Foldable wiring harness substrates with embedded channels for optimized positioning of electrical wiring harnesses

Abstract

Presented are foldable wire harness substrate systems for optimized positioning of electrical wire harnesses, methods for manufacturing / applying such wire harness substrate systems, and motor vehicles assembled using such wire harness substrate systems. A wire harness substrate system includes a wire harness with multiple electrical connectors, multiple cable segments electrically connected to the electrical connectors, and optional connection points, relays, embedded sensors, etc. A foldable wire harness substrate supports the wire harness, e.g., to optimize storage, shipping, unpacking, and installation of the wire harness. Integrally formed with or attached to the wire harness substrate are a series of distributed support features and a network of interconnected wire channels.The retention features releasably secure the electrical connectors and cable segments to the harness substrate, while the cable channels accommodate the cable segments and route them over the harness substrate. The foldable harness substrate is designed to be selectively transitioned between an expanded and a packed state.

Description

[0001] The present disclosure relates generally to electrical wiring systems. More specifically, aspects of this disclosure relate to systems and methods for aligning a wiring harness with a vehicle underbody during installation of the wiring harness to the vehicle.

[0002] Today's production vehicles, such as the modern automobile, are originally equipped with a network of control units, sensors, communication devices, vehicle accessories, and various other electronic components distributed throughout the vehicle body. An on-board electrical system regulates the transmission of electrical signals between the vehicle's individual electronic components and the distribution of electrical energy to these components from a rechargeable energy storage system (RESS), which provides the power required to operate the vehicle. Many electrical systems in vehicles use an electrical wiring harness (also called a "wiring harness") to interconnect the vehicle's distributed electrical components and subsystems.Conventional vehicles used individual electrical wires routed individually through the body and connected to the vehicle's electrical components. Modern computer-controlled vehicles, however, use a wiring harness that bundles the connecting wires, connectors, links, relays, embedded sensors, etc., into a single modular assembly, simplifying the packaging and connection process.

[0003] With the progressive development and deployment of autonomous and electric vehicles containing complex electronics, power, and control systems, the manufacturing processes required to operatively connect these systems have become increasingly complex. To facilitate such connections, manufacturers now use multi-header harnesses with a central harness network consisting of insulated and bundled wire segments and numerous terminal receptacles extending from opposite sides and ends of the central harness network and located throughout the vehicle body and frame. These harnesses can include multiple sections, cross-connects, receptacles, and connectors.In such cases, installing the wiring harness can require tedious, time-consuming unfolding, turning, and precise alignment to properly align all the different sections for mounting on the vehicle.

[0004] DE 10 2020 100 859 A1 describes a wiring harness system and a method for operating a wiring harness system, wherein the wiring harness system has at least one actuator and at least one wiring harness with at least one electrical cable, wherein the actuator is connected to the wiring harness, wherein the actuator is designed to move the wiring harness between a transport position and an assembly position different from the transport position.

[0005] DE 10 2018 128 457 A1 describes a wiring harness assembly comprising one or more wiring harness segments. Each wiring harness segment comprises a plurality of cables, a sheath enclosing the plurality of cables, and one or more connectors operatively connected to the one or more wiring harness segments, configured to connect adjacent wiring harness segments and / or to connect a wiring harness segment of the one or more wiring harness segments to an electrical component.

[0006] Accordingly, it is the object of the present invention to provide a wiring harness system that enables direct, time-efficient assembly.

[0007] The problem is solved by the subject matter of the independent claim.

[0008] The following describes foldable wire harness substrate systems with embedded channels for optimized positioning of electrical wire harnesses, methods for manufacturing and using such wire harness substrate systems, and motor vehicles assembled using such wire harness substrate systems. Automotive wire harnesses are typically presented to assemblers in a pile of cable bundles, requiring a lengthy and laborious process of identifying the individual sections of the wire harness, unfolding and turning the wire harness over, and then pulling the wire harness sections to their target positions on the vehicle body / chassis. To optimize the process of unpacking and positioning the wire harness, systems and methods are presented that attach the wire harness to a foldable wire harness substrate in a predefined pattern that matches the packaging layout of the wire harness on the vehicle.

[0009] For example, a foldable or rollable wiring harness substrate system uses an insulated and protective substrate base with rollable, foldable, and / or flexible (collectively, "bendable") features that allow the substrate and wiring harness to be easily folded / rolled and unfolded / unrolled. The substrate base may include embedded channels for routing the wiring harness cable segments and retention features for securing selected wiring harness segments in their respective target positions "inside the vehicle." The protective substrate material may take various forms, such as a rigid sheet, a vehicle floor carpet or similar material, a rollable cardboard sheet, a foldable cardboard sheet, etc.With the aforementioned features, the foldable wire harness substrate assembly can help: (1) enable compact packaging and shipping of the wire harness; (2) minimize the space required for storing the wire harness prior to installation; and (3) simplify and speed up the unfolding and alignment of the wire harness into the intended positions for vehicle mounting.

[0010] Embodiments of this description relate to foldable wire harness substrate systems having integrated retention features and / or embedded channels that cooperatively facilitate the target positioning of electrical wire harnesses.

[0011] According to the invention, a wire harness substrate system comprises a wire harness having a plurality of electrical connectors, a plurality of electrical cable segments electrically connected to the electrical connectors, and an assortment of optional interconnects, relays, embedded sensors, ground couplers, etc. A foldable wire harness substrate supports the wire harness to, for example, optimize storage, shipping, unpacking, and installation of the wire harness in a vehicle. Integrated into or attached to the wire harness substrate are a series of distributed retention features and a network of interconnected wire channels. The retention features releasably secure the electrical connectors and wire segments to the foldable wire harness substrate, while the wire channels receive the wire segments and route them over the wire harness substrate. The foldable wire harness substrate is designed to be selectively, for example,by a robot or an operator, between an unfolded, unrolled or opened (collectively "expanded") state and a folded, rolled or closed (collectively "packed") state.

[0012] Further embodiments relate to wire harness substrates for the targeted positioning of electrical wire harnesses during assembly in motor vehicles. As used herein, the terms "vehicle" and "motor vehicle" may be used interchangeably and synonymously to include any relevant vehicle platform, such as passenger cars (ICE, HEV, FEV, fuel cell, fully and semi-autonomous vehicles, etc.), commercial vehicles, industrial vehicles, tracked vehicles, off-road and all-terrain vehicles (ATVs), motorcycles, agricultural equipment, aircraft, watercraft, spacecraft, e-bikes, etc. For non-automotive applications, the disclosed wire harness substrate concepts may be implemented for any logically relevant application, including commercial and residential power plants, electric vehicle utilities, photovoltaic systems, pumping systems, wind turbines, server systems, etc.

[0013] Continuing the discussion of the previous example, a wiring harness substrate assembly includes a foldable wiring harness substrate supporting a vehicle wiring harness.

[0014] The foldable wiring harness substrate may essentially comprise, or if desired, consist of, an insulated and flexible plate. A plurality of retention features are mounted on, integrally formed with, or otherwise secured to the foldable wiring harness substrate. Each retention feature releasably secures an electrical connector and / or a wire segment of the wiring harness to the foldable wiring harness substrate. A plurality of wire channels are mounted on, integrally formed with, or otherwise secured to the foldable wiring harness substrate. Each wire channel receives a corresponding wire segment or segments of the wiring harness and routes them over the wiring harness substrate.

[0015] The cable ducts may be arranged in a predefined routing pattern that matches a vehicle-specific routing pattern along which the vehicle wiring harness is attached to the vehicle body / chassis.

[0016] The foldable wiring harness substrate is structurally configured to be selectively bent from an expanded state to a packed state and, if desired, bent back from the packed state to the expanded state.

[0017] Further application examples of this description relate to manufacturing systems, workflows, and control logic for manufacturing or using the foldable wire harness substrates, wire harness substrate systems, and / or motor vehicles described herein. One example presents a method for assembling a wire harness substrate system that helps optimize, for example, the storage, shipping, unpacking, and installation of an electrical wire harness.This representative method includes, in any order and in any combination with any of the options and features disclosed above and below, receiving a wire harness having a plurality of electrical connectors and a plurality of electrical cable segments electrically connected to the electrical connectors; placing the wire harness on a foldable wire harness substrate, the foldable wire harness substrate having a plurality of retention features and a plurality of wire channels; attaching the electrical connectors to the foldable wire harness substrate via the retention features; disposing the electrical cable segments in the wire channels to thereby route the electrical cable segments over the foldable wire harness substrate; and transitioning the foldable wire harness substrate between an expanded state and a packed state.

[0018] In all of the disclosed wire harness substrate systems, foldable wire harness substrates, and methods, each retention feature includes a retention tab formed integrally with the foldable wire harness substrate and wrapping around a corresponding portion of one of the electrical cable segments proximate one of the electrical connectors.

[0019] In all of the disclosed wire harness substrate systems, foldable wire harness substrates, and methods, the foldable wire harness substrate may be in the form of an insulated and bendable substrate sheet that is substantially flat and elongated when expanded.

[0020] In this case, the substrate plate may consist wholly or partly of a corrugated paper material, a fabric material, a carpet material, a polymeric tarpaulin material or any other suitable flexible and non-conductive material.

[0021] To facilitate folding and expanding the wiring harness substrate, the substrate plate may be fabricated with a plurality of fold lines arranged together in a predefined pattern to allow the foldable wiring harness substrate to be selectively bent into and out of the packed state.

[0022] Each fold line may be a straight scored portion, a straight slit portion, and / or a straight portion of reduced thickness of the substrate sheet.

[0023] It may be desirable for the cable channels to be integrally formed with and recessed into the foldable harness substrate. As a further option, a set of cable stiffeners may be attached to the foldable harness substrate; each cable stiffener accommodates and structurally reinforces a corresponding portion of one of the electrical cable segments. As previously mentioned, the wiring harness may be a vehicle wiring harness for a motor vehicle; in this case, the cable channels of the harness substrate may be arranged in a predefined routing pattern that matches a vehicle-specific routing pattern in which the vehicle wiring harness is mounted to the vehicle body / chassis.

[0024] In all of the disclosed wiring harness substrate systems, foldable wiring harness substrates, and methods, the foldable wiring harness substrate may be substantially flat and have a cross-shaped profile in plan view when deployed to the expanded state, and may be polyhedral with a box shape when folded to the packed state. Alternatively, the foldable wiring harness substrate may be substantially flat and have a polygonal plan view profile when deployed to the expanded state, and may be layered with a polygonal plan view profile when folded to the packed state.Another possibility is for the foldable wiring harness substrate to comprise a plurality of substrate sheets, each substantially flat and having a polygonal profile in plan view when deployed to the expanded state, and each polyhedral with a box shape when folded to the packaged state. In at least some applications, the foldable wiring harness substrate may be rolled into a cylindrical form factor in the packaged state or folded / hinged into a clamshell form factor.

[0025] Fig. 1 is a schematic illustration of the underbody of a representative motor vehicle having an electrical wiring harness located on the vehicle chassis using a foldable wiring harness substrate assembly according to embodiments of the present description.

[0026] The Fig. 2A and Fig. 2B are perspective and top view illustrations, respectively, of a representative foldable wire harness substrate assembly supporting an electrical wire harness in a packaged “packaged” state ( Fig. 2A) and an expanded “unpacked” state ( Fig. 2B) in accordance with embodiments of the present description.

[0027] Fig. 3A-3D are a sequence of perspective and plan views illustrating another representative foldable wire harness substrate assembly with an electrical wire harness in a packaged “folded” state ( Fig. 3A), a partially unfolded state ( Fig. 3B), a largely unfolded state ( Fig. 3C) and an expanded “unfolded” state ( Fig. 3D) in accordance with embodiments of the present description.

[0028] Fig. 4A and Fig. 4B are perspective and top view illustrations, respectively, of another representative foldable wire harness substrate assembly supporting an electrical wire harness in a packed, “multi-packed” state ( Fig. 4A) and an expanded, “unpacked” state ( Fig. 4B) according to the embodiments of the present description.

[0029] Referring now to the drawings, wherein like reference numerals refer to like features in the several views, Fig. 1, a representative motor vehicle is illustrated, generally designated 110, which is depicted herein for purposes of discussion as an electrically powered sedan-style automobile. The depicted motor vehicle 110—also referred to herein as a "motor vehicle" or "vehicle" for short—is merely an exemplary application with which aspects of this description may be practiced. Likewise, the use of the present concepts for the depicted vehicle wiring harness should be understood as a non-limiting implementation of the disclosed features. It should be understood that aspects and features of this description may be utilized for other wiring harness configurations, may be incorporated into any logically relevant motor vehicle type, and may be utilized for both automotive and non-automotive applications.Furthermore, only selected components of the motor vehicles and wiring harness systems are shown and described in detail here. Nevertheless, the vehicles and systems described below may include numerous additional and alternative features and other available peripheral hardware for implementing the various methods and functions of this description.

[0030] Fig. Figure 1 shows the underside "chassis" portion of the vehicle 110, depicting a set of four wheels 112 attached to a vehicle chassis and body 114 via, for example, steering knuckles, spindles, control arms, struts, etc. The vehicle chassis / body 114 is a load-bearing and load-absorbing structure that can take on various designs, including unibody, subframe, or body-on-frame chassis designs. To propel the vehicle 110, an electrified powertrain can generate and transmit traction torque to one or more wheels 112 of the vehicle. The powertrain is Fig. 1 by a dual-independent dual-drive (DIDU) powertrain layout with electric drive units (EDUs) 116 at the front and rear axles, mounted on front and rear engine mounts of the vehicle chassis / body 114, respectively. During vehicle operation, the EDUs 116 drive the wheels 112 both individually and collectively, thereby propelling the vehicle 110. A rechargeable energy storage system (RESS), which may be in the form of a chassis-mounted traction battery pack 118 containing an array of lithium-class battery cells, supplies power to the EDUs 116 and a variety of electrical loads on the vehicle 110.It is intended that the disclosed concepts may be similarly implemented for fully electric vehicles (FEVs), hybrid electric vehicles (HEVs), fuel cell electric vehicles (FCEVs), internal combustion engine vehicles (ICEs), and all other logically relevant vehicle types and vehicle propulsion configurations.

[0031] A high voltage (HV) electrical system controls the power transfer between each EDU 116 and the traction battery pack 118, which provides the energy required to operate the electrically powered vehicle 110 from Fig. 1. According to the example shown, the vehicle's electrical system is represented in part by a main-body wire harness (MBWH) 120 that is rigidly connected to the vehicle chassis / body 114 and extends the entire length of the vehicle 110 (e.g., from the front headlights to the rear taillights). The wire harness 120 may consist of a series of electrical connectors (some of which are designated 122) that are electrically connected to a network of electrical cable segments (some of which are designated 124). Each electrical connector 122 may assume a variety of different connector configurations, including crimp connectors, quick connect connectors, keyed connectors, pin connectors, terminal connectors, etc.The cable segments 124 may comprise electrically insulated sleeves enclosing a bundle of individually insulated electrical wires, fiber optic cables, multi-conductor (braided, ribbon, speaker) cables, etc. Once properly installed, the wiring harness 120 connects most / all of the electrical and electronic (E / E) components in the motor vehicle 110, such as sensors, electronic control units, actuators, accessories, and the like. It is conceivable that the wiring harness 120 could adopt different architectures with more or fewer electrical connectors 122 and / or cable segments 124 of similar or different types than those illustrated in the figures.

[0032] The wiring harness 120 may be divided into different zones that indicate where each set of connectors 122 and cables 124 is to be placed on the vehicle chassis / body 114. As shown, the vehicle wiring harness 120 has Fig. 1 ten (10) different zones: a front right zone 120A; a front left zone 120B; a front passenger-side zone 120C; a front driver-side zone 120D; a center passenger-side zone 120E; a center driver-side zone 120F; a rear passenger-side zone 120G; a rear driver-side zone 120H; a rear right zone 120I; and a rear left zone 120J. The vehicle wiring harness 120 may include a number of cross-connect zones, such as the front cross-connect zone 126A, the center cross-connect zone 126B, and the rear cross-connect zone 126C, marked or provided with indicia identifying each zone for proper alignment and mounting to the corresponding target mounting points on the chassis / body 114. It should be appreciated that an electrical wiring harness may include any desired number and arrangement of zones without departing from the intended scope of this disclosure.

[0033] Fig. 1 schematically shows a representative assembly line mapping of the connectors 122 and cables 124 of the wiring harness 120 to the corresponding target mounting points on the vehicle chassis / body 114. According to the illustrated example, the vehicle chassis / body 114 has ten (10) different target mounting points (also referred to as “receiving areas”): a front right mounting point 114A; a front left mounting point 114B; a front passenger-side mounting point 114C; a front driver-side mounting point 114D; a center passenger-side mounting point 114E; a center driver-side mounting point 114F; a rear passenger-side mounting point 114G; a rear driver-side mounting point 114H; a rear left mounting point 114I; and a rear right mounting point 114J.Each harness section 120A-120J is aligned with and securely attached to one of the respective target mounting points 114A-114J of the vehicle to properly install the harness 120 on the motor vehicle 110.

[0034] Next, with reference to the Fig. 2 to 4, three representative examples of foldable wire harness substrate assemblies 210, 310, and 410, respectively, are shown with integrated retention features and / or cable channels that together facilitate the target positioning of electrical wire harnesses. In each illustrated example, the foldable wire harness substrate assembly 210, 310, 410 securely supports an electrical wire harness 220, 320, and 420, e.g., to optimize storage, shipping, unpacking, and installation of the wire harness into a vehicle or other manufactured product. Although the wire harnesses 220, 320, 420 of the Fig. 2 to 4 differ in appearance, they can offer all the features and options described above regarding the wiring harness 120 of the Fig. 1 and vice versa. As a non-limiting point of similarity, each wiring harness 220, 320, 420 may be characterized by a vehicle-specific set of electrical connectors 222 electrically connected to a network of electrical cable segments 224 and, depending on the desired application, an assortment of optional junctions, relays, embedded sensors, ground couplers, etc.

[0035] Each of the foldable wiring harness substrate assemblies 210, 310, 410 is formed as a one-piece insulated and bendable substrate plate 212 and 312 ( Fig. 2B and Fig. 3D) or as several interconnected insulated and flexible substrate plates 412A-412D ( Fig. 4B). The substrate plates 312 and 412(A)-412(D) of the Fig. 3(D) and Fig. 4(B) differ in appearance, but all of the features and options described below with respect to the substrate plate 212 of the Fig. 2(B) and vice versa. For example, in the expanded state, each substrate sheet 212, 312, 412A-412D may be substantially flat and elongated, having a polygonal profile in plan view. To protect and insulate the wiring harness, the substrate sheets 212, 312, 412A-412D may be composed in whole or in part of a corrugated paper material (e.g., cardboard), a woven fabric material (e.g., mesh-reinforced nylon), a carpet material (e.g., polyester tufts on a latex backing), a polymeric sheeting material (e.g., polypropylene sheeting), or other suitable resilient substrate material. Each substrate sheet 212, 312, 412A-412D may be manufactured with intersecting fold lines 211, 311, and 411 arranged in a predefined pattern to allow the foldable wire harness substrate 210, 310, 410 to be manually or robotically bent, rolled, or otherwise folded into a desired packaged state; examples of which are described in the Fig. 2A, Fig. 3A and Fig. 4A. Each fold line 211, 311, 411 may be a linear scored portion, a linear slotted portion, and / or a linear reduced-thickness portion of the substrate plate 212, 312, 412A-412D. Alternatively, a substrate plate may include hinges, joints, flaps, cutouts, etc., to enable the selective folding and expansion of the harness substrate assemblies 210, 310, 410.

[0036] To securely attach the wire harnesses 220, 320, 420, each substrate plate 212, 312, 412A-412D may include a number of retention features (some of which are shown in Fig. 2B are designated 214) that secure selected electrical connectors 222 and selected portions of the cable segments 224 to the wire harness substrate assemblies 210, 310, 410. In the inspection view of Fig. 2A, one of the retention features 214' is illustrated as a retention tab (e.g., a hook or grip cutout) formed integrally with and extending from the substrate plate 212, 312, 412A-412D. As illustrated, the retention feature 214' is an arcuate tab that wraps around a corresponding portion of a cable segment 224 proximate one of the electrical connectors 222 and secures in a mating slot 215' formed through the plate 212. Alternatively, the harness retention features 214 may include other mechanical devices, such as a latch or a fastener. B. rosette clips, rivet fasteners, “Christmas tree” snap fasteners, etc. After proper assembly, the wiring harness substrate 210, 310, 410 and the wiring harness 220, 320, 420 can together form a wiring harness substrate system 200, 300 or400, which keeps the 220, 320, 420 wiring harness compact for storage and transport prior to assembly in a vehicle, while facilitating quick unpacking and routing of the wiring harness on the assembly line.

[0037] To optimize the positioning of the wire harnesses “in-line” with predefined target mounting positions “on the vehicle”, the substrate plates 212, 312, 412A-412D can be provided with embedded cable channels (some of which are in Fig. 2B are designated 228) that receive and guide the cable segments 224 across the width and length of the wire harness substrate assemblies 210, 310, 410. To simplify design and facilitate manufacturing, these wire channels 228 may be integrally formed with and recessed into the wire harness-supporting top surface of the substrate plate 212, 312, 412A-412D. To facilitate the positioning of the wire harness, the wire channels 228 may be arranged (i.e., surface-mapped) in a predefined routing pattern that matches a vehicle-specific routing pattern in which the wire harness 220, 320, 420 is mounted on a vehicle (e.g., vehicle body / chassis 114 of Fig. 1). At least in some applications, the harness substrate assemblies 210, 310, 410 may include labels on the substrate plates 212, 312, 412A-412D that identify the various sections of the harness 220, 320, 420 (e.g., harness zones 120A-120J of Fig. 1) and / or their respective mounting locations in the vehicle (e.g., target mounting points 114A-114J). Similarly, a machine-readable code (e.g., a barcode or QR code) may be added to the substrate plates 212, 312, 412A-412D to identify the wire harness 220, 320, 420 and related information. As a further option, the wire harness substrate assemblies 210, 310, 410 may include rigid cable stiffeners 230 ( Fig. 2B) that are attached to the substrate plates 212, 312, 412A-412D; each cable stiffener 230 receives and structurally reinforces a corresponding portion of one of the cable segments 224.

[0038] To simplify and expedite storage, shipping, and unpacking of the wire harness 220, 320, 420, each foldable wire harness substrate assembly 210, 310, 410 is designed to be selectively transformed, e.g., by a robot, an operator, a mechanic, etc., from an unfolded, unrolled, or opened state (collectively, "expanded state") to a folded, rolled, or closed state (collectively, "packed state"). For example, the foldable wire harness substrate 210 and the wire harness 220 may be Fig. 2A shown folded state (e.g. in a supplier factory) and secured closed and, if necessary, in the Fig. 2B (e.g., in an OEM factory). In the folded state, the substrate 212 may assume a rectangular-prismatic box shape; conversely, in the unfolded state, the substrate 212 may be substantially flat and have a cross-shaped profile in plan view. In comparison, the foldable wire harness substrate 310 and the wire harness 320 may be bent into a folded state ( Fig. 3A) and, if desired, gradually through different stages of development ( Fig. 3B and Fig. 3C) into an unfolded state ( Fig. 3D). The substrate 312 may be substantially flat in the folded state and have a rectangular planar profile; in the unfolded state, the substrate 312 may be layered and have a square planar profile. The foldable wiring harness substrate assembly 410 of the Fig. 4A and Fig. 4B, in contrast, comprises several substrate plates 412A-412D, which form “nested” boxes ( Fig. 4A) which are connected to each other by bands 432 and packaged in a protective outer box 434. Each substrate plate 412A-412D can be used in the packaged state ( Fig. 4A) assume a square-prismatic box shape; in the expanded state ( Fig. 4B), each substrate plate 412A-412D may be substantially flat and have a rectangular profile in plan view.

Claims

[1] Wiring harness substrate system (200, 300, 400), comprising: a wiring harness (120, 220, 320, 420) having a plurality of electrical connectors (122, 222) and a plurality of electrical cable segments (124, 224) electrically connected to the electrical connectors (122, 222); and a foldable wiring harness substrate (210, 310, 410) supporting the wiring harness (120, 220, 320, 420), the wiring harness substrate (210, 310, 410) having a plurality of retention features (214) and a plurality of wire channels (228), the retention features (214) securing the electrical connectors (122, 222) to the wiring harness substrate (210, 310, 410) and the wire channels (228) receiving the electrical wire segments therein and routing them over the wiring harness substrate (210, 310, 410), the wiring harness substrate (210, 310, 410) being configured to be selectively transitioned between an expanded state and a packed state; wherein each of the retention features (214) comprises a retention tab (214') formed integrally with the foldable harness substrate (210, 310, 410) and wrapped around a corresponding portion of one of the electrical cable segments (224) proximate one of the electrical connectors (222). [2] The wiring harness substrate system (200, 300, 400) of claim 1, wherein the foldable wiring harness substrate (210, 310, 410) includes an insulated and bendable substrate plate (212, 312, 412A-412D) that, when in the expanded state, is substantially flat and elongated. [3] The wiring harness substrate system (200, 300, 400) of claim 2, wherein the substrate plate (212, 312, 412A-412D) is formed from a corrugated paper material, a fabric material, a carpet material, and / or a polymeric sheeting material. [4] The wire harness substrate system (200, 300, 400) of claim 2, wherein the substrate plate (212, 312, 412A-412D) includes a plurality of fold lines (211, 311, 411) arranged together in a predefined pattern to enable the foldable wire harness substrate (210, 310, 410) to be selectively bent into the packed state. [5] The wiring harness substrate system (200, 300, 400) according to claim 4, wherein each of the fold lines (211, 311, 411) comprises a straight scored portion, a straight slit portion, or a straight reduced thickness portion of the substrate plate (212, 312, 412A-412D). [6] The wiring harness substrate system (200, 300, 400) of claim 1, further comprising a plurality of cable stiffeners (230) attached to the foldable wiring harness substrate (210, 310, 410), each of the cable stiffeners (230) receiving and structurally reinforcing a corresponding portion of one of the electrical cable segments (224). [7] The wiring harness substrate system (200, 300, 400) of claim 1, wherein the cable channels (228) are integrally formed with and embedded in the foldable wiring harness substrate (210, 310, 410). [8] The wiring harness substrate system (200, 300, 400) of claim 1, wherein the wiring harness (120, 220, 320, 420) is a vehicle wiring harness for a motor vehicle (110) having a vehicle body / chassis (114), and wherein the cable channels (228) are arranged in a predefined routing pattern that matches a vehicle-specific routing pattern in which the vehicle wiring harness (120, 220, 320, 420) is mounted on the vehicle body / chassis (114). [9] The wire harness substrate system (200, 300, 400) of claim 1, wherein the foldable wire harness substrate (210, 310, 410) is substantially flat and has a cross-shaped profile in plan view when in the expanded state, and is polyhedral with a box shape when in the packaged state.

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