Cable harness and cable harness manufacturing processes

Abstract

Wiring harness (10), comprising: a functional external component (30) in the form of a flat element; at least one electrical conductor (12) arranged on a main surface (31a) of the functional outer component (30); and at least one thread (40) with which the electrical conductor (12) is sewn onto the functional outer component (30), characterized in that the functional outer component (30) comprises a heat-radiating component capable of radiating heat from the electrical conductor (12), and wherein a high emissivity section is formed on a surface of the heat-radiating component, wherein the high emissivity section has a higher emissivity than an inner section of the heat-radiating component.

Description

TECHNICAL AREA

[0001] The present invention relates to a technology for attaching electrical conductors to an external component of a wiring harness for vehicles. TECHNICAL BACKGROUND

[0002] JP 2015 - 72 798 A discloses - for attaching a flat element-shaped external component to electrical conductors - a technology for positioning the external component with respect to the electrical conductors by wrapping a tape around the end sections of the external component and the electrical conductors protruding from the end sections.

[0003] US 8,646,397 B2 discloses a method and apparatus for manufacturing a flat wire harness with individual wires in a predetermined orientation. The wires are positioned in grooves in a flat mold, the grooves having the predetermined orientation and the mold having connected thread openings extending through and across the grooves. The wires in the grooves are sewn together by a sewing machine programmed to pass a needle and thread through the openings in the mold to produce the flat wire harness with the individual wires in the predetermined orientation.

[0004] US 5,965,951 A discloses the installation of a wiring harness and a carpet as a modular combination that reduces the required assembly steps for a vehicle. The wiring harness can be attached to the underside of a carpet in any configuration to form the modular combination. Once the modular combination is complete, it is installed in a vehicle.

[0005] KR 10 2014 0 099 793 A discloses a flat element to which an electrical conductor is sewn by means of a thread. OVERVIEW OF THE INVENTION TASKS TO BE SOLVED BY THE INVENTION

[0006] Various components are used as external components in a vehicle wiring harness, each with one or more functions such as sound insulation (sound attenuation, sound absorption, soundproofing, etc.), protection (abrasion resistance, tensile strength, etc.), heat dissipation, shielding, and / or sealing against water, etc. If these various components have different structures for attaching them to electrical wires, the number of processing methods increases accordingly.

[0007] The present invention is based on the objective of providing a structure that is equally applicable to the attachment of electrical conductors to different external components. MEANS OF SOLVING THE TASK

[0008] To solve the problem, a cable harness according to a first aspect has the features of claim 1.

[0009] A cable harness according to a second aspect is the cable harness according to the first aspect, wherein the functional external component includes a sound insulation component with sound insulation properties.

[0010] A cable harness according to a third aspect is the cable harness according to the first or second aspect, wherein the functional outer component has a shielding component capable of shielding the electrical conductor.

[0011] A cable harness according to a fourth aspect is the cable harness according to one of aspects one to three, wherein the functional outer component has a protective component capable of protecting the electrical conductor from abrasion, wherein the protective component has abrasion resistance.

[0012] A cable harness according to a fifth aspect is the cable harness according to one of aspects one to four, wherein the functional external component serves as a tensile element that is subject to a tensile force exerted on the electrical conductor.

[0013] A wiring harness according to a sixth aspect is the wiring harness according to one of aspects one to five, wherein the functional outer component is water-repellent and covers the electrical conductor as well as a section onto which the electrical conductor is sewn.

[0014] A wiring harness according to a seventh aspect is the wiring harness according to one of aspects one to six, wherein a fastening component for attaching the electrical line to a mounting object is sewn onto the functional outer component.

[0015] A wiring harness according to an eighth aspect is the wiring harness according to one of the aspects one to seven, wherein the thread with which the electrical conductor is sewn is a single thread.

[0016] A wiring harness according to a ninth aspect is the wiring harness according to one of aspects one to eight, wherein the at least one thread with which the electrical conductor is sewn comprises an upper thread and a lower thread.

[0017] According to a tenth aspect, a method for manufacturing a cable harness is a method which has the features of claim 10.

[0018] According to an eleventh aspect, a method which has the features of claim 11. EFFECT OF INVENTION

[0019] According to aspects one through eleven, the electrical conductor is sewn to the outer component with thread. This structure can be applied equally to attaching electrical conductors to various outer components. Furthermore, the heat from the electrical conductor can be easily radiated. Moreover, the heat radiation effect can be enhanced.

[0020] In particular, according to the second aspect, a sound insulation structure can be easily achieved.

[0021] In particular, according to the third aspect, the electrical line can simply be shielded.

[0022] In particular, according to the fourth aspect, the electrical wiring can be easily protected.

[0023] In particular, according to the fifth aspect, the electrical conductor is hardly damaged even when tensile force is applied to the cable harness.

[0024] In particular, according to the sixth aspect, the electrical line can easily be protected or sealed against water.

[0025] In particular, according to the eleventh seventh aspect, the fastening component can be easily attached.

[0026] In particular, according to the eighth aspect, the electrical conductor can be sewn on with a minimal number of threads.

[0027] In particular, according to the ninth aspect, it is not necessary to avoid using the electrical wire as either the top or bottom thread. Therefore, an electrical wire that would be difficult to use as a top or bottom thread, for example, a thick wire, can simply be sewn on.

[0028] In particular, according to the tenth aspect, the electrical wiring can be sewn onto the functional outer component. Since sewing machines are readily available, the wiring harness can be easily manufactured.

[0029] In particular, according to the eleventh aspect, the electrical wiring can be sewn onto the functional outer component. Since sewing machines are readily available, the wiring harness can be easily manufactured. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 illustrates a perspective view of a cable harness according to embodiment 1. Fig. Figure 2 illustrates a schematic cross-sectional view of the cable harness according to embodiment 1. Fig. Figure 3 illustrates the steps for manufacturing the wiring harness according to embodiment 1. Fig. Figure 4 illustrates the steps for manufacturing the cable harness according to embodiment 1. Fig. Figure 5 illustrates the steps for manufacturing the cable harness according to embodiment 1. Fig. Figure 6 illustrates the steps for manufacturing the cable harness according to embodiment 1. Fig. Figure 7 illustrates a schematic perspective view of a cable harness according to embodiment 2. Fig. Figure 8 illustrates an enlarged partial view of a cable harness according to embodiment 3. Fig. Figure 9 illustrates a schematic cross-sectional view of a cable harness according to embodiment 4. Fig. Figure 10 illustrates a schematic cross-sectional view of a cable harness according to embodiment 5. Fig. Figure 11 illustrates a schematic top view of a cable harness according to embodiment 6. Fig. Figure 12 illustrates a schematic cross-sectional view of the cable harness in section along line XII-XII. Fig. 11. Fig. Figure 13 illustrates the steps for manufacturing the wiring harness according to embodiment 6. Fig. Figure 14 illustrates a schematic top view of a modification of the cable harness according to embodiment 6. Fig. Figure 15 illustrates a schematic cross-sectional view of the cable harness in section along line XV-XV. Fig. 14. Fig. Figure 16 illustrates a schematic cross-sectional view of a modification of a functional external component. Fig. Figure 17 illustrates a schematic overview of a further modification of the functional outer component. Fig. Figure 18 illustrates a schematic perspective view of a further modification of the cable harness according to embodiment 6. EXECUTIONS OF THE INVENTION Execution form 1

[0030] A cable harness according to embodiment 1 will now be described. Fig. Figure 1 illustrates a perspective view of a cable harness 10 according to embodiment 1. Fig. Figure 2 illustrates a schematic cross-sectional view of the cable harness 10 according to embodiment 1. It should be noted that Fig. Figure 2 shows a cross-sectional view of the cable harness 10 in a section plane along the direction of electrical lines 12.

[0031] The wiring harness 10 is used as wiring for the electrical connection of various electrical devices, such as those installed in a vehicle. The wiring harness 10 is routed around or along, for example, a dashboard, roof, or door in the vehicle. Specifically, the wiring harness 10 comprises a functional external component 30, electrical wires 12, and stranded wires 40. The wiring harness 10 also includes connectors 20 and fastening components 50.

[0032] The functional outer component 30 has the form of a flat element (a panel, plate, layer, film, sheet, sheet, or sheet metal, or a planar extended flat element). In the Fig. In the illustrated example 1, the functional outer component 30 has the form of a rectangular flat element. The shape of the functional outer component 30 is not limited to the aforementioned shape, but can be suitably modified, for example, according to the placement of the electrical conductors 12. The functional outer component 30 is a component with which the electrical conductors 12 are covered or will be covered. The functional outer component 30 is a component that has one or more functions for the electrical conductors 12, such as sound insulation (sound attenuation, sound absorption, soundproofing, etc.), protection (abrasion resistance, tensile strength, penetration resistance, etc.), heat dissipation, shielding, and / or sealing against water, etc.A suitable function of the functional outer component 30 is selected, for example, according to the properties of the electrical conductors 12 and the environment of the section in which the electrical conductors 12 are arranged. Since the electrical conductors 12 are arranged in a section that can chafe against surrounding components, an example is described in which the functional outer component 30 is an abrasion-resistant protective flat element (a protective component).

[0033] The protective flat element is made from a flat element material such as polyvinyl chloride (PVC), polypropylene (PP), or a nonwoven fabric. If the protective flat element is made from a nonwoven fabric, it may, for example, be hot-pressed. As a result, the protective flat element may be hardened. The abrasion resistance of the protective flat element can result from the physical properties of its structure or from the physical properties of the raw material. While the protective flat element is in the Fig. As illustrated in the first example, a structure with protrusions and indentations can also be applied to an outer surface of the protective flat element to increase its abrasion resistance. In another example, the protective flat element can be hardened by applying a structure made of hot-pressed nonwoven fabric, thereby increasing its abrasion resistance. In yet another example, the abrasion resistance can be increased by using a hard raw material for the protective flat element.

[0034] The electrical conductors 12 are arranged on a main surface 31a of the functional outer component 30. The number of electrical conductors 12 can be at least one. In this case, the number of electrical conductors 12 is two or more (two in the Fig. 1 illustrated example). In the present case, the description is based in particular on the fact that insulated electrical cables 12, each with a conductor 14 and an insulating sheath 16 for sheathing the conductor 14, are used as electrical lines 12 (see Fig. 9) The conductor 14 is made of a conductive material such as copper or aluminum. The conductor 14 can be a solid conductor or a stranded wire. The insulating sheath 16 can be formed, for example, by extruding a plastic material around the conductor 14 or, for example, by applying wire enamel all around the conductor 14 and oven-drying the enamel. Bare conductors 14, or bare wire, can be used as electrical conductors 12.

[0035] If a manufacturing process is used, for example, in which a sewing machine is employed, the electrical conductors 12 preferably have a high tensile strength, which will be described in detail later. The electrical conductors 12 are preferably thin. In view of this, signal conductors, which are comparatively thin, are more suitable as electrical conductors 12 than power supply conductors, which tend to be comparatively thick.

[0036] The ends of the electrical conductors 12 are connected to the connectors 20. When the wiring harness 10 is installed at a designated location in a vehicle or the like, the connectors 20 are connected to connectors of the various electrical devices installed in the vehicle. Accordingly, the wiring harness 10 is used as wiring for the electrical connection of the various electrical devices installed in the vehicle.

[0037] Here, the connectors 20 are also sewn onto the functional outer component 30. The connector housings 21 of the connectors 20 have holes 22 or recesses or the like, by means of which the connector housings 21 are sewn onto the functional outer component 30. The holes 22 or the recesses can be existing components, such as those formed on snap-in sections or cassette sections, or they can be new, purpose-built components. It is not necessary to sew the connectors 20 onto the functional outer component 30. The connector 20 can also be attached to the functional outer component 30 by other means, such as adhesive tape or glue, but this is not required.

[0038] As in Fig. As illustrated in Figure 2, the connectors 20 are insulation displacement connectors (IDCs). Specifically, each connector housing 21 has a first component 23 and a second component 24, which can be inserted into the first component 23. The first component 23 can hold an IDC contact 26, with an IDC part 27 exposed to the outside. The IDC part 27 is part of the IDC contact 26 and can be connected to the insulated electrical conductors 12 by pressure. The first component 23 also houses a partner connector 28, which can be connected to a partner conductor. The partner connector 28 is part of the insulation displacement contact 26. The second component 24 is arranged opposite a section of the first component 23 to hold the insulation displacement part 27 and can press the insulated electrical conductors 12 towards the insulation displacement part 27.The second component 24 pushes the insulated electrical conductors 12 towards the insulation displacement connector 27, while the unstripped electrical conductors 12 are located on the insulation displacement connector 27 of the insulation displacement contact 26, which is held by the first component 23. As a result, part of the insulation displacement connector 27 breaks open the insulation sheath of the insulated electrical conductors 12 in such a way that it rests against and connects with the conductor 14.

[0039] Here, both electrical conductors 12 are connected to the threads 40 from the in Fig. The illustrated example is sewn onto the functional outer component 30. If the number of electrical wires 12 contained in the wiring harness 10 is two or more, the electrical wires 12 may include electrical wires 12 that are not sewn onto the functional outer component 30.

[0040] The two electrical lines 12 are in the Fig. The illustrated example shows the wires connected with the same connectors 20. If the number of electrical wires 12 contained in the wiring harness 10 is two or more, the electrical wires 12 can include electrical wires 12 connected with different connectors 20.

[0041] The electrical lines 12 are in the Fig. The illustrated example shows the electrical conductors arranged linearly. The electrical conductors 12 can be curved. If the number of electrical conductors 12 contained in the wiring harness 10 is two or more, both linearly arranged and curved electrical conductors 12 can be present simultaneously. In this case, the multiple electrical conductors 12 can have branches on the functional outer component 30.

[0042] The electrical lines 12 are in the Fig. In the illustrated example, the electrical conductors 12 are arranged closer to the center of the functional outer component 30 in the lateral direction. The path along which the electrical conductors 12 are arranged with respect to the functional outer component 30 is not limited to that described above. For example, the electrical conductors 12 can be arranged closer to one end of the functional outer component 30 in the lateral direction. The electrical conductors 12 can, for example, run diagonally to the functional outer component 30.

[0043] The electrical conductors 12 are sewn to the functional outer component 30 with the threads 40. The threads 40 are preferably components that are more flexible than the electrical conductors 12. The thread 40 preferably has a tensile strength that is greater than that of the electrical conductors 12. The thread 40 can be made of a natural fiber or a synthetic fiber. The thread 40 can be a single yarn or a twisted yarn.

[0044] If the thread 40 can lie against the surrounding components while installed in a vehicle, the thread 40 preferably has an abrasion resistance that corresponds, for example, to that of a fishing line made of nylon or polyester.

[0045] As in Fig. As illustrated in Figure 2, a single continuous thread 40 is used to sew on a single electrical conductor 12, and the electrical conductor 12 is sewn on at several points along its direction of travel using the single continuous thread 40. The single continuous thread 40 runs along another principal surface 31b of the functional outer component 30 and passes section by section through the first principal surface 31a of the functional outer component 30 to form a loop 85. The electrical conductor 12 is then threaded through the loop 85 such that the electrical conductor 12 is sewn on.

[0046] It is not necessary to sew the electrical conductor 12 with a single continuous thread 40. Thus, at several sections along the direction of travel of the electrical conductor 12, the thread 40 can exist, with which the electrical conductor 12 is sewn section by section at a respective position and which is then cut off at both ends.

[0047] The fastening components 50 are components for attaching the electrical conductors 12 to a mounting object 70, such as a body panel or a rod component. The fastening components 50 are also sewn onto the functional outer component 30. The fastening components 50 are components referred to as clamps, clamps, or clips, and each comprises a column part 54 and a wing part 56 extending from the tip of the column part 54.

[0048] The fastening components 50, for example, have holes 52 or recesses by means of which the fastening components 50 are sewn onto the functional outer component 30. The holes 52 or the recesses can be existing components or new, purpose-built components.

[0049] In the Fig. In the illustrated example 2, the fastening components 50 are attached such that they protrude from one main surface 31a, on which the electrical conductors 12 are arranged. The fastening components 50 allow the electrical conductors 12 to rest against the mounting object 70 and can radiate the heat of the electrical conductors 12 via the mounting object 70. If the mounting object 70 is a component that can protect the electrical conductors 12, the mounting object 70 can protect one side of the electrical conductors 12, whereas the functional outer component 30 can protect the other side of the electrical conductors 12. The fastening components 50 can also be attached such that they protrude from the other main surface 31b. Manufacturing process

[0050] Next, we will use the following as an example: Fig. 3, Fig. 4, Fig. 5 to Fig. 6 a method for manufacturing the cable harness 10 according to embodiment 1 is described. Fig. 3, Fig. 4, Fig. 5 to Fig. Figure 6 illustrates the steps for manufacturing the cable harness 10 according to embodiment 1.

[0051] First, the functional outer component 30, the electrical conductor 12, the thread 40, and a needle 80 are prepared. A needle 80 with an eye 82 is used. The eye 82 is provided at the tip of the needle 80. The thread 40 is threaded through the eye 82 as the upper thread 84.

[0052] Next, as in Fig. As illustrated in Figure 3, the needle 80 with the eye 82, through which the upper thread 84 is threaded, is inserted from the other main surface 31b into the functional outer component 30 (step (a)). As a result, part of the upper thread 84 emerges together with the needle 80 through one main surface 31a.

[0053] Next, the loop 85 is formed from the upper thread 84, which has passed through the first main surface 31a (step (b)). For example, after the needle 80, as in Fig. As illustrated in Figure 4, a part or section of the upper thread 84, which together with the needle 80 has passed through the first main surface 31a, has returned to the other main surface 31b, on the first main surface 31a to form the loop 85.

[0054] Next, the electrical conductor 12, serving as the lower thread 86, is threaded through the loop 85 (step (c)). As in Fig. As illustrated in Figure 5, the loop 85 is first widened. Then the loop 85 is guided around a bobbin 90, in which the wound lower thread 86 is housed, in such a way that the bobbin 90 can pass through the loop 85.

[0055] Then, as in Fig. Figure 6 illustrates how the loop 85 is narrowed to thread the lower thread 86 through the loop 85. This completes the sewing on of the electrical conductor 12 in the section.

[0056] By repeating the same processes while the functional outer component 30 is transported, the single electrical conductor 12 can be sewn continuously with the single thread 40.

[0057] Then the connectors 20 and the fastening components 50 are sewn onto the outer component 30, onto which the electrical wires 12 have been sewn. They can also be sewn on before the electrical wires 12. After the connectors 20 and the electrical wires 12 have been sewn on, the ends of the electrical wires 12 are connected with the insulation displacement connectors 20. As a result, the wiring harness 10 is complete.

[0058] The sewing step in the manufacturing process can be performed by a sewing machine or by hand. Using a sewing machine allows part of the step to be automated.

[0059] When the sewing machine is used, a known rotating hook in the sewing machine performs a process in which the loop 85 is rotated around the bobbin 90 and simultaneously the loop 85 is expanded. By keeping the upper thread 84 less taut than the lower thread 86, it is possible to prevent the electrical conductor 12, which serves as the lower thread 86, from being pulled by the upper thread 84 towards the other main surface 31b of the functional outer component 30.

[0060] According to the cable harness 10 structured as above and its manufacturing process, the electrical conductors 12 are sewn to the functional outer component 30 with the thread(s) 40. This structure can be applied equally to attaching electrical conductors 12 to the various functional outer components 30. Since a sewing machine is available for the sewing step, the cable harness 10 can be manufactured easily.

[0061] Since the functional outer component has an abrasion resistance of 30, the electrical lines can be easily protected.

[0062] Since the fastening components 50 for attaching the electrical lines 12 to the mounting object are also sewn onto the functional outer component 30, the fastening components 50 can be easily attached.

[0063] Since the connectors 20 provided at the ends of the electrical lines 12 are also sewn onto the functional outer component 30, the connectors 20 can be easily positioned. Design 2

[0064] Next, a cable harness 110 according to embodiment 2 is described. Fig. Figure 7 illustrates a schematic perspective view of the cable harness 110 according to embodiment 4. In the following description of the embodiments, components that are identical to those described above bear the same reference numerals, and their description is omitted.

[0065] The cable harness 110 according to embodiment 2 differs from the cable harness 10 according to embodiment 1 in that a functional external component 130 is a shielding component with shielding properties.

[0066] The shielding component is formed, for example, from a metal foil, a metal mesh, a laminate of a metal foil and a plastic layer, or a flat element or film material made of a conductive plastic. The metal foil can be used if the needle 80 can penetrate the shielding component that incorporates the metal foil. If, for example, the metal mesh is used, the needle 80 can be inserted into holes provided in the mesh, or it can penetrate a metallic section of the mesh. In this case, the shielding component is flexible enough to be wrapped around the electrical conductors 12. The shielding component covers the area around the electrical conductors 12, with the electrical conductors 12 being sewn onto the shielding component. This allows the shielding component to shield the electrical conductors 12 within it.The shielding component has fixing pieces 132, each with a screw hole 134. The shielding component is grounded by fixing the fixing pieces 132 to, for example, a body panel with screws. The grounding method can include routing a discharge conductor located at the shielding component, or a portion of the electrical conductors 12 sewn onto the shielding component can be used as a discharge conductor.

[0067] The electrical lines 12 can be easily shielded in the cable harness 110 with such a structure. embodiment 3

[0068] Next, a cable harness 210 according to embodiment 3 is described. Fig. Figure 8 illustrates an enlarged partial view of the cable harness 210 according to embodiment 3.

[0069] The cable harness 210 according to embodiment 3 differs from the cable harness 10 according to embodiment 1 in that a functional external component 230 is a tensile member which is subject to the tensile force exerted on the electrical lines 12.

[0070] For example, a flat element material that is less stretchable than the electrical conductors 12 is used as the functional outer component 230, and the part of the electrical conductors 12 that is sewn onto the functional outer component 230 is, as in Fig. As illustrated in Figure 8, the electrical conductors 12 are arranged slackly or with a slack length. For example, in a section between adjacent seams, the electrical conductors 12 are arranged slackly or with a slack length. This allows the functional outer component 230 to withstand the tensile force exerted on the cable harness 210 along the direction of travel of the electrical conductors 12. Consequently, excessive tensile force on the electrical conductors 12 can be avoided.

[0071] Even when the tensile force is exerted on the cable harness 210 with such a structure, the electrical lines 12 are hardly damaged. Design 4

[0072] Next, a cable harness 310 according to embodiment 4 is described. Fig. Figure 9 illustrates a schematic cross-sectional view of the cable harness 310 according to embodiment 4. It should be noted that Fig. Figure 9 shows a cross-sectional view of the cable harness 310 in a section plane perpendicular to the direction of the electrical lines 12.

[0073] The cable harness 310 according to embodiment 4 differs from the cable harness 10 according to embodiment 1 in that a functional external component 330 is a water-repellent flat element with water-repellent properties.

[0074] The water-repellent flat element is, for example, a polyethylene flat element. The water-repellent flat element is flexible enough to be wrapped around the electrical conductors 12. The water-repellent flat element covers the electrical conductors 12 and the area around the seam sections where the electrical conductors 12 are sewn onto the water-repellent flat element. This prevents, for example, water from penetrating the interior of the water-repellent flat element. The winding end of the water-repellent flat element can be secured without gaps, for example, with adhesive tape or glue. It is not necessary for the water-repellent flat element to completely cover the electrical conductors 12 and the area around the seam sections. The water-repellent properties can be improved by filling the seam holes of the water-repellent flat element with a waterproofing agent.

[0075] The electrical lines 12 can be easily protected against water in the wiring harness 310 with such a structure. Design 5

[0076] Next, a cable harness 410 according to embodiment 5 is described. Fig. Figure 10 illustrates a schematic cross-sectional view of the cable harness 410 according to embodiment 5.

[0077] The cable harness 410 according to embodiment 5 differs from the cable harness 10 according to embodiment 1 in that a functional outer component 430 is wound around the electrical conductors 12 and a fastening component 450 maintains the wound state.

[0078] In the functional outer component 430, a through hole 432 can be formed into which a fastening section of the fastening component 450 can be inserted; the through hole 432 can be formed in a section that overlaps a section in which the fastening component 450 is provided.

[0079] The wound state of the functional external component 430 can be easily maintained in the cable harness 410 with such a structure. Design 6

[0080] Next, a cable harness 510 according to embodiment 6 is described. Fig. Figure 11 illustrates a schematic top view of the cable harness 510 according to embodiment 6. Fig. Figure 12 illustrates a schematic cross-sectional view of the cable harness 510 in section XII-XII from Fig. 11. Fig. Figure 13 illustrates the steps for manufacturing the wiring harness according to embodiment 6.

[0081] The cable harness 510 according to embodiment 6 differs in the manner in which the electrical conductors 12 are sewn on from the cable harness 10 according to embodiment 1.

[0082] Specifically, in the wiring harness 10 according to embodiment 1, the electrical conductor 12 is sewn on with the single thread 40. The electrical conductor 12 is sewn as the bobbin thread 86, which is a machine sewing thread.

[0083] In the wiring harness 510 according to embodiment 6, the electrical conductor 12 is sewn on with threads 540, which comprise an upper thread 584 and a lower thread 586. The upper thread 584 and the lower thread 586, which are machine sewing threads, are thus provided separately from the electrical conductor 12. The electrical conductor 12 is sewn onto the functional outer component 30 with the upper thread 584 and the lower thread 586 as the threads 540.

[0084] The upper thread 584 and the lower thread 586 are sewn into the functional outer component 30 with offset (zigzag) stitches. The electrical conductor 12 is arranged between seam points S, which are spaced apart and run horizontally, such that it is positioned, clamped, or sewn between the functional outer component 30 on one side and either the upper thread 584 or the lower thread 586 on the other side.

[0085] A method for manufacturing such a cable harness comprises the following steps (a) and (b).

[0086] Step (a) is a step to arrange the electrical conductor 12 on the first principal surface 31a of the functional outer component 30. For example, a guide component 594 guides the electrical conductor 12, which is wound and housed in a coil 592, to the first principal surface 31a of the functional outer component 30, as shown in Fig. Figure 13 illustrates this. For example, a known guide component for guiding a belt to a surface of an object to be sewn can be used as guide component 594 in an embroidery sewing machine.

[0087] Step (b) is a step for sewing the upper thread 584 and the lower thread 586 onto the functional outer component 30, wherein the electrical conductor 12 is positioned, clamped, or sewn between the upper thread 584 and / or the lower thread 586 on one side and the first main surface 31a of the functional outer component 30 on the other side. The upper thread 584 and the lower thread 586 are sewn with offset stitches, wherein the electrical conductor 12 is guided through the guide component 594 to the first main surface 31a of the functional outer component 30, and wherein the electrical conductor 12, the functional outer component 30, and the sewing machine body with the needle 80 are moved in a transport direction and in a horizontal direction relative to each other.

[0088] Since, according to this aspect, it is not necessary to use the electrical conductor 12 as the upper thread 584 or as the lower thread 586, an electrical conductor 12 can simply be sewn on that would be difficult to use as the upper thread 584 or lower thread 586, for example a thick conductor such as a power supply conductor.

[0089] Since the coil 592 does not need to pass through any loops to wind and accommodate the electrical conductor 12, the coil 592 can be larger. The electrical conductor 12 to be sewn can simply be longer.

[0090] If, as described, the upper thread 584 and the lower thread 586 are provided separately from the electrical conductor 12, and the electrical conductor 12 can be sewn to the functional outer component 30 with the upper thread 584 and the lower thread 586, then the method of sewing with the upper thread 584 and the lower thread 586 is not limited to offset stitches. For example, an upper thread 584A and a lower thread 586A can be used as in a cable harness 510A according to a Fig. 14 and Fig. 15 illustrated variations can be sewn.

[0091] Specifically, the cable harness 510A, according to the modification, has seams S in an area of ​​the functional outer component 30 that overlaps with the electrical conductor 12. At least one section between the adjacent seams S in the upper thread 584A or lower thread 586A (in which in Fig. 14 and Fig. In the illustrated example 15, the upper thread 584A is wound around the electrical conductor. To carry out such a sewing process, the electrical conductor 12 or the guide component 594 for guiding the electrical conductor 12 can be offset horizontally relative to the needle 80 when forming the seams S1 and S2. Since the other of the two threads consists of upper thread 584A and lower thread 586A (in which in Fig. 14 and Fig. As illustrated in example 15, the lower thread 586A) is not wound around the electrical conductor 12, this other thread runs parallel to the electrical conductor 12.

[0092] Since a thread for securing the electrical conductor 12 (here the upper thread 584A) in the wiring harness 510A can be wound around an area corresponding to at least half the length of the electrical conductor 12, specifically an area almost a full circle, the electrical conductor 12 is hardly displaced horizontally on the functional outer component 30. Since there is hardly any gap between the thread for securing the electrical conductor 12 (here the upper thread 584A), the electrical conductor 12, and the functional outer component 30, the thread for securing the electrical conductor 12 (here the upper thread 584A) hardly gets caught in the surrounding components. Variations

[0093] Although embodiment 1 describes the protective flat element as having abrasion resistance, this is not necessary. The protective flat element can also have penetration resistance. It is sufficient if the protective flat element has a penetration resistance sufficient for use in a vehicle environment. The needle 80 used to sew the electrical conductor 12 onto the protective flat element can be inserted into the protective flat element with a penetration force exceeding the penetration resistance.

[0094] Although embodiment 1 describes the functional outer component 30 as a protective flat element, this is not necessary. The functional outer component 30 can also be a sound-insulating flat element (a sound-absorbing component). For example, the sound-absorbing flat element could be a flat element component made of a nonwoven fabric or a foamed plastic. If the functional outer component 30 is a sound-absorbing flat element, a structure is conceivable in which the sound-absorbing flat element encloses the electrical conductors 12 sewn onto the functional outer component 30. This can improve the sound insulation properties.The sound-insulating flat element can be folded to enclose the electrical conductors 12, or the electrical conductors 12 can be surrounded on one side by a first sound-insulating flat element on which the electrical conductors 12 are sewn, and on the other side by another sound-insulating flat element that is provided separately from the first sound-insulating flat element.

[0095] Embodiment 2 describes that the functional outer component 130 is made of a metal; however, the functional outer component 130 made of a metal can also be used not as a shielding component, but as a heat-radiating component. If the functional outer component 130 is used as a heat-radiating component, it is conceivable that the functional outer component 130 and the electrical conductor 12 are in contact with each other at least in a partial area and that at least a partial area of ​​the functional outer component 130 is exposed on the outside.

[0096] If the functional outer component 130 is used as a heat-radiating component, metals are generally superior with respect to thermal conductivity, but inferior with respect to emissivity. Therefore, on the surfaces of the functional outer component 130, as shown in Fig. As illustrated in Figure 16, sections 138 with high emissivity are formed. These high-emissivity sections 138 have an emissivity greater than that of an inner section 137.

[0097] According to Wien's displacement law, the peak wavelength of light emitted by an object through thermal radiation is inversely proportional to the object's temperature. It is also known that the same material can exhibit different emissivity values ​​depending on the object's temperature (wavelength of the light). Since it is desirable to increase the emissivity of the wiring harness 110 mounted on a vehicle, the high-emissivity sections 138 can have a higher emissivity corresponding to the peak wavelength in a high-temperature zone generated in the vehicle's operating environment.

[0098] To form the high-emissivity sections 138, the surfaces of the functional outer component 130 are subjected to a surface treatment to increase emissivity. The high-emissivity sections 138 are, for example, oxide films formed by oxidation of the metal surfaces of the inner section 137. The high-emissivity sections 138 can be, for example, clad sections or painted sections that have undergone a plating or painting process on the surface of a component forming the inner section 137. The paint used in the painting process can, for example, be a synthetic resin.

[0099] In the Fig. In the illustrated example 16, the high-emissivity sections 138 are formed on both main surfaces of the functional outer component 130; however, the high-emissivity section 138 can also be formed on only one of the main surfaces. If the high-emissivity section 138 is formed on only one of the main surfaces of the functional outer component 130, it can be formed on the main surface on which the electrical conductors 12 are arranged or on the main surface opposite it. The high-emissivity section 138 can be formed over the entire area of ​​the main surface of the functional outer component 130 or only on a portion thereof. If the high-emissivity section 138 is formed on only a portion of the main surface of the functional outer component 130, it can—but does not have to—be formed on a section in which the electrical conductors 12 are arranged.The high-emissivity section 138 can preferably be formed on an outward-facing plane of the functional outer component 130. If the high-emissivity section 138 is formed on a section of the functional outer component 130 where heat dissipation by conduction or convection is not expected when the wiring harness 110 is mounted on a vehicle, then the heat dissipation from this section via the high-emissivity section 138 is more effective.

[0100] Designing the section with high emissivity enables more efficient heat radiation. Since the temperature rise of the electrical conductors 12 can be kept small, the electrical conductors 12 can be made smaller. Because the heat storage requirement decreases with increasing heat radiation from the functional outer component 130, the functional outer component 130 can be made thinner.

[0101] The functional outer component 30 can have different tensile strengths in a first direction and a second direction, which are perpendicular to each other and run in the direction of propagation of the main surface of the functional outer component 30. The direction with greater tensile strength is preferably the same as the direction of travel of the electrical conductors 12 in the functional outer component 30. This is because, when the wiring harness 10 is mounted on a vehicle, the functional outer component 30 can be pulled more in the direction of travel of the electrical conductors 12 than in a direction perpendicular to the direction of travel of the electrical conductors 12, and the tensile force is greater in the first case than in the second case.By aligning the direction of the higher tensile strength with the direction of the electrical conductors 12, the wiring harness 10 is hardly damaged even when subjected to strong tension in its direction of travel; this is a key advantage for easy installation of the wiring harness 10 on the vehicle. The functional outer component 30 with such an anisotropy of tensile strength is suitable, for example, as a functional outer component 230 according to embodiment 3, which can be used as a tensile element.

[0102] The functional outer component 30 can be any material, as long as the tensile strength differs between the first and second directions. The material and manufacturing process, etc., are irrelevant. A functional outer component 30 with differing tensile strength in the first and second directions can be obtained by drawing a flat element material formed by extrusion, such as a uniaxially oriented or biaxially oriented film, during manufacturing. Fiber-reinforced nonwovens, such as spunlaid nonwovens, typically exhibit high tensile strength in the longitudinal fiber direction.

[0103] As in Fig. As illustrated in Figure 17, the functional outer component 30 can, for example, have an additional shape with different tensile strength in the first and second directions. In the case of the Fig. Figure 17 illustrates that changing the shape of compressed sections 638 results in different tensile strengths for a functional outer component 630. Specifically, after undergoing a compression process such as embossing, the functional outer component 630 exhibits compressed sections 638 that are more compressed than a surrounding section 637. In this case, the compressed sections 638 are elongated, for example, as rectangles or ovals. The tensile strength of the compressed sections 638 in the longitudinal direction is then greater than the tensile strength of the compressed sections 638 in the transverse direction.

[0104] In the Fig. In the illustrated example 17, several compressed sections 638 are configured such that they are arranged side by side in the vertical and horizontal directions of the image plane of the figure. The several compressed sections 638 are oriented the same way in both directions. Specifically, the several compressed sections 638 are arranged side by side such that their transverse direction coincides with the vertical direction of the image plane. The several compressed sections 638 are also arranged side by side such that their longitudinal direction coincides with the horizontal direction of the image plane. The functional outer component 630 can be located at least at one position of a section centrally located in the horizontal direction of the image plane, or at any position along the horizontal direction of the image plane as shown in the illustration. Fig. Figure 17 illustrates this, and at least in a partial area along the perpendicular direction of the image plane at that position, the compressed sections 638 are present. This is because, if the compressed sections 638 are not formed at the position of the central section of the functional outer component 630 along the horizontal direction of the image plane and along the perpendicular direction of the image plane at that position, the load is concentrated on the central section when the tensile force is applied to the functional outer component 630 in the horizontal direction of the image plane.

[0105] The functional outer component 30 can exhibit different extensibility in the first and second directions. If the electrical conductors 12 are arranged such that they run linearly in a section where the functional outer component 30 is attached, then the direction in which the functional outer component 30 is less extensible is preferably the same as the direction of travel of the electrical conductors 12. This makes it easier to maintain the linear course of the electrical conductors 12. The load component of the tensile force on the electrical conductors 12 absorbed by the functional outer component 30 is higher because the functional outer component 30 is less extensible. It can therefore be expected that it offers an advantage if the functional outer component 30 serves as a tensile element.If the functional outer component 30 is wound around the electrical conductors 12, or if the functional outer component 30 is wound around a rod component for reinforcement, with the electrical conductors 12 being placed around the rod component, then the electrical conductors 12 can be wound easily, since the electrical conductors 12 can be wound in a direction in which the functional outer component 30 is more stretchable.

[0106] If the electrical conductors 12 are arranged such that they run with a curvature in a section to which the functional outer component 30 is attached, then the direction in which the functional outer component 30 is more extensible is preferably the same as the direction of travel of the electrical conductors 12. This allows the functional outer component 30 to follow the curvature of the electrical conductors 12.

[0107] The functional outer component 30 can be any material, as long as the extensibility differs between the first and second directions. The material and manufacturing process, etc., are irrelevant. A functional outer component 30 with differing extensibility in the first and second directions can be achieved by extruding a flat element material, such as a uniaxially oriented or biaxially oriented film, during manufacturing. Fiber-reinforced nonwovens, such as spunbond nonwovens, are typically more extensible perpendicular to the fiber direction.

[0108] The functional outer component 30 can, for example, have an additional shape with different extensibility in the first and second directions. In the Fig. In the 17 illustrated example of the functional outer component 630, the compressed sections 638 with the aforementioned shape are more extensible in the perpendicular direction of the image plane than in the horizontal direction of the image plane.

[0109] Regarding the first and second directions, the direction with greater tensile strength can be the same as or different from the direction with lower elongation. The first and second directions can exhibit different tensile strengths and the same elongation, or they can exhibit the same tensile strength and different elongation.

[0110] Although the above describes sewing each of the electrical conductors 12 on with thread 40, this is not necessary. Several electrical conductors 12 can be sewn on together with thread 40. The several electrical conductors 12 can be bundled together, for example, with adhesive tape. A cable can be used that contains the several electrical conductors 12 and a sheath surrounding them.

[0111] As in Fig. As illustrated in Figure 18, the multiple electrical conductors 12 can be sewn on with the same thread 540B, running parallel to each other. In the Fig.In the illustrated example 18, no joints S are formed between the electrical conductors 12; however, it is also possible to form a joint S between the electrical conductors 12. As a result, the electrical conductors 12 are hardly displaced in the horizontal direction.

[0112] Although the application of the insulation displacement connectors 20 as connectors 20 is described above, this is not necessary. For example, the connectors can contain crimp contacts that are crimped onto the ends of the electrical conductors 12.

[0113] The structures described in the embodiments and their variations can be suitably combined as long as they are not incompatible with each other. For example, a functional outer component can be a combination of several flat element materials with different functions. REFERENCE MARK LIST 10 Wiring harness 12 electrical lines 14 leaders 16 Insulating jacket 20 connectors 21 connector housings 22 holes 23 first component 24 second component 26 Insulation clamp contact 27 Insulation clamping element 30 functional external components 31a a main area 31b other main area 40 threads 50 fastening components 52 holes 54 column section 56 Wing section 70 Assembly item 80 needles 82 ears 84 Upper thread 85 loop 86 lower thread 90 coil

Claims

[1] Wiring harness (10), comprising: a functional external component (30) in the form of a flat element; at least one electrical conductor (12) arranged on a main surface (31a) of the functional outer component (30); and at least one thread (40) with which the electrical conductor (12) is sewn onto the functional outer component (30), characterized by , that the functional external component (30) includes a heat-radiating component capable of radiating heat from the electrical conductor (12), and wherein a high emissivity section is formed on a surface of the heat-radiating component, wherein the high emissivity section has a higher emissivity than an inner section of the heat-radiating component. [2] Cable harness (10) according to claim 1, wherein the functional outer component (30) comprises a sound insulation component with sound insulation properties. [3] Cable harness (10) according to one of claims 1 to 2, wherein the functional outer component (30) has a shielding component capable of shielding the electrical conductor (12). [4] Cable harness (10) according to one of claims 1 to 3, wherein the functional outer component (30) comprises a protective component capable of protecting the electrical conductor (12) from abrasion, wherein the protective component has abrasion resistance. [5] Cable harness (10) according to one of claims 1 to 4, wherein the functional outer component (30) serves as a tensile member which is subject to a tensile force exerted on the electrical conductor (12). [6] Cable harness (10) according to any one of claims 1 to 5, wherein the functional outer component (30) is water-repellent and covers the electrical conductor (12) and a section onto which the electrical conductor (12) is sewn. [7] Cable harness (10) according to one of claims 1 to 6, wherein a fastening component (50) for fastening the electrical line (12) to a mounting object is sewn onto the functional outer component (30). [8] Cable harness (10) according to any one of claims 1 to 7, wherein the thread (40) with which the electrical conductor (12) is sewn on is a single thread. [9] Cable harness (10) according to any one of claims 1 to 8, wherein the at least one thread (40) with which the electrical conductor (12) is sewn comprises an upper thread (84) and a lower thread (86). [10] Method by which the cable harness (10) according to claim 8 is manufactured, the method comprising the steps: (a) Inserting a needle (80) into the functional outer component (30) from another principal surface (31b) of the functional outer component (30), the needle (80) having an eye (82) through which the thread (40) is passed as the upper thread (84); (b) Forming a loop (85) from the upper thread (84) which has passed through one main surface (31a); and (c) Threading the electrical conductor (12) through the loop (85) as the bobbin thread. [11] Method by which the cable harness (10) according to claim 9 is manufactured, the method comprising the steps: (a) Arranging the electrical conductor (12) on one main surface (31a) of the functional outer component (30); and (b) Sewing the upper thread (84) and the lower thread (86) onto the functional outer component (30), clamping the electrical conductor (12) between the upper thread (84) and / or the lower thread (86) on one side and the first main surface (31a) of the functional outer component (30) on the other side.

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