WIRING HARNESS, FORM AND FORM SYSTEM

Description

[0001] The invention relates to a wiring harness according to claim 1, a mold for producing a wiring harness according to claim 2 and a molding system according to claim 8.

[0002] Wiring harnesses with individual cables for connecting different components in a motor vehicle are common. The cables are pulled along a mounting board and wrapped with a wrapping tape. The manufacturing of the wiring harness is largely done manually, making it particularly cost-intensive.

[0003] For example, a wiring harness is known from EP 0 787 626 A2 and US 2014 / 190742 A2. US 2014 / 190742 A2 also shows a mold for manufacturing the wiring harness.

[0004] It is an object of the invention to provide an improved wiring harness, an improved mold and an improved molding system.

[0005] This object is achieved by means of a wiring harness for a motor vehicle according to claim 1. Advantageous embodiments are specified in the dependent claims. It has been recognized that an improved wiring harness for a motor vehicle can be provided in that the wiring harness has a cable bundle with at least two cables and a sheath. The cable bundle is at least partially embedded in the sheath. The sheath has a transition section. The transition section is arranged between the first sheath section and the second sheath section. The first sheath section has a first side surface and the second sheath section has a second side surface. The transition section has a transition surface which has an inclination with respect to the first side surface and the second side surface.The inclination has an angle, wherein the angle has a value that is less than 45°, in particular less than 30°, in particular less than 20°, in particular less than 15°, in particular less than 10°.

[0006] In this way, there is no need for time-consuming winding of the cable bundle.

[0007] Furthermore, the sheathing ensures that the cable harness can be bent particularly easily and routed around tight radii. The sheathing also protects the individual cables in the cable bundle.

[0008] In a non-claimed embodiment, the sheath has a signaling element on its outside, wherein the signaling element is guided parallel to the cable bundle to signal a position of the cable bundle. The signaling element preferably extends substantially over the entire longitudinal extent of the sheath, wherein the signaling element is designed, at least in sections, to correspond to a geometric configuration of a holding device of a shape. The orientation of the cable bundle in the sheath can be easily signaled by means of the first bulge, so that the cable harness can be laid particularly quickly in the motor vehicle.

[0009] In a non-claimed embodiment, the signaling element has a first bulge, wherein the first bulge is bead-like, and / or wherein the signaling element has a recess on the outside of the sheath. This allows the cable bundle to be located particularly quickly in the sheath during repair of the wiring harness.

[0010] In a non-claimed embodiment, the first bulge extends substantially over an entire longitudinal extent of the casing.

[0011] In a non-claimed embodiment, the cable harness has a first fastening element. The first fastening element is at least partially embedded in the sheath. The first fastening element is designed to hold at least one of the cables of the cable bundle in a predefined position. In this way, heating of the cable harness can be defined, so that even local overheating of the cable harness is reliably prevented. Irreversible damage to the cable harness can thus be easily prevented.

[0012] In a non-claimed embodiment, the wiring harness comprises a second fastening element. The second fastening element has a first portion embedded in the sheath. The second fastening element further comprises a second portion configured to engage a vehicle component of the motor vehicle in order to fasten the wiring harness to the vehicle component.

[0013] In a non-claimed embodiment, the sheathing comprises a first layer, a second layer and preferably a third layer, wherein the cable bundle is embedded in the first layer, wherein the first layer comprises a first material and the second layer comprises a second material, wherein the second material preferably has a different, preferably greater, elasticity than the first material, wherein the second layer is preferably rectangular or has a ribbed structure, wherein the second layer preferably has a surface provided with a predefined surface structure on a side facing the first layer, wherein the second layer preferably has a flat surface on a side facing away from the first layer, wherein the third layer is preferably arranged on a side of the second layer facing away from the first layer,The third layer comprises at least one material, the third material comprising an adhesive and / or a third elasticity that is different, preferably lower, than the first and / or second elasticity. Thus, the second layer can serve as protection for the cable bundle, preventing possible damage to the cable bundle, for example, from sharp edges of a vehicle body.

[0014] In a non-claimed embodiment, the first layer is slimmer in the direction transverse to the cable bundle than the second layer, wherein the first layer is designed to engage an indentation of a vehicle component, wherein preferably the first layer has a trapezoidal cross-section and the second layer has a substantially rectangular cross-section.

[0015] In a non-claimed embodiment, the sheath has a second bulge, wherein the cable harness can be passed through a leadthrough in a vehicle component, wherein the second bulge extends inclined to a longitudinal extent of the cable bundle, wherein the second bulge is designed to form, at least in sections, a preferably fluid-tight separation between two spaces of the vehicle component, wherein the second bulge has a bulge contour, wherein the second bulge is designed to press the bulge contour against a leadthrough contour of the leadthrough in order to provide a substantially fluid-tight separation between the spaces.

[0016] In an embodiment not claimed, the sheath has a second bulge, wherein the second bulge extends at an angle to a longitudinal extent of the cable bundle, wherein the second bulge is designed to form, at least in sections, a preferably fluid-tight separation between two spaces of the vehicle component, wherein the second bulge has a bulge contour, wherein the second bulge is designed to press the bulge contour against an indentation contour of an indentation of a vehicle component in order to provide a frictional connection between the indentation and the second recess and to frictionally fasten the cable harness in the indentation. This allows the cable harness to be fastened in the motor vehicle particularly easily.

[0017] According to the invention, the sheathing comprises a first sheathing section and a second sheathing section. The first sheathing section has a first transverse extension relative to a first longitudinal extension direction of the first sheathing section. The second sheathing section has a second transverse extension relative to a second longitudinal extension of the second sheathing section. The first transverse extension is greater than the second transverse extension.

[0018] However, the object is also achieved by means of a mold for producing the above-described cable harness according to claim 2. Advantageous embodiments are specified in the dependent claims.

[0019] It has been recognized that an improved mold for producing a wiring harness can be provided by having a mold with a wall and an opening. The wall defines a mold cavity at least laterally. The mold cavity borders the opening on the top side.The wall has a first wall surface section, a second wall surface section and a wall surface transition section, wherein the first wall surface section is preferably arranged lower than the second wall surface section, wherein the wall surface transition section is arranged between the first wall surface section and the second wall surface section, wherein the wall surface transition section is arranged inclined with respect to the first wall surface section and the second wall surface section, wherein the inclination preferably has an angle, wherein the angle has a value that is less than 45°, in particular less than 30°, in particular less than 20°, in particular less than 15°, in particular less than 10°. This prevents cracking in the cable harness at the transition between the first wall sheathing section and the second wall sheathing section.

[0020] The upwardly open shape allows for the cables to be laid particularly easily during the wiring harness production process, without having to pull them around pins. This allows for particularly fast production. Furthermore, the cables can also be laid automatically using a robot, further reducing production costs through automation.

[0021] In a non-claimed embodiment, the mold has a holding device. The holding device is arranged on the wall and covers the opening at least in sections. The holding device is plate-like and / or brush-like, the holding device comprising a material that is reversibly elastically deformable and that can be bent reversibly by at least 70°, preferably by 90°, preferably into the mold cavity. This prevents the cables inserted into the mold cavity from accidentally slipping out. Floating of the cables in the mold cavity during foaming of the sheath is also prevented.

[0022] It is particularly advantageous if the wall has a wall base, wherein the holding device is arranged at least in sections parallel to the wall base.

[0023] According to the invention, the wall has a first wall section and a second wall section. The first wall section is arranged opposite the second wall section, wherein the holding device comprises a first holding element and a second holding element, wherein the first holding element is arranged on the first wall section and the second holding element is arranged on the second wall section, wherein the first holding element and the second holding element each end with a free end above the opening and close the mold space at least in sections, wherein preferably the first wall section and / or the second wall section is profiled in a wave-like manner at least in sections.

[0024] In a non-claimed embodiment, the free ends of the holding elements are arranged at a distance from one another, and / or the holding devices are arranged overlapping over the opening.

[0025] In a non-claimed embodiment, the first wall section has a first wall region and a second wall region, wherein the first wall region is arranged substantially parallel to the second wall section, wherein the second wall region extends offset from the first wall region in a direction facing away from the second wall section, so that the mold space has a widening, wherein the second wall region is formed corresponding to the first bulge contour and / or to the second bulge contour.

[0026] In a non-claimed embodiment, a recess is provided in the wall, wherein the recess is designed as a through-opening and is arranged in a wall base of the mold, wherein the wall base delimits the mold space on the underside, wherein the recess is designed to accommodate at least some of the first and / or second fastening element of the cable harness, and / or wherein an ejector for removing the cable harness from the mold is designed to pass through the recess, wherein the recess is preferably designed to correspond to the ejector. This allows the cable harness to be removed from the mold particularly easily and mechanically.

[0027] In a non-claimed embodiment, a recess is provided in the wall, wherein the recess is designed to receive at least in sections the first and / or the second fastening element of the cable harness.

[0028] In a further embodiment, the first wall surface section and the second wall surface section are arranged in two planes arranged parallel to one another.

[0029] In an embodiment not claimed, the holding device is interrupted in sections and / or designed to follow the wall continuously.

[0030] In a further embodiment, the holding device comprises silicone as its material. Additionally or alternatively, the wall comprises at least one of the following materials: polytetrafluoride, polyoxymethylene.

[0031] These materials exhibit a particularly low surface tension compared to the sheathing material, ensuring reliable demolding of the cable harness after the sheathing has cured. In particular, the use of these materials for the wall also ensures that a large number of cable harnesses can be produced with the mold without the need for additional cleaning or reprocessing steps to create the original mold.

[0032] In an embodiment not claimed, the wall has a wall surface facing the mold cavity, wherein the wall surface is laser-polished at least in sections. Laser polishing softens any grooves present in the wall surface, which may arise in particular from milling the mold cavity into the mold, thus reliably ensuring demolding and removal of the cable harness from the mold.

[0033] In a non-claimed embodiment, the wall is at least partially corrugated and / or ribbed and / or flatly profiled. This allows the wiring harness to be easily and optimally adapted to the geometric constraints in the vehicle.

[0034] In a further embodiment, a sealing element is arranged at one longitudinal end of the wall in order to at least partially prevent the casing from escaping from the molding space.

[0035] In an embodiment not claimed, the mold has a first mold part and a second mold part. The first mold part has a first engagement element at one longitudinal end. The second mold part has a first receptacle formed corresponding to the first engagement element at a longitudinal end of the second mold part facing the longitudinal end of the first mold part. The first engagement element engages in the first receptacle and positively connects the first mold part to the second mold part, wherein the engagement element and the receptacle are formed in relation to one another in such a way that withdrawal in the longitudinal direction is blocked by the engagement of the engagement element in the receptacle, wherein preferably the engagement element and the first mold part are formed in one piece and from the same material. In this way, the mold can be expanded or adapted particularly easily.

[0036] In a further embodiment, the mold is designed to be attached to a mounting board of a molding system.

[0037] However, the problem is also solved by a molding system according to patent claim 8.

[0038] It has been recognized that an improved mold system can be provided in that the mold system comprises a mold and a mounting board, wherein the mold is designed as described above, wherein the mold has a further engagement element on a side facing a mounting board and the mounting board has at least one grid field with a plurality of further receptacles on a side facing the mold, or wherein the mold has a further receptacle on a side facing the mounting board and the mounting board has a grid field with a plurality of further engagement elements on a side facing the mold, wherein the further engagement element and the further receptacle are arranged corresponding to one another, wherein the further engagement element engages in one of the further receptacles and connects the mounting board to the mold in a form-fitting, reversibly detachable manner,wherein the other further receptacles of the grid field remain free or wherein one of the further engagement elements engages in the further receptacle and connects the mounting board to the mold in a form-fitting, reversibly detachable manner, wherein the other further engagement elements of the grid field remain free, wherein preferably the further engagement element is formed in one piece and of the same material with the mold or with the mounting board.

[0039] This allows the mold to be mounted on the assembly board particularly quickly or allows the mold system to be adapted particularly quickly to a different cable harness that is to be manufactured.

[0040] The invention is explained in more detail below with reference to the figures. These show: Figure 1A a section of a cross section through a vehicle component of a motor vehicle according to a first embodiment; Figure 1B a detail of a top view of the Figure 1Avehicle component shown; Figure 2 a sectional view through a vehicle component according to a second embodiment; Figure 3A a section of a cross section through a vehicle component of the motor vehicle according to a third embodiment; Figures 3B to 3D each show a section of a cross-section of a further training of the Figure 3A vehicle component shown; Figure 3E a longitudinal section through a further training of the Figure 3A vehicle component shown; Figure 4A a section of a cross section through a vehicle component of the motor vehicle according to a fourth embodiment; Figure 4B a section of a cross-section through a further training of the Figure 4A vehicle component shown; Figure 5 a longitudinal section through a wiring harness; Figure 6 a perspective view of a wiring harness in another embodiment; Figure 7a perspective view of a wiring harness in another embodiment; Figure 8 a perspective view of a wiring harness in another embodiment; Figure 9A a perspective view of a molding system for producing at least one in the Figures 1 to 8 wiring harness shown; Figure 9B a top view of the Figure 9A shown form system; Figure 10 a perspective view of the first molded part of the Figure 9A and Figure 9B shown form according to a first embodiment; Figure 11A a sectional view through the Figure 10 shown shape along a Figure 10 shown section plane AA; Figure 11B a sectional view of a variant of the Figure 10 shown shape along the Figure 10 shown section plane AA; Figure 12 a sectional view through a first molded part according to a second embodiment along the line shown in Figure 10 shown section plane AA; Figure 13a perspective view of a first molded part according to a third embodiment; Figure 14 a section of a perspective view of the form; Figure 15 a perspective view of a further training of the Figures 9A to 14 shown form; Figure 16 a perspective view of a further training of the Figures 9A to 15 shown form; Figure 17 a section of a perspective view of a further training course in Figure 16 shown form; Figure 18 a perspective view of the first molded part according to a fourth embodiment; Figure 19 a perspective view of the form with the Figure 18 shown molded part; Figure 20 a perspective view of the wall in a further development; Figure 21 a perspective view of the wall in a variant to that shown in Figure 20 shown design; Figure 22 a perspective view of the mold in another embodiment; Figure 23a longitudinal section through the mold in a further embodiment; Figure 24 a perspective view of a mold in another embodiment; Figure 25 a perspective view of a mold in another embodiment; Figure 26 a perspective view of a mold in another embodiment; Figure 27 a perspective view of the first fastening element according to a first embodiment; Figure 28 a perspective view of a first fastening element according to a second embodiment; Figure 29 a perspective view of a first fastening element according to a third embodiment; Figure 30 a perspective view of a first fastening element according to a fourth embodiment; Figure 31 a perspective view of a second fastening element; Figure 32 a perspective view of the second fastening element according to a second embodiment; Figure 33a flowchart of a method for manufacturing the wiring harness; Figure 34 a plan view of the molding system during a third process step; and Figure 35 a sectional view along a Figure 34 shown section plane DD.

[0041] It is pointed out that the Figures 1A to 4B , 6 to 22 , 24 to 35 serve to clarify general understanding. Figure 5 shows a wiring harness 1010 according to the invention and Figure 23 a mold according to the invention 15.

[0042] Figure 1Ashows a section of a cross-section through a vehicle component 1000 of a motor vehicle according to a first embodiment. The vehicle component 1000 has a structure 1005 and a wiring harness 1010. The structure 1005 can be, for example, a body, a deep-drawn part, a headliner, a door panel, an intermediate panel, a soundproofing bulkhead, or a cockpit. The structure 1005 can be made of sheet metal or plastic, for example. However, the structure 1005 can also be a plastic structure, a carpet, or the like. The structure 1005 has a contact surface 1015. The contact surface 1015 faces the wiring harness 1010.

[0043] The cable harness 1010 comprises a cable bundle 1020 with a plurality of cables 1025. The cables 1025 serve to transmit electrical signals or an electrical current between two points. The cables 1025 are arranged to run in approximately the same direction relative to one another. A connection system for electrically connecting the cable harness 1010 to another electrical device can be provided at each end of the cable harness 1010. The cables 1025 of the cable bundle 1020 are embedded in a sheath 1030 of the cable harness 1010. The sheath 1030 has a side surface 1035 with a sheath contour on its outside.

[0044] The sheathing 1030 preferably comprises at least one of the following materials: polyurethane, silicone, foam, closed-cell foam, open-cell foam, silicone foam, polyurethane foam. The cable harness 1010 rests with the side surface 1035 against the contact surface 1015. An adhesive layer can additionally be provided between the contact surface 1015 and the side surface 1035 to firmly bond the cable harness 1010 to the structure 1005.

[0045] The cross-section of the sheath 1030 is freely selectable and preferably corresponding to the geometric design of the contact surface 1015. It is particularly advantageous if the contact contour and the sheath contour are identical in sections, thus ensuring a particularly good flat fit of the cable harness 1010 against the structure 1005.

[0046] It is particularly advantageous if the sheath 1030 comprises a signaling element 1038. The signaling element 1038 comprises a first bulge 1036, advantageously on an upper side 1037 of the cable harness 1010. The first bulge 1036 protrudes beyond the upper side 1037. The first bulge 1036 is preferably bead-like and preferably extends at least partially parallel to the cable bundle 1020. The signaling element 1038 can be arranged centrally to a maximum first transverse extent b 1 . This allows the course of the cables 1025 of the cable bundle 1020 to be signaled in a simple manner. Furthermore, the signaling element 1038 can be used to signal a predefined side for inserting the cable harness 1010 into the structure 1005, so that the cable harness 1010 can be mounted particularly quickly in the assembly of the motor vehicle.Additionally or alternatively, it is also conceivable that the signaling element 1038 comprises a recess 1040 in the upper side 1037 (dashed in . Figure 1A shown). The recess 1040 may, for example, be used to signal a particular type of wiring harness 1010.

[0047] Figure 1B a detail of a top view of the Figure 1A vehicle component shown 1000.

[0048] The signaling element 1038 extends essentially over the entire longitudinal extent of the cable harness 1010. This makes it particularly easy to determine the insertion position of the cable bundle 1020 in the sheath 1030. This is particularly advantageous when the sheath 1030 is particularly thick and the cable bundle 1025 is neither palpable nor visually detectable in the sheath.

[0049] Figure 2shows a sectional view through a vehicle component 1000 according to a second embodiment. The vehicle component 1000 is substantially identical to the vehicle component 1000 shown in Figure 1A. The structure 1005 has a first space 1100 and a second space 1105. A partition wall 1110 is provided between the first space 1100 and the second space 1105. The partition wall 1110 has an opening 1115. The cable harness 1010 is routed through the opening 1115.

[0050] The wiring harness 1010 is essentially identical to the one in Figure 1A and Figure 1BThe sheath 1030 of the cable harness 1010 is formed as explained above. In addition, the sheath 1030 of the cable harness 1010 has a second bulge 1120. The second bulge 1120 extends transversely to a longitudinal extent of the cable bundle 1020. The sheath 1030 advantageously comprises a soft-elastic material at least in the region of the second bulge 1120. The second bulge 1120 has a bulge contour 1121. The second bulge 1120 is arranged in the opening 1115 and fills the opening 1115. Preferably, the second bulge 1120 is pressed / compressed into the opening 1115. As a result, the second bulge 1120 presses the bulge contour 1121 circumferentially against an opening contour 1122 of the opening 1115 and fluidically seals the first chamber 1100 from the second chamber. Furthermore, sound transmission between the first chamber 1100 and the second chamber 1105 through the second bulge 1120 is prevented.It is particularly advantageous if the second bulge 1120 is arranged circumferentially around the cable bundle 1020. In this case, the second bulge 1120 can be particularly advantageously triangular in cross-section. This eliminates the need for a grommet in the opening 1115.

[0051] Figure 3A shows a section of a cross section through a vehicle component 1000 of the motor vehicle according to a third embodiment. The vehicle component is similar to that shown in Figures 1 and 2shown vehicle component 1000. In contrast, the cable harness 1010 has a first layer 1200 and a second layer 1205. The second layer 1205 is arranged underneath the first layer 1200 and between the first layer 1200 and the structure 1005. The cable bundle 1020 is embedded in the first layer 1200. The first bulge 1036 borders the first layer 1200. The first layer 1200 preferably has a first material and the second layer 1205 preferably has a second material. The first layer 1200 and the second layer 1205 can also have an identical material. The second material can have a different elasticity than the first material.Thus, if the elasticity of the second material is greater than the elasticity of the first material, it is advantageous that rattling of the cable bundle 1020 can be avoided by the particularly elastic properties of the second layer 1205 on the structure 1005.

[0052] Furthermore, it is advantageous if the elasticity of the second material of the second layer 1205 is lower than the elasticity of the first material, since the second layer 1205 thereby forms a type of plate that effectively protects the cable bundle 1020 from possible damage.

[0053] In the embodiment, the second layer 1205 is rectangular in cross-section. Other configurations of the second layer 1205 are also conceivable. For example, the second layer 1205 can also be semicircular, elliptical, U-shaped, C-shaped, cylindrical or otherwise. It is also conceivable that the second layer 1205, instead of the Figure 3The planar configuration shown has a ribbed structure in the longitudinal direction of the cable harness 1010. This allows the cable harness 1010 to be guided particularly well around a radius, while at the same time ensuring a high level of protection for the cable bundle 1020 by the second layer 1205.

[0054] Figure 3B shows a section of a cross-section of a further training of the Figure 3A vehicle component 1000 shown. The wiring harness 1010 is essentially identical to that shown in Figure 3 shown cable harness 1010. In contrast, the second layer 1200 has a defined surface structure 1215 on a surface 1220 facing the first layer 1200. The surface structure 1215 is, for example, wave-shaped. This increases the size of the surface 1220 of the second layer 1205 and prevents adhesion of the first layer 1205 compared to the Figure 3A shown embodiment at the second layer 1200.

[0055] Figure 3C shows a section of a cross-section of a further training of the Figure 3A shown vehicle component 1000. Deviating from this, the first layer 1200 is slimmer in the transverse direction to the cable bundle 1020 than the second layer 1205.

[0056] Figure 3D shows a section of a cross-section of a further training of the Figure 3shown vehicle component 1000. In addition, the sheathing 1030 has a third layer 1210. The third layer 1210 is arranged on a side of the second layer 1205 facing away from the first layer 1200 and is connected to the latter. The third layer 1210 has a third material with a third elasticity. The third elasticity is preferably lower than the first elasticity and / or the second elasticity. Preferably, the third layer 1210 is designed as a baffle plate or as an adhesive layer. When designed as a baffle plate, it is advantageous that the third layer 1210 can prevent damage to the cable bundle 1020 and, at the same time, vibrations can be particularly well dampened by the second layer 1205. In the embodiment, the layers 1200, 1205, 1210 are arranged, for example, in a rectangular shape with identical widths in a layer stack.The layers 1200, 1205, 1210 may also have different widths or configurations.

[0057] Figure 3E shows a longitudinal section through a further training of the Figure 3A shown vehicle component 1000. A rib structure 1225 is provided in the second layer 1200. The rib structure 1225 has ribs 1230 and rib recesses 1235 arranged between the ribs 1230 in the longitudinal direction, which delimit the ribs 1230 in the longitudinal direction. The rib recesses 1235 each have a recess base 1240, which is arranged at a distance from the cables 1025 of the cable bundle 1020.

[0058] Figure 4A shows a section of a cross section through a vehicle component 1000 of the motor vehicle according to a fourth embodiment. The vehicle component 1000 is essentially identical to that shown in Figures 1A to 3EThe structure 1005 is formed as shown in the vehicle component 1000. The structure 1005 has a groove-like recess 1300 with a recess contour 1301. The recess 1300 is, for example, rectangular in shape. The recess 1300 can be introduced into the structure 1005, for example, during a pressing process.

[0059] The wiring harness 1010 is essentially identical to the one shown in the Figure 3AThe cable harness 1010 is arranged in the recess 1300. The sheath 1030 has the second bulge 1120. The second bulge 1120 is preferably circumferential, encompassing the cable bundle 1020 on preferably three sides, and preferably layered. The second bulge 1120 has a bulge contour 1121. The material of the second bulge 1120 is preferably elastic and integral with the material of the sheath 1030. In the unassembled state, the bulge contour 1121 of the second bulge 1120 is preferably larger than the indentation contour of the indentation 1300.

[0060] When the wiring harness 1010 is assembled, the second protrusion 1120 and its material are compressed, so that the second protrusion 1120 presses its protrusion contour 1121 against the indentation contour of the indentation 1300, so that the wiring harness 1010 is frictionally connected to the indentation 1300 of the vehicle component 1000 via the second protrusion 1120. This allows the wiring harness 1010 to be accommodated in the structure 1005 of the vehicle component 1000 in a particularly space-saving manner.

[0061] In particular, it is advantageous here that the structure 1005 has a surface 1310 adjacent to the indentation 1300, wherein the upper side 1037 of the cable harness 1010 is formed substantially seamlessly / steplessly relative to the surface 1310. Preferably, the upper side 1037 and the surface of the structure 1005 lie in a common plane. In this case, the second bulge 1120 can be omitted from the cable harness 1010, wherein in this embodiment the cable harness 1010 substantially completely fills the indentation 1300. The second bulge 1120 can also be provided only in sections in the longitudinal direction; in the remaining regions (without the second bulge 1120), for example, the sheathing 1030 is arranged at a distance from the indentation contour 1305.

[0062] Figure 4B shows a cross-section of a further training of the Figure 4A vehicle component shown 1000.

[0063] The Figure 4BThe design shown is essentially a combination of the Figure 3C shown configuration of the wiring harness 1010 with the Figure 4A shown embodiment of the vehicle component 1000. Deviating from this, the vehicle component 1000 has, in addition to the structure 1005, a holding structure 1006, which is arranged on the upper side at a distance from the indentation 1300. Only the first layer 1200 engages in the indentation 1300, while the second layer 1205, in contrast, is arranged outside the indentation 1300 between the holding structure 1006 and the structure 1005. Preferably, the holding structure 1006 presses against the second layer 1205 with a holding force FH and thus secures the cable harness 1010 to the structure 1005. The holding structure 1006 can be fastened to the structure 1005. The holding structure 1006 can also be a different vehicle assembly to the structure.

[0064] Figure 5shows a longitudinal section through a cable harness 1010. The sheathing 1030 of the cable harness 1010 has a first sheathing section 1400, a second sheathing section 1405, and a transition section 1410. The transition section 1410 is arranged in the longitudinal direction of the cable harness 1010 between the first sheathing section 1400 and the second sheathing section 1405. The first sheathing section 1400 has a first side surface 1415, and the second sheathing section 1405 has a second side surface 1420. The side surfaces 1415, 1420 are preferably arranged parallel in two planes offset from one another. The side surfaces 1415, 1420 are, for example, flat. Another configuration of the side surfaces 1415, 1420 is also conceivable. The transition section 1410 has a transition surface 1425.The side surfaces 1415, 1420 and the transition surface 1425 can be arranged on the underside of the cable harness 1010, on the side of the cable harness 1010 or on the top of the cable harness 1010. The transition surface 1425 is arranged at an incline with respect to the first side surface 1415 and the second side surface 1420. The inclination has an angle α 1, wherein the angle α 1 has a value that is less than 45°, in particular less than 30°, in particular less than 20°, in particular less than 15°, in particular less than 10°. This prevents cracking in the sheath 1030 at the transition between the first sheath section 1400 and the second sheath section 1405. It is also conceivable for the transition surface 1425 to be arranged instead of the way in which it is arranged. Figure 5 The planar configuration shown is curved. A convex or concave curvature is particularly conceivable.

[0065] Due to the offset side surfaces 1415, 1420, the first sheathing section 1400 has the first transverse extent b 1 relative to a first longitudinal extension direction of the first sheathing section 1400, and the second sheathing section 1405 has a second transverse extent b 2 relative to a second longitudinal extension direction of the second sheathing section 1405. The first transverse extent b 1 is greater than the second transverse extent b 2 .

[0066] An example is Figure 5 The first longitudinal direction is identical to the second longitudinal direction. The first longitudinal direction can also be different from the second longitudinal direction, and, for example, the transition section 1410 can be curved. This configuration of the cable harness 1010 has the advantage that the width of the cable harness 1010 can be flexibly adapted to the installation space available on the structure 1005.

[0067] Figure 6shows a perspective view of a wiring harness 1010 in another embodiment.

[0068] The wiring harness 1010 is similar to the one in the Figures 1 to 5 The cable harness 1010 shown is formed. In contrast, the side surface 1035 is formed with an exemplary wave-like profile 1500. The profile 1500 has a first profile section 1505 and a second profile section 1510. The first profile section 1505 is, for example, wider in the longitudinal direction than the second profile section 1510. Preferably, the first profile section 1505 is concave and the second profile section is convex. The first and second profile sections 1505, 1510 alternate in the longitudinal direction.

[0069] Figure 7 shows a perspective view of a wiring harness 1010 in another embodiment; The wiring harness 1010 is substantially identical to that shown in Figure 6shown cable harness 1010. Deviating from this, the first profile section 1505 and the second profile section 1510 are of identical width.

[0070] Figure 8 shows a perspective view of a wiring harness 1010 in another embodiment; The wiring harness 1010 is substantially identical to that shown in Figure 6 shown cable harness 1010. Deviating from this, the profile 1500 is essentially rectangular, wherein the first profile section of the Figure 6 shown cable harness 1010 is substantially planar and the second profile section 1510 is formed as an indentation in the side surface 1035.

[0071] Figure 9A shows a perspective view of a molding system 10 for producing at least one in the Figures 1 to 8 shown wiring harness 1010.

[0072] The molding system 10 preferably comprises a mold 15 and a mounting board 20. The mounting board 20 is, for example, flat. The mold 15 can comprise a first mold part 16 and at least one second mold part 17, each of which abuts at a longitudinal end 18 and is arranged with a bottom side 19 on a top side 25 of the mounting board 20, preferably in a common plane.

[0073] Figure 9B shows a section of a top view of the Figure 9A shown form system 10.

[0074] The mounting board 20 has, for example, a grid field 27 with several identically formed first receptacles 142 on the upper side 25. The first receptacles 142 are arranged in a regular pattern in the grid field 27. For reasons of clarity, only some of the first receptacles 142 have been shown in Figure 9B shown.

[0075] Figure 10 shows a perspective view of the first molded part 16 of the Figure 9A and Figure 9B shown form 15 according to a first embodiment.

[0076] To facilitate the explanation of the shape 15, reference is made below to a coordinate system 26. The coordinate system 26 is preferably designed as a right-hand system and has an x-direction (transverse direction), a y-direction (longitudinal direction), and a z-direction (height).

[0077] The mold 15 has a wall 30, an opening 35, and a holding device 40. The wall 30 delimits a molding chamber 45. The cable bundle 1020 and the sheath 1030 are introduced into the molding chamber 45 via the opening 35 during the production of the cable harness 1010. The opening 35 is arranged on the top and borders the molding chamber 45. In the exemplary embodiment, the molding chamber 45 is designed with a rectangular cross-section. The molding chamber 45 can also be designed differently and have a different cross-section. For example, it is also conceivable for the molding chamber 45 to be (sections of) polygonal, triangular, rounded, circular, and / or elliptical.

[0078] The wall 30 has a first wall section 50, a second wall section 55, and a wall base 60. The wall base 60 is arranged between the first wall section 50 and the second wall section 55. The first wall section 50 and the second wall section 55 laterally delimit the molding space 45. The wall base 60 delimits the molding space 45 on the underside. The opening 35 is preferably arranged above the wall base 60.

[0079] The first wall section 50 has a first wall surface 61 facing the mold cavity 45, the second wall section 55 has a second wall surface 62 facing the mold cavity 45, and the wall base 60 has a wall base 63 facing the mold cavity 45. In the exemplary embodiment, the first and second wall surfaces 61, 62 are parallel. The wall base 63 is arranged perpendicular to the first wall surface 61 and the second wall surface 62. The wall base 63 and / or the wall surfaces 61, 62 can also be arranged differently. For example, the first wall surface 61 can be arranged obliquely to the second wall surface 62. It would also be conceivable for the first wall surface 61 and the second wall surface 62 to be directly adjacent to one another and for the wall base 60 to be omitted, so that, for example, the mold cavity 45 has a triangular cross-section.

[0080] It is particularly advantageous if at least one of the wall surfaces 61, 62 and / or the wall base 63 is laser-polished, at least in sections. This ensures a particularly high surface quality. Furthermore, score lines and / or grooves, which arise, for example, when the mold cavity 45 is introduced into a base body for producing the mold 15 using a machining process, are at least partially eliminated by the laser polishing. This ensures a particularly long-term stable mold 15, with which numerous cable harnesses 1010 can be produced without additional preparation of the mold 15.

[0081] In contrast to the flat design of the wall surface 61, 62 and / or the wall base 63, the wall surface 61, 62 and / or the wall base 63 can also be profiled in a wave-like and / or rib-like manner, at least in sections.

[0082] The holding device 40 comprises a first holding element 65, a second holding element 70, a first pressing element 75, a second pressing element 80, and a first fastening means 85. The first holding element 65 and the second holding element 70 are, for example, designed symmetrically to a plane of symmetry 86, which preferably runs centrally through the mold cavity 45. The plane of symmetry 86 is preferably designed as a YZ plane. The first holding element 65 and the second holding element 70 can also be designed differently from one another.

[0083] The mold 15 is positively connected to the mounting board 20 by means of a second fastening means 135, which in the embodiment has at least one pin 140 designed as a first engagement element. The pin 140 is connected to the wall 30 and engages with a free longitudinal end 141 in the first receptacle 142 of the grid field 27 in the mounting board 20, said receptacle corresponding to the pin 140. To ensure particularly simple mounting of the mold 15 on the mounting board 20, preferably several pins 140 are provided, which correspond to the first receptacles 142 and are identical to one another and are connected to the wall 30. Depending on the orientation of the mold 15, the pins 140 each engage in a first receptacle 142 of the grid field 27, while the other first receptacles 142 of the grid field 27 remain free.The engagement can be additionally secured with a force fit to prevent the mold 15 from accidentally falling off the mounting board 20, for example, if the mold system 10 is tilted. This can be achieved, for example, by designing the pin 140 and the receptacle 142 as a transition fit system or as a press fit system.

[0084] The second fastening means 135 can also be designed differently. In particular, it is also conceivable that the second fastening means 135 is designed as a screw system.

[0085] The first receptacle can also be arranged on the underside 19 of the molded part 16, 17. On the upper side of the mounting board 20, the mounting board 20 preferably has a plurality of pins 140 designed as first engagement elements.

[0086] Alternatively, instead of the first receptacles 142, the grid field 27 can have pins 140 designed as first engagement elements, which extend in the direction of the mold 15. In the alternative, the first receptacle 142 on the mold 15 is preferably arranged in the wall 30. Depending on the orientation of the mold 15, when the mold 15 is mounted on the mounting board 20, some of the pins 140 of the grid field 27 engage in the first receptacles 142 and, as described above, reversibly fasten the mold 15 to the mounting board 20. The other pins 140 that do not engage in the first receptacle 142 remain free (at least circumferentially) and / or are at least partially covered (on the top side) by the mold 15.

[0087] Figure 11A shows a sectional view through the Figure 10 shown form 15 along a Figure 10 shown section plane AA in a closed position of the holding elements 65, 70.

[0088] The first holding element 65 is plate-like and comprises a first section 90 and a second section 95. The first holding element 65 is arranged with a first section 90 on the upper side of the first wall section 50. The first pressing element 75 is arranged on the upper side of the first section 90. The first pressing element 75 is preferably non-positively connected to the first wall section 50 by means of the first fastening means 85. The first fastening means 85 provides a first clamping force F S1 with which the first pressing element 75 presses the first holding element 65 against the upper side of the first wall section 50. In the exemplary embodiment, the first pressing element 75 is designed to be just as wide in the X direction as the first wall section 50. This ensures that the first holding element 65 is reliably pressed against by the first pressing element 75.Furthermore, unwanted deformation of the first holding element 65 can be avoided.

[0089] A first free end 100 of the first holding element 70 ends above the opening 35. With a second section 95, which adjoins the first free end 100 of the first holding element 65, the first holding element 65 covers the opening 35 on the upper side. The second section 95 can preferably be wedge-shaped, at least in sections. It is particularly advantageous if a first underside 105 of the first holding element 65 is essentially flat and the first holding element 65 becomes thicker (Z direction) on the upper side from the free end 100 toward the first wall section 50.

[0090] The second holding element 70 is preferably arranged opposite the first holding element 65 at the same height, that is to say, for example, in a common XY plane. The second holding element 70 is arranged mirror-symmetrically to the plane of symmetry 86. The second holding element 70 is arranged on top of the second wall section 55 and has a third section 110 and a fourth section 115 and is, for example, plate-shaped. The third section 110 of the second holding element 70 rests against the top of the second wall section 55. The second pressing element 80 is arranged above the third section 110. The first fastening means 85 provides a second pressing force F S2 for the second pressing element 80, with which the second pressing element 80 presses the second section 110 against the top of the second wall section 55.For example, the second pressing element 80 is designed to be as wide as the second wall section 55. The first pressing element 75 and the second pressing element 80 laterally define a first gap 120 which is as wide as the opening 35.

[0091] The fourth section 115 borders a second free end 130 of the second retaining element 70. Like the second section 95, the fourth section 115 is wedge-shaped, with a second underside 125 of the second retaining element 70 being arranged in a common plane with the first underside 105 of the first retaining element 65. The second free end 130 ends above the opening 35. On the upper side, the fourth section 115 thickens from the second free end 130 toward the third section 110.

[0092] The fourth section 115 adjoins a second free end 130 of the second holding element 70.

[0093] The first free end 100 is preferably arranged at a distance from the second free end 130 of the second holding element 70. A distance a between the first free end 100 and the second free end 130 is preferably ten times smaller than the width of the opening 35 (relative to a common XZ plane). As a result, the holding device (40) covers the opening 35 exclusively in sections. The first free end 100 and the second free end 130 can also be in contact with one another.

[0094] It is particularly advantageous if the holding element 65, 70 is made of a material that is particularly elastic and can be bent reversibly by at least 90°, preferably into the mold cavity 45. It is particularly advantageous if the holding element 65, 70 is made of silicone. Furthermore, this allows the holding device 65, 70 to be designed to follow the geometric configuration of the wall section 50, 55.

[0095] Figure 11Bshows a sectional view of a variant of the Figure 10 shown form 15 along the in Figure 10 shown section plane AA.

[0096] Form 15 is essentially identical to that in Figure 11A The first holding element 65 and the second holding element 70 are designed in a brush-like manner. The first holding element 65 has a first brush 66 with a plurality of brush fibers 67, and the second holding element 70 has a second brush 71 with a plurality of second brush fibers 72.

[0097] The brush fibers 67, 72 extend essentially in the transverse direction. The second section 95 and the fourth section 115 are wider than half the width of the opening 35 in the transverse direction (x-direction). As a result, the brushes 66, 71 engage with the respective opposite brushes 66, 71 and completely close the opening 35 on top.

[0098] The free ends 100, 130 can also be used as in Figure 11A shown spaced apart from each other.

[0099] Figure 12 shows a sectional view through a first molded part 16 according to a second embodiment along the Figure 10 shown section plane AA.

[0100] Form 15 is similar to that shown in the Figures 9A to 11 Form 15 shown. Deviating from this, the second section 95 and the fourth section 115 of the holding elements 65, 70 are arranged overlapping in sections above the opening 35. Overlapping is understood to mean that they overlap at least in sections when projecting the second section 95 and the fourth section 115 into a common XY plane.

[0101] The wall 30 of the first molded part 16 is formed in one piece and from a single material. Advantageously, the wall 30 comprises at least one of the following materials: polypropylene (PP), polytetrafluoride (PTFE), polyethylene (PE), preferably polyethylene with highly branched polymer chains (PE-LD), or polyoxymethylene (POM). Additionally or alternatively, it is also conceivable for the wall 30 to comprise a material that has a particularly low surface tension compared to polyurethane and / or silicone.

[0102] Figure 13 shows a perspective view of a first molded part 16 according to a third embodiment.

[0103] The first molded part 16 is similar to the one shown in the Figures 10 to 12 shown form 15. In contrast to this, the first mold part 16 has a Figure 10 shown embodiment has an enlarged longitudinal extension.

[0104] The holding device 40 is configured to correspond to the enlarged longitudinal extent. In addition, in order to enable the second fastening means 135 to be mounted on top of the wall 30, a first indentation 145 is provided in the holding device 4, preferably on a side facing away from the opening 45. For example, the first indentation 145 in the holding device 40 extends over both the holding element 65, 70 and the pressing element 75, 80. The first indentation 145 results in a slimmer design in the X direction, i.e., transverse to the longitudinal extent of the mold 15 and the holding device 40 in the region of the second fastening means 135.

[0105] The first fastening means 85 and the second fastening means 135 can also be combined with each other, so that the mold 15 and the holding device 40 are fastened to the mounting board 20 via the combined fastening means 85, 135.

[0106] In addition, compared to the Figures 9A to 12 In the mold 15 shown, a sealing element 150 (shown in dashed lines) is provided at the longitudinal end 18 of the mold 15. The sealing element 150 delimits the mold space 45 at the longitudinal end 18. The sealing element 150 can be plate-shaped. It is particularly advantageous if the sealing element 150 is arranged exclusively at the longitudinal end 18 at which the molded part 16 does not adjoin any further molded part 17. This prevents the sheathing 1030 from escaping during the production of the cable harness 1010 at the longitudinal end 18 of the mold 15.

[0107] Figure 14 shows a section of a perspective view of form 15.

[0108] The first molded part 16 can be formed as shown in the Figures 9A to 13The mold 15 additionally has a cover 155 on the top side of the wall 30. The cover 155 is connected to the wall 30 of the first mold part 16 by means of a third fastening means 160. The cover 155 is on the top side of the holding device 40 (not shown in Figure 14 shown) and prevents the holding elements 65, 70 from bending in a direction away from the mold space 45.

[0109] Figure 15 shows a perspective view of a further training of the Figures 9A to 14 shown form 15.

[0110] Form 15 is similar to the one in the Figures 9A to 14 shown form 15. Deviating from this, in Figure 15 different variants of the holding device 40 are shown.

[0111] The holding device 40 comprises a plurality of holding elements 65, 70 arranged at regular intervals in the longitudinal direction (x-direction). The holding elements 65, 70 are each connected to the wall section 50, 55. The holding element 65, 70 preferably extends perpendicular to an upper side 165 of the wall 30. In the variants of the holding elements 65, 70, each of the holding elements 65, 70 has a different cross-section in a plane parallel to the upper side 165 (xy plane). For example, the holding element 65, 70 can have a circular cross-section, a rectangular cross-section, a trapezoidal cross-section, an elliptical cross-section and / or a circular cross-section. It is also conceivable for the holding element 65, 70 to taper away from the upper side 165 of the wall 30.It is particularly advantageous if the retaining element 65, 70 has a wedge-shaped cross-section extending from the upper side 165 of the wall 30, with a free end 170 of the retaining element 65, 70 being set back from the cable harness 1010. This can facilitate the insertion of individual cables 1020 of the cable bundle 1015.

[0112] In the embodiment, the first holding element 65 is arranged opposite the second holding element 70, so that the first and second holding elements 65, 70 are each arranged in a common XZ plane.

[0113] Of course, the first and second holding elements 65, 70 can also be arranged offset from one another.

[0114] Figure 16 shows a perspective view of a further training of the Figures 9A to 15 shown form 15. For reasons of clarity, Figure 16 the representation of the holding device 40 is omitted.

[0115] Form 15 is similar to that shown in the Figures 9A to 15 shown mold 15. Deviating from this, the wall 30 on the first wall section 50 has a first web 175 on the side, and the second wall section 55 has a second web 180 on the side. The web 175, 180 extends away from the mold space 45 and borders on the underside 19 of the first mold part 16. Furthermore, a plurality of first recesses 185 are preferably provided in each of the webs 175, 180. The first recess 185 is preferably designed in the shape of an elongated hole. As a result, the first mold part 16 can be positioned particularly precisely in the longitudinal direction, so that the first mold part 16 with its longitudinal end 18 and the adjoining end face 190 rests against a further end face 195 of the further mold part 17 arranged at the longitudinal end 18.

[0116] For the first recess 185, the second fastening means 135 preferably comprises a screw instead of the pin 140. Also, the molded part 16, 17, as shown in Figure 10 shown, be connected to the mounting board 20 by means of pins 140, which are anchored, for example, in the web 180, 175.

[0117] The cable bundle 1020 of the cable harness 11 is inserted into the molding cavity 45. For example, the cable bundle 12 is held in a predefined position by means of a first fastening element 200, 205. The first fastening element 200 rests on the wall 30 on a side facing away from the cable bundle 12 and is embedded in the sheathing 1030 of the cable harness 1010.

[0118] The first fastening element 200 is described in detail in the Figures 27 to 30 received.

[0119] Figure 17 shows a section of a perspective view of a further training course in Figure 16 shown form 15.

[0120] Form 15 is similar to that in Figure 16 shown mold 15. Deviating from this, for the reliable connection of the first mold part 16 with the second mold part 17, the first mold part 16 has a second engagement element 205 and the second mold part 17 comprises a second receptacle 210 formed corresponding to the second engagement element 205. The second engagement element 205 is arranged on the front side at the longitudinal end 18 of the first mold part 16. The second engagement element 205 engages in the second receptacle 210, so that the first mold part 16 is positively coupled to the second mold part 17. This allows a reliable alignment of the mold parts 16, 17 to one another to be established. In particular, it is ensured that, as in Figure 17 shown, the mold space 45 runs in a straight line over a transition between the first mold part 16 and the second mold part 17 and a leak at the transition is avoided.

[0121] Figure 18shows a perspective view of the first molded part 16 according to a fourth embodiment.

[0122] The first engagement element 205 is arranged on the end face of the webs 175, 180. For example, two second engagement elements 205 are provided for the end face 190 of the first molded part 160, which are preferably each arranged on the web 175, 180. The first engagement element 205 has a trapezoidal cross-section when cut in an xy plane, with the second engagement element 205 thickening away from the end face 190 of the first molded part 160.

[0123] Figure 19 shows a perspective view of the form 15 with the Figure 18 shown first molded part 16 and a second molded part 17 corresponding to the first molded part 16. The second molded part 17 has the second receptacle 210, which corresponds to the Figure 18trapezoidal second engagement element 205. The second engagement element 205 engages in the second receptacle 210. Due to the trapezoidal cross-section of the second engagement element 205, the two mold parts 16, 17 can only be separated from each other in the Z direction. This ensures that no gap forms between the two end faces 190, 195 and thus the mold cavity 45 is sealed at the end face.

[0124] Furthermore, the design of the second receptacle 210 and the second engagement element 205 ensures that the molded parts 16, 17 can be reversibly detached from one another. In this way, the molding system 10 can be adapted particularly quickly to different configurations for producing the cable harness 1010. This allows the setup times for the molding system 10 to be reduced.

[0125] Figure 20shows a perspective view of the wall 30 in a further development of the Figures 10 to 19 shown form 15.

[0126] The wall 30 is designed with a thin wall thickness, for example. The wall 30 can be deep-drawn, for example.

[0127] The first wall section 50 has a first wall region 215 and a second wall region 220. For example, the first wall region 215 and the second wall region 220 adjoin one another in the longitudinal direction. The second wall section 55 is preferably formed symmetrically to the plane of symmetry 86 of the first wall section 50 and has a third wall region 225 and a fourth wall region 230. The fourth wall region 230 is preferably arranged opposite the second wall region 220 in the transverse direction (x-direction), and the third wall region 215 is preferably arranged opposite the first wall region 215 in the transverse direction. The first wall region 215 and the third wall region 225 preferably run parallel. The second and fourth wall regions 220, 230 are, for example, arc-shaped.

[0128] The second wall region 220 is arranged set back from the second wall section 55. For example, the fourth wall region 230 is arranged set back from the second wall region 220, so that the molding space 45 has a widened portion 235 between the second wall region 220 and the fourth wall region 230. The widened portion 235 can serve to form the second bulge 1120. It is also conceivable for at least one of the wall regions 220, 225, 230, 235 to have a different geometric configuration.

[0129] Figure 21 shows a perspective view of the wall 30 in a variant to that shown in Figure 20 Deviating from this, the second and fourth wall region 220, 230 is longer in the longitudinal direction (y-direction) than in Figure 20 . The second wall region 220 and the fourth wall region 230 form a slot-shaped widening 235.

[0130] Furthermore, the wall 30 has a second recess 240 in the wall base 60 in the longitudinal direction at the level of the second and fourth wall regions 220, 230. The second recess 240 is, for example, rectangular in shape and designed as a through-opening in the wall base 60. The second recess 240 is designed to accommodate a second fastening element 400 (not shown). The second fastening element 400 is described in detail in the Figures 31 and 32 The second recess 240 can also be arranged in the wall section 50, 55.

[0131] The second recess 240 can also correspond to an ejector 245 (dashed in Figure 21shown) to press the cable harness 1010 out of the mold 15 from below after the cable harness 1010 has been produced in the mold 15. This can prevent damage to the cable harness 1010, in particular to the sheath 1030, since the sheath 1030 is essentially only subjected to a compressive load and not a tensile load by the ejector 245. The ejector 245 can bear directly against the sheath 1030 or be attached to the second fastening element 400. If no second fastening element 400 is inserted into the second recess 240 during the production of the cable harness 1010, the mold space 40 is open downwards via the second recess.

[0132] Figure 22 shows a perspective view of the mold 15 in a further embodiment. The wall 30 is similar to that shown in the Figures 20 and 21shown wall 30. Deviating from this, the wall 30 defines several mold spaces 45, which open into one another at a common area 241. The geometric design, as in Figure 22 shown, by way of example. The wall 30 can also be designed differently. Due to the opening of the mold cavities 45 in the common area, individual cable bundles 1020 and / or cables 1025 of the cable harness 1010 can be easily branched or combined in the mold 15.

[0133] Figure 23 shows a longitudinal section through the mold 15 in a further embodiment. The mold 15 is similar to the one shown in the Figures 9A to 22 shown form 15.

[0134] The wall base 63 and / or the wall section 55, 60 has a first wall surface section 250, a second wall surface section 255, and a wall surface transition section 260. The wall surface transition section 260 is arranged in the longitudinal direction between the first wall surface section 250 and the second wall surface section 255. The first wall surface section 250 is arranged lower than the second wall surface section 255. The first wall surface section 250 and the second wall surface section 255 are arranged in planes that are preferably arranged parallel and offset from one another. The wall surface transition section 260 is arranged at an angle to the first wall surface section 250 and the second wall surface section 255.The inclination of the wall surface transition section 260 advantageously has an angle α 2 , wherein the angle α 2 has a value that is less than 45°, in particular less than 30°, in particular less than 20°, in particular less than 15°, in particular less than 10°. The sheathing section 1400, 1405 and the transition section 1410 of the cable harness 1010 can be formed by the wall surface section 250, 255 and the wall surface transition section 260.

[0135] Figure 24 shows a perspective view of a mold 15 in another embodiment.

[0136] Form 15 is similar to that shown in the Figures 9A to 23 shown form 15. Deviating from this, the wall surface 61, 62 corresponds to the shape of the profile 1500 of the Figure 6 shown wiring harness 1010 is wave-shaped.

[0137] Figure 25shows a perspective view of a mold 15 in another embodiment. The mold 15 is similar to that shown in Figure 24 shown form 15, wherein the wall surface 61, 62 corresponding to the shape of the profile 1500 of the in Figure 7 shown wiring harness 1010 is wave-shaped.

[0138] Figure 26 shows a perspective view of a mold in another embodiment.

[0139] Form 15 is similar to that in Figure 24 and Figure 25 shown form 15, wherein the wall surface 61, 62 corresponding to the shape of the profile 1500 of the in Figure 8 shown wiring harness 1010 is rib-shaped.

[0140] Figure 27 shows a perspective view of the first fastening element 200 according to a first embodiment.

[0141] The first fastening element 200 has a fastening plate 300, a first fastening bracket 305, and a second fastening bracket 310. The first fastening bracket 305 and the second fastening bracket 310 are arranged on the fastening plate 300 at a distance from one another in the longitudinal direction. In the exemplary embodiment, the fastening plate 300 is flat. The fastening plate 300 can also be curved. The fastening plate 300 rests against the wall surface 61, 62 and / or the wall base 63 with a side surface 315 facing away from the fastening bracket 305, 310. The fastening bracket 305, 310 has at least one laterally arranged contact surface 311, 312, which preferably rests against the wall surface 61, 62 assigned to it.

[0142] The first fastening bracket 305 has a third recess 320. The second fastening bracket 320 has a fourth recess 325. The third and / or fourth recess 320, 325 is configured to correspond to the cable bundle 1020 or one or more cables 1025 of the cable bundle 1020. The third and / or fourth recess 320, 325 can preferably be circular. Other cross-sections are also conceivable. The third and fourth recesses 320, 325 are arranged opposite one another in the longitudinal direction.

[0143] The first fastening bracket 305 has a first insertion opening 330, and the second fastening bracket 310 has a second insertion opening 335. The first insertion opening 330 opens into the third recess 320. The second insertion opening 335 opens into the fourth recess 325. The insertion openings 330, 335 are arranged in the transverse direction (X-direction) on opposite sides of the respective fastening bracket 305, 310. The insertion opening 330, 335 can preferably enclose a 90° angle segment. This ensures stable fixation and positioning of the cable bundle 1020 and / or one or more cables 1025 of the cable bundle 1020 by means of the first fastening element 200 in the molding space 45.

[0144] Figure 28 shows a perspective view of a first fastening element 200 according to a second embodiment.

[0145] The first fastening element 200 is similar to that shown in Figure 27shown embodiment of the first fastening element 200. Deviating from this, the fastening bracket 305, 310 is preferably designed in a hook-like manner. The first fastening bracket 305 has a first bracket section 340 and a second bracket section 345. The first bracket section 340 is designed, for example, perpendicular to the fastening plate 300. The second bracket section 345 is perpendicular to the first bracket section 340 and, for example, parallel to the fastening plate 300. The second fastening bracket 310 is preferably designed identically to the first fastening bracket 305. Deviating from this, the second fastening bracket 310 is arranged offset in the longitudinal direction (y-direction) from the first fastening bracket 305.The second bracket section 345 of the second fastening bracket 310 extends in the direction of the second bracket section 345 of the first fastening bracket 305 (x-direction) and is preferably arranged parallel to the first fastening bracket 305.

[0146] Also, as in Figure 28 shown, adjacent to a free end 349 of the second bracket portion 345, the second bracket portion 345 may be wedge-shaped on a side facing the fastening plate 300.

[0147] Figure 29 shows a perspective view of a first fastening element 200 according to a third embodiment.

[0148] The first fastening element 200 is similar to that in Figure 28shown first fastening element 200. Deviating from this, the second bracket section 345 of the first and / or second bracket section 305, 310 is arranged at an angle to the fastening plate 300. The second bracket section 345 extends obliquely downwards towards the fastening plate 300. As a result, an angle between the first bracket section 340 and the second bracket section 345 is less than 90°. Furthermore, a support section 350 is provided between the first bracket section 340 and the fastening plate 300. The support section 350 has a support surface 355, which is preferably designed to correspond to the cable bundle 1020 and / or one or more cables 1025 of the cable bundle and is, for example, rounded, on a side facing the second bracket section 345. As a result, the cable bundle 1020 can be fixed particularly well in the molding space 45 by the fastening brackets 305, 310.

[0149] Figure 30shows a perspective view of a first fastening element 200 according to a fourth embodiment.

[0150] The first fastening element 200 is similar to that in Figure 28shown first fastening element 200. Deviating from this, the first fastening bracket 305 and the second fastening bracket 310 are arranged at the same height in the longitudinal direction (y-direction). Furthermore, the second bracket section 345 of the first fastening bracket 305 tapers towards the second bracket section 345 of the second fastening bracket 310. The taper is preferably designed such that the second bracket section 345 is wedge-shaped. The second bracket section 345 of the second fastening section 310 is designed analogously to the second bracket section 345 of the first fastening bracket 305 and tapers down to the second bracket section 345 of the second fastening bracket 310. A second gap 360 is arranged between the second bracket section 345 of the first fastening bracket 305 and the second bracket section 345 of the second fastening bracket 310.The cable bundle 1020 or individual cables 1025 of the cable bundle 1020 can be inserted through the second gap 360, so that the cables 1025 of the cable bundle 1020 are encompassed by the fastening brackets 305, 310. This allows the cable bundle 12 to be positioned in a predefined position in the mold space 45.

[0151] Figure 31 shows a perspective view of a second fastening element 400.

[0152] The second fastening element 400 comprises a support plate 405, a first engagement portion 410 and a second engagement portion 415. The first engagement portion 410 is shown by way of example in Figure 31arranged on top of the support plate 405. The second engagement section 415 is arranged on the underside of the support plate 405. The support plate 405 is tapered outwardly toward its boundary edge 420. The first engagement section 410 is designed like a Christmas tree and has at least one engagement plate 425 running obliquely to the fastening plate 405, which is preferably arranged on all sides of the first engagement section 410. The engagement plates 425 are embedded in the sheath 1030 of the cable harness 1010. The Christmas tree-like design allows for particularly good fixation of the cable harness 1010 via the sheath 1030 to the second fastening element 400.

[0153] The second engagement portion 415 preferably has a rib-shaped structure 430 on its outside. The second engagement portion 415 is designed to engage an opening 435 in the structure 1005 of the vehicle component 1000 of the motor vehicle. This allows the cable harness 11 to be particularly well secured to the structure 1005.

[0154] It is particularly advantageous if the second recess 240 (cf. Figure 21 ) is formed corresponding to the second engagement portion 415, and the upper side of the support plate 405 is formed larger than the second recess 240. As a result, the fastening plate 405 simultaneously acts as a sealing element and delimits the molding space 45, for example, on the underside. Furthermore, a shoulder in the sheath 103 of the cable harness 1010 is reduced by the support plate 405 tapering outwardly.

[0155] Figure 32shows a perspective view of the second fastening element 400 according to a second embodiment. The second fastening element 400 is a combination of the Figure 29 shown first fastening element 200 and the one in Figure 31shown second fastening element 400. The fastening plate 300 of the first fastening element 200 is formed in one piece and of the same material as the support plate 405 of the second fastening element 400. The first engagement section 410 is omitted by way of example. Furthermore, two first fastening elements 200 are arranged on the fastening plate 405 by way of example. The first fastening element 200 can ensure a position of the cable bundle 1020 and / or at least one cable 1025 in the molding space 45. At the same time, after completion of the cable harness 1010, the cable harness 1010 can be reliably fixed to the structure 1005 via the second engagement section 415. At the same time, the support plate 405 preferably forms a materially bonded connection with the sheath 1030 of the cable harness 1010.

[0156] Figure 33 shows a flowchart of a method for manufacturing the wiring harness 1010. Figure 34shows a plan view of the molding system 10 during a third process step and Figure 35 shows a sectional view along a Figure 34 shown section plane DD.

[0157] In a first method step 3000, the molding system 10 is prepared. Heating of the mold 15 is omitted, so that the mold 15 is essentially at room temperature. Furthermore, the introduction of a release agent into the mold cavity 45, in particular into the wall surface 61, 62 and / or the wall base 63, is omitted. This prevents the cables 1025 from coming into contact with the release agent and prevents a sheathing 1030 to be introduced from adhering to the cables 1025.

[0158] In a second method step 3005, which is optional, the first fastening element 200 and / or the second fastening element 400 are introduced into the mold cavity 45. In this process, the second engagement element 415 is inserted into the second recess 240 until the support plate 405 rests on the wall base 63 or the wall surface 61, 62. The first fastening element 200 is inserted such that it does not protrude from the top of the mold 15 and / or rests with the contact surface 311, 312 against the wall surface 61, 62 or preferably rests on the bottom of the wall base 63.

[0159] In a third method step 3010, the individual cables 1025 of the cable bundle 1020 are inserted. In this process, the first holding element 65 and the second holding element 70 are reversibly deformed from a closed position in a first region 1605 by means of a means 1600 such that an insertion opening 1610 is formed between the holding elements 65, 70. For example, the first and second holding elements 65, 70 are bent into the molding cavity 40 or away from the molding cavity 40. For example, the insertion opening is delimited in the longitudinal direction by the means 1600 and in the transverse direction by the first and second holding elements 65, 70. The means 1600 can be a mechanical tool and / or fingers of a human hand and / or the cable 1025 to be inserted. The means 1600 protrudes, for example, in sections into the molding cavity 40 on the upper side.

[0160] In a second region 1615, which borders the first region 1605 on both sides in the longitudinal direction, the holding elements 65, 70 are in the closed position. Additionally, the first and / or second fastening element 200, 400 optionally secures a defined position of a predefined cable 1025 of the cable bundle 1020 relative to the other cables 1025 of the cable bundle 1020. The first and / or second fastening element 200, 400 can also position and secure the cable bundle 1020 in its position in the molding space. In particular, the defined arrangement of one or more cables 1025 in the cable bundle 1020 allows for precise heating of the cable bundle 1020 in the cable harness 1010. In particular, overheating of the cable harness 1010 is thereby avoided. This prevents possible spontaneous combustion of the wiring harness 1010, short circuits or other irreversible damage to the wiring harness 1010.

[0161] Additionally, in the second region 1615, the holding device 40 prevents the cables 1025 from slipping out of the molding chamber 45. At least one of the cables 1025 of the cable bundle 1020 is inserted via the insertion opening 1610 by moving the means 1600 in the longitudinal direction following the molding chamber 40 and, in parallel, inserting the cable 1025 to be inserted into the molding chamber 40 from above via the insertion opening 1610. During the movement of the means 1600, the holding elements 65, 70 bend open in front of the means 1600 and form the insertion opening 1610. After the means 1600 has passed, they move back into their closed position and cover the opening 35 of the molding chamber 40.

[0162] Through the Figures 10 to 15Thanks to the geometric configuration of the holding device 40 described above, the cables 1025 can be inserted particularly quickly, both manually and automatically, so that the cable harness 1010 can be manufactured particularly cost-effectively. Furthermore, inserting the cable 1025 in shape 15 with the holding device 40 is perceived as particularly ergonomic.

[0163] In a fourth method step 3015, the material of the casing 1030 is introduced into the mold cavity 45 via the opening 35 using a low-pressure process. For this purpose, the holding elements 65, 70 can be reversibly bent again from their closed position (for example, into the mold cavity 40 or away from the mold cavity 40) in order to introduce the material of the casing 1030 into the mold cavity.

[0164] In this case, the second material is preferably first used to form the second layer 1205 (cf. Figure 3) and subsequently the first material of the first layer 1200 is introduced. Both the first and second materials are preferably thin-flowing when introduced. During the processing time of the material, the material sags in the direction of gravity and encloses the cables 1025 of the cable bundle 1020. The second material is accumulated at the wall base 63 and the second layer 1205 is formed. It is particularly advantageous here if the first material is applied to the second material when the second material is already curing and preferably the processing time of the second material has already elapsed.

[0165] If at least part of Form 15 is as in Figure 5described, it is particularly advantageous if the material is first introduced above the first wall surface section 250 and, after filling the lower first wall surface section 250, into the second wall surface section 255 above the second wall surface section 255. Finally, the material is introduced above the wall surface transition section 260. This procedure has the advantage that running off of the material from the second wall surface section 255 via the wall surface transition section 260 to the first wall surface section 250 is avoided.

[0166] When introducing the material into the mold cavity 45, it is particularly advantageous if the material of the sheathing 1030 is applied in a wave-like manner in a plane parallel to the wall base 63 between the first wall section 50 and the second wall section 55. This ensures reliable embedding of the cables 1025 of the cable bundle 1020 in the sheathing 1030.

[0167] If the material is designed such that it foams upon curing, the holding device 40 additionally prevents the cable bundle 1020 from being pushed out of the molding cavity 45 at the top and secures the cable bundle 1020 in the molding cavity 45. This ensures that the cable bundle 1020 is securely enclosed by the sheathing 1030. The first bulge 1036 can be easily formed through the first gap 120. The first bulge 130 is then formed, at least in sections, corresponding to the geometric configuration of the holding elements 65, 70 at the respective free end 100, 130 (cf. Figure 11A and Figure 12 ). If the holding elements 65, 70 are designed like brushes, the first bulge 1036 is produced by the material from the molding chamber 40 pressing against the underside 105, 125 of the brushes 66, 71 during foaming, and the brushes 66, 71 are thereby slightly bent upwards from the molding chamber 40 (in Figure 11B(shown symbolically in dashed lines). The signaling element 1038 corresponds to an imprint of the brushes 66, 71. If the gap 120 is arranged between the brushes 66, 71, the material of the casing 1030 va pushes into the gap 120, so that the first bulge 1036 laterally has a brush imprint of the brushes 66, 71. The design of the signaling element 1038 as a recess 1040 can also be produced particularly easily by means of the brushes 66, 71.

[0168] In a fifth method step 3020, the cover 155 is placed on the mold 15, whereby the cover 155 prevents the retaining elements 65, 70 from bending upwards to a side facing away from the mold cavity 45. This ensures a particularly reliable geometric design of the casing 1030, in particular of the first bulge 1036, even when using foaming materials.

[0169] It should be noted that in addition to the process steps 3000, 3005, 3010, 3015, and 3020 just described, further process steps may be provided. It is also conceivable that some of the process steps 3000, 3005, 3010, 3015, and 3020 may be omitted.

[0170] Furthermore, it is pointed out that the Figures 9A to 26 The different configurations of the molds 15 and / or molded parts 16, 17 described can be combined with each other. The features of the fastening elements 200, 400 can also be combined with each other in different ways. The features of the Figures 1 to 8 described wiring harness 1010 can be combined with each other. Reference symbol

[0171] 10Mold system 15Mold 16First molded part 17Second molded part 18Longitudinal end 19Underside of the molded part 20Mounting board 25Top of the mounting board 26Coordinate system 27Grid field 30Wall 35Opening 40Holding device 45Mold cavity 50First wall section 55Second wall section 60Wall bottom 61First wall surface 62Second wall surface 63Wall base 65First holding element 70Second holding element 75First pressure element 80Second pressure element 85First fastening element 86Plane of symmetry 90First section of the first holding element 95Second section of the first holding element 100First free end of the first holding element 105First underside of the first holding element 110Third section 115Fourth section 120Gap 125Second bottom side 130Second free end 135Second fastening element 140Pin (first engagement element) 141Free end of the pin 142First receptacle 145First indentation 150Sealing element 155Cover 160Third fastening element 165Top of the wall 170Free endof the holding element 175 first web 180 second web 185 first recess 190 end face of the molded part 195 end face of the further molded part 200 first fastening element 205 second engagement element 210 second receptacle 215 first wall area 220 second wall area 225 third wall area 230 fourth wall area 235 widening 240 second recess 241 common area 245 ejector 250First wall surface section 255Second wall surface section 260Wall surface transition section 300 First mounting plate 305 First mounting bracket 310 Second mounting bracket 311 Contact surface of the mounting bracket 312 Contact surface of the mounting bracket 315 Side surface 320 Third recess 325 Fourth recess 330 First insertion opening 335 Second insertion opening 340 First bracket section 345 Second bracket section 349 Free end of the second bracket section 350 Support section 355 Support surface 360 ​​Second gap 400Second fastening element 405Fastening plate 410First engagement section 415Second engagement section 420Limiting edge 425Engagement plate 430Structure 1000Body 1005Structure 1006Supporting structure 1010Cable harness 1015Contact surface 1020Cable bundle 1025Cable of the cable bundle 1030Sheathing 1035Side surface 1036First bulge 1037Top 1038Signaling element 1040Recess 1100First space 1105Second space 1110Partition 1115Opening 1120Second bulge 1121Bulge contour 1122Opening contour 1200First layer 1205Second layer 1210Third layer 1215Surface structure 1220Surface 1225Ribbed structure 1230Rib 1235Rib recess 1240Recess base of the Rib recess 1300Indentation 1305Indentation contour 1310Surface of the structure 1400First sheathing section 1405Second sheathing section 1410Transition section 1415Side surface of the first sheathing section 1420Side surface of the second sheathing section 1425Transition surface 1500 profile 1505 first profile section 1510 second profile section 1600Middle 1605First area 1610Insertion opening 1615Second area 3000first process step 3005second process step 3010third process step 3015fourth process step 3020fifth process step adistance b 1 first transverse extension b 2 second transverse extension

Claims

1. Cable harness (1010) for a motor vehicle, - having at least one cable bundle (1020) having at least two cables (1025), and a sheathing (1030), - wherein the cable bundle (1020) is embedded at least in portions in the sheathing (1030), - wherein the sheathing (1030) has a first sheathing portion (1400) and a second sheathing portion (1405), - wherein the first sheathing portion (1400) has a first transverse extent (b1) relative to a first longitudinal extent direction of the first sheathing portion (1400), - wherein the second sheathing portion (1405) has a second transverse extent (b2) relative to a second longitudinal extent direction of the second sheathing portion (1405), - wherein the first transverse extent (b1) is larger than the second transverse extent (b2), - wherein the sheathing (1030) has a transition portion (1410), - wherein the transition portion (1410) is disposed between the first sheathing portion (1400) and the second sheathing portion (1405), - wherein the first sheathing portion (1400) has a first lateral face (1415) and the second sheathing portion (1405) has a second lateral face (1420), - wherein the transition portion (1410) has a transition face (1425) which has an inclination relative to the first lateral face (1415) and the second lateral face (1420), - wherein the inclination has an angle (α1), wherein the angle (α1) has a value of less than 45°, in particular less than 30°, in particular less than 20°, in particular less than 15°, in particular less than 10°.

2. Mould (15) for producing a wire harness (1010) according to Claim 1, - having a wall (30) and an opening (35), - wherein the wall (30) at least laterally delimits a mould cavity (45), - wherein the mould cavity (45) on the upper side is adjacent to the opening (35), - wherein the wall (30) has a first wall face portion (250), a second wall face portion (255) and a wall face transition portion (260), - wherein the first wall face portion (250) is disposed lower than the second wall face portion (255), - wherein disposed between the first wall face portion (250) and the second wall face portion (255) is the wall face transition portion (260), - wherein the wall face transition portion (260) is disposed at an angle relative to the first wall face portion (250) and the second wall face portion (255), - wherein the inclination has an angle (α2), wherein the angle (α2) has a value of less than 45°, in particular less than 30°, in particular less than 20°, in particular less than 15°, in particular less than 10°.

3. Mould(15) according to Claim 2, - wherein the first wall face portion (250) and the second wall face portion (255) are disposed in two mutually parallel planes.

4. Mould (15) according to Claim 2 or 3, - wherein the wall (30) comprises at least one of the following materials: - polytetrafluoride (PTFE), - polyoxymethylene (POM).

5. Mould (15) according to one of Claims 2 to 4, - wherein the wall (30) has a wall face (61, 62) facing the mould cavity (45), - wherein the wall face (61, 62) is laser-polished at least in portions.

6. Mould (15) according to one of Claims 2 to 5, - wherein a sealing element (150) is disposed on a longitudinal end (18) of the wall (30), so as to at least partially prevent the sheathing (1030) from exiting the mould cavity (45).

7. Mould (15) according to one of Claims 2 to 6, - having a first mould part (16) and a second mould part (17), - wherein the first mould part (16) has an engaging element (205) on a longitudinal end (18), - wherein the second mould part (17) has a receptacle (210), designed so as to correspond to the engaging element (205), on a longitudinal end (18) of the second mould part (17) that faces the longitudinal end (18) of the first mould part (16), - wherein the engaging element (205) engages in the receptacle (210) and connects the first mould part (16) to the second mould part (17) in a form-fitting manner, - wherein the engaging element (205) and the receptacle (210) are mutually designed in such a manner that an extraction in the longitudinal direction is blocked by the engagement of the engaging element (205) in the receptacle (210).

8. Mould system (10) - having a mould (15) and an assembly board (20), - wherein the mould (15) is designed according to one of Claims 2 to 7, - wherein the mould (15) on a side facing the assembly board (20) has an additional engaging element (140), and the assembly board (20) on a side facing the mould (15) has at least one grid field (27) having a plurality of additional receptacles (142), - or wherein the mould (15) on a side facing the assembly board (20) has an additional receptacle (142), and the assembly board (20) on a side facing the mould (15) has a grid field (27) having a plurality of additional engaging elements (140), - wherein the additional engaging element (140) and the additional receptacle (142) are disposed in a mutually corresponding manner, - wherein the additional engaging element (140) engages in one of the additional receptacles (142) and releasably connects the assembly board (20) to the mould (15) in a form-fitting and reversible manner, - wherein the other additional receptacles (142) of the grid field remain vacant, or - wherein one of the additional engaging elements (140) engages in the additional receptacle (142) and releasably connects the assembly board (20) to the mould (15) in a form-fitting and reversible manner, - wherein the other additional engaging elements (140) of the grid field remain vacant.