective winding shapes of the electrical cables (21, 22, 23) in relation to the core (11) made of magnetic material when viewed from the axial direction (X2) of the core (11) made of magnetic material. [3] The core unit (10) according to claim 1 or 2, wherein each of the cut-out areas (12b, 12c, 12d) holds the corresponding electrical cable (21, 22, 23) which is wound around the core (11) made of magnetic material from both sides around the axial axis (X2) of the core (11) made of magnetic material. [4] The core unit (10) according to any one of claims 1 to 3, wherein the limiting element (42) further comprises several webs (42n) that project upwards. [5] A wiring harness (1) with: a core unit (10) according to any one of claims 1 to 4. [6] The wiring harness (1) according to claim 5, which further comprises: a holding unit (33) which can be attached to a vehicle body and is designed to hold the core (11) made of magnetic material and the limiting element (32), wherein the body (32a) of the limiting element (32) is a conductive body with a connection area (32n) that is electrically connected to the holding unit (33), and the holding unit (33) can electrically connect the connecting area (32n) to the vehicle body.

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