wiring harness

Abstract

Wiring harness (1), comprising: an electrical conductor (10) comprising a core conductor (11) and a sheathing material (12) which encloses the core conductor (11); a connector (20) attached to one end of the electrical conductor (10); and a sealing element (40) arranged between the electrical conductor (10) and the connector (20), wherein the sheathing material (12) has a thin section (12a) which is thinner than other sections of the sheathing material (12), a section of the thin section (12a) abuts the sealing element (40) in a radial direction, the sheathing material (12) has a distal non-thin section (12b) and a proximal non-thin section (12b) on the two sides of the thin section (12a) in the longitudinal direction, a first annular step surface is formed between the thin section (12a) and the distal non-thin section (12b), and a second annular step surface is formed between the thin section (12a) and the proximal non-thin section (12b), and the sealing element (40) is not in contact with one or both of the first annular step surface and the second annular step surface.

Description

TECHNICAL AREA

[0001] The present invention relates to a cable harness. TECHNICAL BACKGROUND

[0002] A wiring harness installed in an automobile or the like is known as a wiring harness comprising electrical conductors and a connector provided at the ends of the electrical conductors (see, for example, JP 2008 - 204 960 A). This connector has terminal fittings, each provided at the end of the core conductors of the electrical conductors, and a connector housing holds the terminal fittings. A sealing element is provided between the connector housing and a sheathing material of the electrical conductor, preventing liquids, such as water, from penetrating through the gaps between the connector and the electrical conductors.

[0003] JP 2010-073485A discloses an electrical conductor comprising an aluminum core conductor and a sheathing material encasing the core conductor. A connector is attached to one end of the electrical conductor. A rubber plug, acting as a sealing element, is positioned between the electrical conductor and the connector. The sheathing material features a retaining groove, which is a thin section of the sheathing material that is thinner than other sections and radially overlaps the sealing element. Specifically, a rib of the rubber plug is positioned within and fills the retaining groove. The sheathing material has a non-thin distal section and a non-thin proximal section on both sides of the retaining groove.

[0004] JP 2002-324618 A discloses a conductor comprising a core conductor and a sheathing material that encases the core conductor. A connector housing is attached to one end of the electrical conductor. Specifically, a cylindrical rubber molding is fixed to the sheathed surface of the conductor at one end by means of hot-melt adhesive. A sealing element is attached to the outer circumference of the cylindrical rubber molding. The electrical conductor, along with the rubber molding and the sealing element, is inserted into the connector housing.

[0005] DE 195 30 422 A1 discloses a cable gland in which insulated cable strands lead into a gland housing produced by overmolding. In a sealing area of ​​the cable strands, the insulation is completely removed and heat-shrink tubing is applied to the stripped cable strand. The heat-shrink tubing acts as a seal against the gland housing. OVERVIEW OF THE INVENTION TASKS TO BE SOLVED BY THE INVENTION

[0006] The sealing element of the cable harness described above is ring-shaped, and a predetermined surface pressure is generated between the sealing element and the sheathing material of the electrical conductor located inside the sealing element. This creates a seal (waterproof seal) between the sealing element and the sheathing material of the electrical conductor. At this point, the sheathing material is deformed by the surface pressure of the sealing element. However, the deterioration of the sealing element progresses due to the heat generated in the connector, and the surface pressure between the sealing element and the sheathing material of the electrical conductor can decrease, so that the sealing performance cannot be maintained.

[0007] The present invention was made to solve the above problems, and one object of this is to provide a cable harness that can maintain the sealing performance. MEANS OF SOLVING THE TASK

[0008] A wiring harness that solves the above problems is a wiring harness comprising: an electrical conductor having a core conductor and a sheathing material that encloses the core conductor; a connector attached to one end of the electrical conductor; and a sealing element arranged between the electrical conductor and the connector, wherein the sheathing material has a thin section that is thinner than other sections of the sheathing material. A portion of the thin section rests radially against the sealing element.The sheathing material has a distal non-thin section and a proximal non-thin section on the two sides of the thin section in the longitudinal direction, wherein a first annular step surface is formed between the thin section and the distal non-thin section and a second annular step surface is formed between the thin section and the proximal non-thin section, and the sealing element is not in contact with either of the first annular step surface and the second annular step surface.

[0009] Since, according to the above considerations, the sheathing material has a thin section—thinner than the other sections—on the section that overlaps the sealing element in the radial direction, the degree of deformation caused by the sealing element can be reduced compared to the case where the sealing element is attached to a different section to generate the same pressure. Even if, for example, the sealing element deteriorates due to heat generated in the connector and the surface pressure between the sealing element and the thin section (the sheathing material) decreases, the degree of deformation of the thin section caused by the sealing element is less than in the case where the sealing element is attached to a different section.This reduces the formation of a gap between the sealing element and the thin section. With this design, the sealing performance can be maintained.

[0010] In the cable harness, it is preferred that the thin section is formed by compressing part of the sheathing material inwards in the radial direction.

[0011] Since, according to the above aspect, the thin section is formed by compressing part of the sheathing material inwards in the radial direction, the thin section can be formed after the sheathing material has been extruded, for example. Accordingly, the thin section can be formed easily.

[0012] In the above cable harness, it is preferred that the thin section be provided in a position that is longitudinally spaced from one end of the sheathing material.

[0013] Since, according to the above aspect, the thin section is provided in a position that is spaced at a distance from the end in the longitudinal direction of the sheathing material, the thin section has a shape that is recessed in relation to a section of the sheathing material that is adjacent to the thin section, and thus it is possible to easily position the sealing element. ADVANTAGEOUS EFFECTS OF THE INVENTION

[0014] The sealing performance can be maintained with the cable harness according to some aspects of the present invention. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 is a schematic diagram showing a cable harness according to one embodiment. Fig. Figure 2 is a cross-sectional view around a connector of the cable harness according to the embodiment. FORMS OF EXECUTION OF THE INVENTION

[0015] One embodiment is described below with reference to the accompanying drawings. It should be noted that in the accompanying drawings, some components are exaggerated or simplified for illustrative purposes. The dimensional ratio between sections may also differ in the accompanying drawings from the actual ratio.

[0016] A in Fig. 1. The wiring harness 1 shown electrically connects two, three, or more electronic devices (devices). 2. According to the present embodiment, the wiring harness 1 electrically connects an inverter 3, which is installed in the front section of a vehicle, such as a hybrid or electric vehicle, to a high-voltage battery 4, which is installed behind the inverter 3 in the vehicle. The wiring harness 1 is routed, for example, so that it runs under the vehicle floor. The inverter 3 is connected to a wheel drive motor (not shown), which serves as a power source for propelling the vehicle. The inverter 3 generates AC power from the DC power of the high-voltage battery 4 and supplies the AC power to the motor. The high-voltage battery 4 can supply a voltage of, for example, several hundred volts.

[0017] The wiring harness 1 comprises several (two in the present embodiment) electrical conductors 10, a pair of connectors 20 attached to the two ends of the electrical conductors 10, and a protective tube 30 that completely surrounds the electrical conductors 10. One connector 20 is connected to the inverter 3, and the other connector 20 is connected to the high-voltage battery 4. The protective tube 30 can be, for example, a metal or plastic tube, a flexible corrugated tube made of plastic or the like, a waterproof rubber sheath, or a combination thereof. The protective tube 30 protects the electrical conductors 10 contained therein from, for example, flying objects and liquids.

[0018] Each electrical conductor 10 has a core conductor 11 and a sheathing material 12 that encloses the outer circumference of the core conductor 11. For example, the core conductor 11 can be a stranded conductor formed by twisting together several bare metal conductors. The core conductor 11 can be made of a metal with excellent conductivity, such as copper, a copper alloy, aluminum, or an aluminum alloy. The sheathing material 12 encloses the outer circumferential surface of the core conductor 11 over its entire circumference in a state of close contact. The sheathing material 12 is made of an insulating material, such as cross-linked polyethylene. The sheathing material 12 can be formed on the core conductor 11, for example, by extrusion (extrusion sheathing).

[0019] As in Fig.As shown in Figure 2, each connector has 20 connection fittings 21 and a connection housing 22.

[0020] The connecting fittings 21 are each connected to the ends of the electrical conductors 10. The connecting fittings 21 each have a cylindrical section 21a and a connecting section 21b. The cylindrical section 21a is crimped to the core conductor 11 of the electrical conductor 10 so that it is electrically connected to the core conductor 11 of the electrical conductor 10.

[0021] The connector housing 22, for example, is essentially tubular in shape. The connector housing 22 is made from a single plastic element.

[0022] The cable harness 1 according to the present embodiment further comprises a sealing element 40 between an inner circumferential surface 22a of the connector housing 22 and the sheathing material 12.

[0023] A rubber stopper can, for example, be used as the sealing element 40. The sealing element 40 is held in close contact between the inner circumferential surface 22a of the connector housing 22 and the sheathing material 12 over its entire circumferential direction. A retainer 50 is arranged on the side of the connector housing 22 opposite the connecting fitting 21 with respect to the sealing element 40.

[0024] Here, the sheathing material 12 has a thin section 12a, in which a section abuts the sealing element 40 in the radial direction and is thinner than other sections. The thin section 12a is formed along the entire circumferential direction of the sheathing material 12 at a position spaced apart from one end 12e of the sheathing material 12. The thin section 12a has a shape that is recessed inwards in the radial direction with respect to an outer circumferential surface 12b of the section, which is different from the thin section 12a of the sheathing material 12. Furthermore, the thin section 12a is configured such that an inner circumferential surface 12c of it is substantially in the same plane as an inner circumferential surface 12d, which is different from the thin section 12a of the sheathing material 12.The thin section 12a is formed, for example, by heating the sheathing material 12 so that it is slightly deformable, compressing it inwards in the radial direction, and then cooling it. The thin section 12a is formed before the sealing element 40 is attached to the outer circumference of the sheathing material 12.

[0025] The operating mode of the present embodiment will be described next.

[0026] The cable harness 1 of the present embodiment has a thin section 12a, which is thinner than other sections, on a section of the sheathing material 12 that overlaps (behind) the sealing element 40 in the radial direction. With this design, even when pressure is exerted by the sealing element 40 towards the side of the sheathing material 12 (inwards in the radial direction), the degree of deformation of the thin section 12a due to the pressure from the sealing element 40 is reduced because the degree of deformation of the thin section 12a is limited compared to the degree of deformation of the section of the sheathing material 12 that differs from the thin section 12a.

[0027] The effects of the present embodiment will be described next. (1) Because the sheathing material 12 has the thin section 12a, which is thinner than other sections, on the section that overlaps the sealing element 40 in the radial direction, the degree of deformation due to the sealing element 40 is reduced compared to a case in which the same pressure is generated by attaching the sealing element 40 to the other section, which is different from the thin section 12a. Even if the sealing element 40 deteriorates due to the heat generated in the connector 20, and the surface pressure between the sealing element 40 and the thin section 12a (the sheathing section 12) decreases, the degree of deformation of the thin section 12a due to the sealing element 40 is less than in the case in which the sealing element 40 is attached to a section that is different from the thin section 12a.Accordingly, the formation of a gap between the sealing element 40 and the thin section 12a is reduced. With this design, the sealing performance can be maintained. (2) Because the thin section 12a is formed by compressing part of the casing material 12 inwards in the radial direction, the thin section 12a can be formed after the casing material 12a has been, for example, extruded. Accordingly, the thin section 12a can be easily formed. (3) By providing the thin section 12a on a section spaced from the end 12e at a distance in the longitudinal direction of the sheathing material 12, the thin section 12a has a recessed shape with respect to a section of the sheathing material 12 adjacent to the thin section 12a. Accordingly, the sealing element 40 can be easily positioned.

[0028] The above embodiment can also be modified as follows.

[0029] In the above embodiment, the thin section 12a is provided at a position spaced apart from the end 12e in the longitudinal direction of the sheathing material 12, but the present invention is not limited to this embodiment. An embodiment can also be assumed in which, for example, the thickness is reduced from one end 12e to a predetermined position towards the other end 12e.

[0030] In the embodiment above, the thin section 12a is formed by compressing a portion of the sheathing material 12 inwards in the radial direction, but the present invention is not limited to this. The thin section 12a can also be formed by thinning a portion of the sheathing material 12, for example by cutting or the like.

[0031] The outer circumferential surfaces (12a and 12b) of the sheathing material 12 can be referred to as a radial outer surface of the sheathing material 12. The outer circumferential surface and the inner circumferential surface of the sealing element 40 can each be referred to as a radial outer sealing surface and the radial inner sealing surface of the sealing element 40.

[0032] The thin section 12a of the sheathing material 12 can be described as a small-diameter section of the sheathing material 12 (or of the electrical conductor 10) located on the outer circumferential surface of the sheathing material 12 at a local position along the longitudinal direction. Non-thin sections, which are sections on the two sides of the thin section 12a along the longitudinal direction, for example, the remaining sections of the sheathing material 12 other than the thin section 12a, can be described as a large-diameter section of the sheathing material 12. The diameter of the sheathing material 12 in the non-thin section, i.e., the diameter of the sheathing material 12 in the large-diameter section, can be described as the first diameter.In a state where the sealing element 40 is not in contact with the small-diameter section of the sheathing material 12, the sheathing material 12 in the small-diameter section has a second diameter that is smaller than the first diameter. In the example shown, the sheathing material 12 is a single layer of sheathing material.

[0033] The sealing element 40 is inserted radially between the inner circumferential surface 22a of the connector housing 22 and the outer circumferential surface of the small-diameter section of the sheathing material 12, and is held in a compressed radial position between the inner circumferential surface 22a of the connector housing 22 and the outer circumferential surface of the small-diameter section of the sheathing material 12. The outer circumferential surface and the inner circumferential surface of the sealing element 40 are each in close contact, preferably in a liquid-sealing manner, with the inner circumferential surface 22a of the connector housing 22 and the outer circumferential surface of the small-diameter section of the sheathing material 12. In the example shown, the sealing element 40 is a single element or a one-piece element.

[0034] In a state where the sealing element 40 is not in contact with the small-diameter section of the sheathing material 12, in this example shown, the small-diameter section of the sheathing material 12 and the large-diameter sections on the two sides of the small-diameter section form two steps in the sheathing material 12 in the longitudinal direction. These steps can each be referred to as a distal step surface and a proximal step surface of the sheathing material 12.

[0035] In a non-restrictive example, the sealing element 40 has a distal or end annular end face located close to the connecting fitting 21 and a proximal or base annular end face located close to the opening of the connector housing 22. The non-thin sections on the two sides of the thin section 12a in the axial direction can each be referred to as a distal non-thin section and a proximal non-thin section. The length of the thin section 12a in the axial direction is longer than the length of the sealing element 40 in the axial direction, i.e., the length from the distal annular end face to the proximal annular end face of the sealing element 40. Thus, the sealing element 40 does not come into contact with either the distal or the proximal non-thin section.

[0036] The embodiment and modifications described above can be freely combined as appropriate.

[0037] The present disclosure covers the following implementation examples. The reference numerals for the components of the embodiments are included not to limit scope, but for the sake of clarity. ADDITIONAL NOTE 1

[0038] A cable harness (1) according to some implementation examples comprises: an electrical conductor (10) having a core conductor (11) and an insulating sheathing layer (12) enclosing the core conductor (11); a connector fitting (21) fixed to an exposed distal end section of the core conductor (11) projecting from an end face (12e) of the insulating sheathing layer (12); a connector housing (22) having an opening for the passage of the electrical conductor (10) and an inner circumferential surface (22a) that surrounds at least one connection section between the core conductor (11) and the connector fitting (21) from the outside; a tubular sealing element (40) attached to the inner circumferential surface (22a) of the connector housing (22); and a holder (50) which is attached to the opening of the connector housing (22) and which is in contact with the sealing element (40) to prevent,that the sealing element (40) detaches from the connector housing (22), wherein the insulating sheathing layer (12) has a small-diameter section (12a) formed at a local position (12a) of the insulating sheathing layer (12) in a longitudinal direction on radial outer surfaces (12a, 12b) of the insulating sheathing layer, and large-diameter sections (12b), except for the small-diameter section (12) on the radial outer surfaces (12a, 12b) of the insulating sheathing layer (12), and wherein the sealing element (40) is inserted in a radial direction between the inner circumferential surface (22a) of the connector housing (22) and the radial outer surface of the small-diameter section (12a) of the insulating sheathing layer (12),and is held in a compressed state in the radial direction between the inner circumferential surface (22a) of the connector housing (22) and the radial outer surface of the section (12a) of the small-diameter insulating sheathing layer (12). ADDITIONAL NOTE 2

[0039] In some implementation examples, the large-diameter insulating sheathing section (12) is thick, each having a first thickness in a state where the sealing element (40) is not in contact with the small-diameter insulating sheathing section (12), and the small-diameter insulating sheathing section (12a) is thin, with a second thickness less than the first thickness of the thick sections in a state where the sealing element (40) is not in contact with the small-diameter insulating sheathing section (12). ADDITIONAL NOTE 3

[0040] In some implementation examples, the non-thin sections (12b) of the insulating sheathing layer (12) exhibit a first maximum degree of compression deformation when compressed in the radial direction at a predetermined pressure, and the thin section (12a) of the insulating sheathing layer (12) exhibits a second maximum degree of compression deformation, which is smaller than the first maximum degree of compression deformation when compressed in the radial direction at a predetermined pressure. ADDITIONAL NOTE 4

[0041] In some implementation examples, the thin section (12a) is formed by compressing the radial outer surface (12b) from the outside at the local position of the insulating sheathing layer (12). ADDITIONAL NOTE 5

[0042] In some implementation examples, the thin section (12a) is formed by cutting out the local position of the insulating sheathing layer (12) from the outside of the insulating sheathing layer (12). ADDITIONAL NOTE 6

[0043] In some implementation examples, the sealing element (40) has a distal annular end face that is close to the connecting fitting (21) and a proximal annular end face that is close to the opening of the connecting housing (22), and the length of the thin section (12a) in the axial direction is longer than the length of the sealing element (40) in the axial direction, which is the length from the distal annular end face to the proximal annular end face of the sealing element (40). ADDITIONAL NOTE 7

[0044] The large diameter sections (12b) are large diameter sections (12b) formed on the two sides of the small diameter section (12a) in the longitudinal direction, wherein the two large diameter sections (12b) and the small diameter section (12a) form two annular step surfaces between them, and the sealing element (40) does not come into contact with one or both of the two annular step surfaces.

[0045] It is obvious to a person skilled in the art that the present invention can also be implemented in other specific ways without departing from the underlying technical idea. Some of the components described in the embodiment (or one or more aspects thereof) can be omitted, or some components can be combined. The scope of the present invention shall be determined with respect to the attached claims together with the full scope of the equivalence of the claims. REFERENCE MARK LIST 1 wiring harness 10 electrical conductors 11 Core conductors 12 Sheathing material 12a thin section 20 connectors 40 sealing element

Claims

[1] Wiring harness (1), comprising: an electrical conductor (10) comprising a core conductor (11) and a sheathing material (12) which encloses the core conductor (11); a connector (20) attached to one end of the electrical conductor (10); and a sealing element (40) arranged between the electrical conductor (10) and the connector (20), wherein the sheathing material (12) has a thin section (12a) which is thinner than other sections of the sheathing material (12), a section of the thin section (12a) abuts the sealing element (40) in a radial direction, the sheathing material (12) has a distal non-thin section (12b) and a proximal non-thin section (12b) on the two sides of the thin section (12a) in the longitudinal direction, a first annular step surface is formed between the thin section (12a) and the distal non-thin section (12b), and a second annular step surface is formed between the thin section (12a) and the proximal non-thin section (12b), and the sealing element (40) is not in contact with one or both of the first annular step surface and the second annular step surface. [2] Cable harness (1) according to claim 1, wherein the thin section (12a) is formed by compressing a part of the sheathing material (12) inwards in the radial direction. [3] Cable harness (1) according to claim 1 or 2, wherein the thin section (12a) is provided at a position which is spaced longitudinally apart from an end (12e) of the sheathing material (12).

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