Method for producing an electric line set, and electric line set

Abstract

The invention relates to a method for producing an electric line set (2) and to such a line set (2). According to the method, an installation device (4) is provided which has a support (6) with guiding pins (8) arranged thereon. A support layer (10) is first applied onto the support (6), then conductors (14), and finally a cover layer (18). The support layer (10) and preferably also the cover layer (18) have a plurality of passage openings (12) for respective guiding pins (8), which can be guided through the passage openings. The conductors (14) are arranged according to a desired installation pattern and are routed around the guiding pins (8) for this purpose. A laminate composite (20) formed in this way is then removed from the support (6) and pulled from the guiding pins (8). In this way a simple production of such a line set (2) is facilitated.

Description

[0001] Description Method for producing an electrical wiring harness and electrical wiring harness

[0002] The invention relates to a method for producing an electrical wiring harness and to such an electrical wiring harness, in particular for a motor vehicle.

[0003] When manufacturing conductor sets that are intended to connect several components and usually have several conductors and often also a branched conductor structure, automated production is often desired.

[0004] In applications where a specific routing pattern for the individual conductors is required, considerable effort is often required. Especially in automotive applications, especially with large-area, branched routing patterns, such as those used in doors or as cell contact systems in batteries, manufacturing with conventional, simple cables is complex. Due to the size of such cable harnesses, the use of printed circuit boards (PCBs) is often not technically and economically feasible.

[0005] DE 10 2012 205 020 A1 and WO 2020 / 161047 A1 each disclose cell contacting systems for batteries in which pin-shaped guide elements are arranged on a base plate along which the conductors are laid according to a predetermined laying pattern.

[0006] For the production of small components, such as plastic cards, labels, or transponders, WO 02 / 056657 A1 describes a method in which conductors are pressed into an adhesive layer of a support layer using a clamping frame according to a desired laying pattern. The clamping frame has several pin-shaped guide elements along which the conductors are laid. The individual guide pins are spring-mounted on the clamping frame so that they spring back upon contact with the support layer. After the conductors are pressed into the adhesive layer and the clamping frame is removed, a second support layer is applied from above so that the conductors are sandwiched between the support layers in the adhesive layer.

[0007] Based on this, the object of the invention is to provide a cost-effective and simple production of a wiring harness, especially for a motor vehicle.

[0008] The object is achieved according to the invention by a method for producing an electrical cable harness, in which

[0009] - a mounting device is provided which has a support with guide pins arranged thereon and projecting from a support plane,

[0010] - a carrier layer is placed on the carrier, wherein the carrier layer has several through-openings for each guide pin and the guide pins are each guided through a respective through-opening through the carrier layer,

[0011] - several conductors are arranged on the carrier layer according to a desired laying pattern and for this purpose at least some of the conductors are guided around the guide pins,

[0012] - a cover layer is applied and laminated to the carrier layer so that a laminate composite is formed in which the conductors are fixed between the cover layer and the carrier layer according to the laying pattern, and in which

[0013] - the laminate composite is subsequently removed from the carrier and pulled off the guide pins. The object is further achieved according to the invention by an electrical cable harness which was produced in particular using such a method and which has a laminate composite with a carrier layer, with a cover layer laminated to the carrier layer, and with a plurality of conductors arranged between the two films and held according to a desired laying pattern, wherein at least some of the conductors have at least one bend and the carrier layer has a passage opening in the region of each bend, along which the conductor runs in regions on the circumference.

[0014] The two layers, i.e. the carrier layer and the cover layer, are preferably (plastic) films or alternatively textile layers, in particular nonwoven layers. A textile layer is generally understood to be a layer consisting of a large number of individual fibers connected to one another, so that a textile fabric is formed. The fibers are connected to one another by a textile process, such as weaving, knitting, braiding. However, a conventional process for producing a nonwoven fabric is preferably used as the textile process, such as a mechanical, chemical or thermal bonding process. The nonwoven fabric preferably consists in particular of thermoplastic fibers such as PET (polyethylene terephthalate), PBT (polybutylene terephthalate), PP (polypropylene), PA (polyamide) and PE (polyethylene). Alternative materials, such asThe use of natural fibers or mixtures of synthetic fibers and natural fibers is also possible.

[0015] In particular, the textile layers are preferably suitably prepared, for example by being provided with or impregnated with a (thermally) activatable adhesive, so that the two layers can be firmly bonded to one another by thermal bonding to form the laminate composite. Alternatively or additionally, the fibers used are already suitably designed and are, for example, in the form of plastic fibers and / or have a softenable or meltable outer layer. The layers are generally designed as thin, flexible layers that are particularly not inherently rigid. They can therefore easily adapt to a surface structure formed, for example, by the conductors, and conform to the surface structure.

[0016] This process enables the cost-effective production of such a wiring harness, especially a large-area wiring harness, particularly for automotive applications. The assembly device with its attached guide pins therefore serves only as temporary guidance and support during the construction of the laminate composite. This approach is based on a conventional process in which the conductors are laid individually along guide pins on a cable board.

[0017] Accordingly, the method also provides for the conductors to be laid successively, one at a time. Each conductor is guided along a predetermined installation path. This is preferably done automatically, e.g., with the help of a laying robot, or alternatively manually.

[0018] The various conductors are routed along different installation paths. A change in direction and bend of at least 30° typically occurs at each guide pin. Therefore, each conductor rests directly against the guide pin.

[0019] The desired routing pattern is only created when the cables are laid. Therefore, no prefabricated cable harness with a pre-defined routing pattern is placed on the support layer, i.e., no prefabricated cable harness that already has branches. Also, when laying the cables, connectors or other connection elements that accommodate multiple cables are usually not yet attached to the ends.

[0020] The specified installation pattern, and thus the cable harness after the individual conductors have been laid, forms a branched structure. This typically consists of a main line from which one or more secondary lines branch off. A secondary line comprises one or more conductors that were previously part of the main line (before the branch).

[0021] Therefore, usually only a portion of the conductors of the cable set are redirected at a guide pin.

[0022] According to a preferred embodiment, a guide pin is provided for each conductor for deflection. If a branching branch consists of multiple conductors, a guide pin and a corresponding through-hole are preferably provided / formed for each conductor of this branch. Accordingly, in the finished cable harness, only exactly one conductor runs around each through-hole.

[0023] When laying individual conductors successively, the various conductors are typically guided differently at defined length positions. Specifically, only a portion of the conductors (e.g., forming a secondary strand) is bent at a guide pin or group of guide pins and at a defined length position, while the other conductors (further conductors of the main strand) continue in a straight line and are not bent at this length position.

[0024] The two layers (carrier layer and cover layer) are each one-piece layers that cover the entire cable harness with its branched laying pattern - except for the edge areas where the conductors protrude at the ends.

[0025] Of particular note are the through-holes in the carrier layer, which are also visible in the finished wiring harness. These through-holes allow the carrier layer to be easily placed on the assembly device, as the guide pins are guided through them.

[0026] The guide pins also secure and align the carrier layer on the assembly device, ensuring the most precise alignment of the individual conductors on the carrier layer. Due to the special manufacturing process, each conductor runs circumferentially along a particular through-opening for a portion of its bend. Depending on how the through-openings are created, the conductor may, for example, run directly along the edge of the through-opening. Alternatively, the conductor may also run partially through the through-opening or be spaced radially from the edge of the through-opening.

[0027] The respective conductors are therefore bent in the area of ​​the through-holes within a laying plane defined by the carrier layer and running parallel to it. In particular, no components are located in the area of ​​the through-holes when the laminate is removed from the guide pins. They therefore exist as a free opening.

[0028] The guide pins extend vertically beyond the support layer, particularly to the extent that they also extend vertically beyond the conductors. The conductors are laid along the circumference of the guide pins.

[0029] When it is mentioned here that the two layers are laminated together, this means that they are bonded together. For this purpose, for example, a special adhesive layer is applied to at least one layer, especially in the form of a film, to which the second layer, preferably a film, is bonded. Alternatively or additionally, a temperature treatment (heating) or UV treatment is provided for the lamination process, for example, so that, for example, a special surface layer of the film softens and forms a bond with the other film and / or an adhesive applied to the film is activated.When designed as a textile layer with a large number of fibers, these are softened or at least partially melted by the introduction of heat, so that fibers of the two layers are bonded to one another by the introduction of heat and, if necessary, additionally by the introduction of force, and remain reliably bonded to one another by subsequent curing.

[0030] When referring to a film in this context, this refers to a film-like, flexible structure made of an electrically insulating material, particularly plastic. A textile layer is also a flexible structure made of an electrically insulating material.

[0031] The textile layer preferably has additional functions, such as an insulating and / or thermal insulation function. For this purpose, the layer is suitably designed, for example, by having a suitable thickness or by a multi-layer structure with, for example, differently designed individual layers.

[0032] The conductors are preferably bare, solid single wires. Alternatively, they can be enameled wires, in which a coating of enamel is applied to the bare conductor wire. Instead of solid single wires, stranded wire can also be used. The conductors are preferably not conventional cores, where the electrical conductor is typically surrounded by an extruded insulating sheath.

[0033] Preferably, a plurality of guide pins are provided in the method, and several of the conductors are preferably guided around a guide pin several times each. Therefore, the finished cable harness comprises several conductors, for example, more than 5 or 10, each of which preferably has several bends.

[0034] During each bend, the conductor is bent according to a radius of the guide pins, i.e., the bending radius corresponds to the radius of the guide pins. The bending occurs within a plane and typically at a bending angle of at least 45°, or at least 60°, or at least 90°. In a preferred embodiment, the openings are only formed when the carrier layer is applied. For this purpose, the guide pins pierce the carrier layer. The guide pins therefore perforate the carrier layer at their respective positions. The guide pins are preferably suitably designed for this purpose and, for example, have a tapered end similar to a piercing pin.

[0035] According to an alternative variant, the through-openings are created in advance, for example by punching.

[0036] In a useful further development, the cover layer also has through-openings for the guide pins and these are also guided through the cover layer when the cover layer is placed on top.

[0037] Similar to the carrier layer, in a preferred embodiment, the cover layer is perforated using guide pins. Alternatively, the through-holes are pre-cut.

[0038] In the finished cable harness, the carrier layer and the cover layer therefore have through-openings in the area of ​​a respective bend of a respective conductor that are aligned with each other.

[0039] According to a preferred embodiment, a shielding film is additionally applied to the laminate composite. This preferably takes place before the laminate composite is removed from the carrier. This shielding film is in particular an additional, electrically conductive film, for example a metal foil or a plastic film provided with a metal layer. The shielding film is preferably also materially bonded to one of the two layers, in particular the cover layer, in the manner of a lamination and is part of the laminate composite. The shielding film serves to electromagnetically shield the laying pattern formed by the conductors, at least in some areas. This achieves good EMC compatibility. According to a preferred development, the carrier layer and in particular also the cover layer have an opening so that a window is formed in the laminate composite.In the area of ​​this window and thus the aligned openings of the two layers, at least some of the conductors are exposed, allowing them to be contacted and, when assembled, also connected to a connecting element. The window or openings therefore form a contact zone for conductors that are generally freely accessible in the area of ​​the opening.

[0040] The conductors are electrically contacted via the connecting element. The connecting element has one or more contact elements, which are designed, for example, as clamp contacts, plug contacts, insulation displacement contacts, etc. The connecting element preferably has an insulating housing in which several such contact elements are arranged. An outgoing cable harness is preferably attached to the connecting element, which is thus in contact with the conductors. When installed, this cable harness leads, for example, to an electrical component.

[0041] The connecting element is preferably connected to the laminate composite and thus forms an integral part of the wiring harness. For example, the insulating housing is designed in two parts and is clamped to the laminate composite, for example, by riveting. Additionally or alternatively, it is integrally connected to the laminate composite.

[0042] According to a preferred embodiment, the carrier has a structured surface that forms a guide structure for the conductors. When the carrier layer is placed on this structured surface, the carrier layer adapts to it, thus adopting the surface structure, so that the guide structure is reproduced by the carrier layer and imprinted on it.

[0043] For this purpose, the carrier layer generally exhibits sufficient flexibility so that it can conform directly to the carrier's guide structure. In a preferred embodiment, the carrier layer and the cover layer have different stiffnesses and / or different thicknesses.

[0044] In the final laminate composite, the high flexibility of the carrier layer is reflected in the fact that the outer surface of the laminate composite, formed by the carrier layer, is also structured and, in particular, corrugated. This corrugated surface structure essentially represents a negative of the carrier's guiding structure.

[0045] Specifically, when the conductors are routed individually, each individual conductor is embedded in a corrugated elevation. In a first variant, the side of the laminate composite formed by the cover layer is also structured and corrugated. Therefore, in this variant, the cover layer also conforms to the conductors' contours.

[0046] In a preferred alternative embodiment, the cover layer and thus the second side of the laminate composite is flat.

[0047] In addition to the individual guide pins, the guide structure therefore provides an additional guide structure so that reliable guidance of the conductors is ensured, particularly between the individual guide pins.

[0048] The conductors are preferably guided individually through the guide structure. Adjacent conductors are kept at a distance from one another by the guide structure. This reliably achieves sufficient insulation even between the individual conductors. Specifically, it is provided that the two layers in the spacing area between the two conductors are connected to one another, in particular continuously along the conductors, so that each conductor is completely surrounded by the two interconnected (insulating) layers, preferably over its entire length (as long as it runs between the two layers). The guide structure preferably holds the individual conductors at a constant, predetermined pitch to one another, for example at a pitch in the range of 1.5 mm to 5 mm and specifically, for example, at 2.53 mm.The pitch is in particular adapted to a pitch of the previously described connection element (plug), in which contact elements are usually held to one another in the defined pitch.

[0049] The guide structure is preferably formed by a plurality of individual guide grooves, which in particular run parallel to one another. The guide grooves preferably extend in a straight line between two guide pins.

[0050] Preferably, a respective guide groove for a respective conductor is composed of several sub-grooves, wherein each sub-groove preferably runs in a straight line and the sub-grooves are oriented at an angle to each other (not equal to 180°). In particular, a guide pin is arranged between each of the sub-grooves, at which a respective conductor is deflected.

[0051] The individual guide grooves preferably have the previously described grid dimension relative to one another.

[0052] The guide grooves are preferably formed by a space between ribs, which are applied, for example, to a flat surface of the carrier, apart from the ribs. The carrier generally preferably has a carrier plate, onto which the ribs are preferably applied.

[0053] For example, the ribs are arranged detachably on the surface, allowing them to be positioned in different ways. Alternatively, they are a permanent part of the support. With a detachable attachment, the support can be prepared for different installation patterns.

[0054] In contrast to the structured surface of the carrier, the surface of the laminated plate is preferably flat, at least in the area of ​​the conductors, and in particular has no guide grooves and / or ribs for guiding the conductors.

[0055] With regard to the intended lamination process, a laminating plate is preferably provided for lamination, i.e., for bonding the two layers together. This plate is preferably heatable. Alternatively, or additionally, the carrier is preferably heatable.

[0056] For lamination, the laminated board is placed on the layered structure with the two layers and the conductors arranged between them. This layered structure is therefore located between the carrier and the laminated board. The carrier and the laminated board are pressed against each other. By heating the laminated board and / or the carrier, in particular electrically, a thermal, material-to-material bond is created between the two layers. This particularly involves a partial softening or melting of the plastic, thus achieving the desired material-to-material bond. Alternatively, the heat can also be used to activate an adhesive or adhesive layer.

[0057] In a preferred embodiment, the laminating plate has recesses into which the guide pins engage when the laminating plate is placed. According to a first embodiment, the recesses are arranged according to an individual pattern, as determined by the positioning of the guide pins on the carrier.

[0058] Alternatively, for example, a plurality of recesses are formed distributed over the surface of the laminating plate, for example in a predetermined grid dimension.

[0059] In general—regardless of the lamination board—the carrier, in a preferred embodiment, has pin receptacles for the guide pins, which are also arranged according to a grid spacing. The guide pins can be inserted into these pin receptacles in a variable manner depending on the desired installation pattern. The carrier and / or the lamination board are therefore each, for example, a perforated board with a predetermined grid spacing for the guide pins.

[0060] Positioning elements, in particular positioning pins, are also attached to the carrier or to the laminating plate, which engage and insert into corresponding positioning recesses on the other plate. This achieves mutual guidance and alignment of the two plates. Spring elements are preferably attached to the positioning elements, which exert a spring force in such a way that the carrier and the laminating plate are pressed apart. During the lamination process, the two plates are therefore pressed against each other against this spring force. The spring elements at least assist in separating the two plates after the lamination process. The spring elements are designed, in particular, as helical springs, which are mounted on the positioning elements.

[0061] Furthermore, it is provided, for example, that in addition to the conductors, electrical components are attached between the two layers and thus within the laminate composite or alternatively also on the laminate composite and are electrically contacted with some of the conductors. These components include, for example, circuit components, processors, or even circuits mounted on a carrier in the manner of a printed circuit board / printed circuit.

[0062] The electrical wiring harness is intended in particular for use in a vehicle and is used in a vehicle when assembled.

[0063] In a preferred embodiment, the wiring harness forms a separating element to separate a wet area from a dry area. Specifically, the wiring harness is arranged in or on a door module for this purpose.

[0064] Alternatively, the wiring harness is merely part of the door module, without forming such a separating element. According to an alternative application, the wiring harness forms a cell contact system or is at least part of such a cell contact system. Such a cell contact system serves to electrically contact the individual cells of a battery. The battery is, for example, a traction battery for an electrically powered motor vehicle.

[0065] An embodiment of the invention is described in more detail below with reference to the figures, which show, in highly simplified representations:

[0066] FIG 1 is a cross-sectional view of a cable harness during assembly along section line I - 1 in Figure 2,

[0067] FIG 2 is a plan view of the wiring harness according to Figure 1,

[0068] FIG 3 a highly simplified schematic diagram of a motor vehicle door in sectional view,

[0069] FIG 4 a highly simplified schematic diagram of a cell contact system in plan view

[0070] FIG 5 shows a simplified plan view of a carrier with a cable harness applied thereon according to a further embodiment,

[0071] FIG 6 is a partially enlarged view of the plan view according to Figure 5, showing further details, and

[0072] FIG 7 is a side view in the form of an exploded view of an assembly device for producing the cable harness.

[0073] In the manufacture of an electrical cable harness 2 shown in FIG. 1 and FIG. 2 or also in FIG. 5, an assembly device 4 is first provided. This device has a preferably plate-shaped support 6 on which guide pins 8 are arranged, which protrude vertically upwards from the support 6.

[0074] In the first step, a carrier layer 10 is placed onto the mounting device 4 from above. The individual guide pins 8 are inserted through through-openings 12 in the carrier layer 10. Preferably, the through-openings 12 are first formed by the guide pins 8. The guide pins 8 preferably have a piercing tip at their free end. Alternatively, the through-openings 12 are already introduced. In this case, they have a larger diameter than the typically circular guide pins 8.

[0075] The carrier layer 10 can be a film provided with an adhesive layer. Alternatively, the carrier layer can be a nonwoven fabric.

[0076] In the next step, a plurality of individual conductors 14, which are preferably bare, solid individual wires, are arranged on the carrier layer 10 according to a desired laying pattern.

[0077] The individual conductors 14 are preferably laid one at a time, one after the other, i.e., successively. Each individual conductor is therefore laid along a predetermined installation path and, in the process, is guided around one of the guide pins 8 in the area of ​​changes in direction.

[0078] As can be seen specifically in FIG. 2, some of the conductors 14 run in a straight line. However, some of the conductors 14 change their orientation and are guided around the guide pins 8. These conductors 14 each have a bend 16 in the area of ​​the guide pins.

[0079] The laying of the conductors 14 on the carrier layer 10 is preferably carried out automatically with the aid of a laying head (not shown in detail), which automatically guides the conductors around the guide pins.

[0080] By successively laying the conductors 14, a desired laying pattern is created. Overall, a branched structure is formed in which at least one secondary strand, which has (only) a portion of the conductors 14, typically branches off from a main strand with all the conductors 14. In the exemplary embodiment, only one secondary strand with two conductors 14 is shown. The conductor pattern often has multiple secondary strands. As can be seen in particular from FIG 2, the exemplary embodiment provides for each of the conductors 14 of the secondary strand to be guided around an associated guide pin 8. Therefore, in the exemplary embodiment, only exactly one conductor 14 is guided around each guide pin 8. The guide pins 8 for the conductors of a secondary strand are positioned such that the individual conductors 14 of the secondary strand run parallel to one another.

[0081] After laying the conductors 14, a cover layer 18 is applied. This cover layer also has through-holes 12, which are preferably formed by the guide pins 8. This cover layer 18 also preferably has an adhesive layer. The two layers 10, 18 are bonded together, forming an overall laminate assembly 20 in which the conductors 14 are sandwiched between the two layers 10, 18.

[0082] As can also be seen, both layers 10, 18 have a significantly larger opening 22 compared to the through-holes 12, with the two openings 20 aligned one above the other, thus forming a type of contact window. In the area of ​​these openings 20, a portion of the conductors 14 is exposed, allowing them to be accessed and contacted. The openings 20 therefore define a contact zone.

[0083] Optionally, there is also the possibility of applying and, in particular, laminating a shielding film 24 to the laminate composite 20, specifically to the cover layer 18, at least in some areas, so that the shielding film 24 is part of the laminate composite 20. This shielding film 24 serves for electrical and / or magnetic shielding.

[0084] In the exemplary embodiment, the shielding foil 24 covers only a partial area, namely the portion of the conductors 14 that run in a straight line. Alternatively, the shielding foil 24 covers the entire installation pattern formed by the conductors 14.

[0085] The formed laminate composite 20 is subsequently lifted from the assembly device 4. If the through-openings 12 were formed by perforation using the guide pins 8, the through-openings 12 close again slightly, so that, for example, a portion of the respective layer 10, 18 protrudes radially beyond the conductors 14 in the region of the bend 16, so that the conductors are not exposed in the region of the through-openings 12.

[0086] In the exemplary embodiment (left half of the image), it is shown that at least some of the conductors 14 extend beyond the carrier layer 10 at the edges, so that they are exposed at the edge of the carrier layer 10 for contacting purposes. These can be contacted, for example, via a connection element 26, which is only indicated by dashed lines. Such a connection element 26, such as a connector, typically accommodates several conductors 14. The connection elements 26 are, in particular, only attached after the individual conductors 14 have been laid.

[0087] Such a connecting element 26 is also provided, particularly in the area of ​​the contact zone formed by the openings 22, and is also only indicated schematically and by dashed lines. The connecting element 26 is, in particular, firmly connected to the laminate composite 20 and is thus an integral component of the cable harness 2. For example, the connecting element 26 has a two-part insulating housing, with the laminate composite 20 clamped between the two housing parts.

[0088] The cable set 2 is designed in particular as a large-area cable set 2, which has an area of ​​at least 0.25 m 2 , preferably at least 0.5 m 2 or even more covered. Wiring harness 2 is specifically designed for a motor vehicle and, when assembled, is installed in a motor vehicle.

[0089] FIG. 3 shows a preferred application in a motor vehicle. Specifically, the wiring harness 2 is arranged within a vehicle door 28, namely as a separating element between a wet area 30 and a dry area 32. The wiring harness 2 is preferably part of a door module 34, on which electrical components such as loudspeakers, servomotors (window lifters), control units, etc. are arranged. The wiring harness 2 serves to connect these components of the door module 34. The door has an inner panel 36 toward the passenger compartment and an outer panel 38 toward the outside.

[0090] Finally, FIG. 4 shows an alternative embodiment in which the cable harness 2 forms a cell contact system 40 for a battery 42, specifically for a traction battery of an electrically powered vehicle. FIG. 4 shows a top view in which the cable harness 2 with the conductors 14, and thus the cell contact system 40, are shown only in dashed lines.

[0091] The battery 42 generally comprises a plurality of battery cells 44 that are electrically connected to one another. The cable harness 2 serves this purpose. The individual battery cells 44 are electrically contacted via the individual conductors 14 in a conventional manner. A control element (not shown in detail here), for example, a so-called battery management system, is preferably also part of the cable harness 2. At least one such control element is connected to the cable harness 2.

[0092] FIG 5 shows, by way of example, a plan view of the carrier 6 with a further cable set 2 in a simplified representation in which several elements of the carrier 6 and also of the cable set 2 are not shown.

[0093] The individual conductors 14 are laid according to a branched laying pattern, as is frequently encountered in practice. For example, several secondary strands 48 branch off from a main strand 46. In the exemplary embodiment, the main strand 46 extends, in particular in a straight line, from a left-hand, first connection side with a first connection element 26 to a right-hand, second connection side with a second connection element 26, preferably over the entire length of the support 6, at least over the entire length of a predetermined laying area of ​​the support 6. The secondary strands 48 branch off from the main strand 46 at right angles or at an angle, for example at 45°. In the exemplary embodiment, a connection element 26 is also connected to the end of each secondary strand 48.

[0094] In the exemplary embodiment, it is further provided that a further secondary strand 48 branches off from the one secondary strand 48, which in the exemplary embodiment runs, for example, below and partly parallel to the main strand 46.

[0095] Furthermore, FIG. 5 shows positioning pins 50 of the carrier 6, the function of which will be explained further below in connection with FIG. 7.

[0096] In FIG. 6, the enlarged view of the upper left corner area of ​​FIG. 5 shows as an additional detail that the surface of the carrier 6 is structured. In particular, a large number of individual ribs 52 are applied to the surface, each of which preferably runs in a straight line. The ribs 52 are formed in particular by strips which are applied, for example, to the surface of the carrier 6, for example by gluing or detachably, for example by screwing. Alternatively, the ribs are milled out of the surface, for example. The ribs 52 each form elevations, and the free spaces formed between adjacent ribs 52 form depressions in the manner of grooves. For each conductor 14, a guide groove 54 is formed by the ribs 52, in which guide groove the conductor 14 is guided individually. The conductor 14 is in particular a bare wire or an enamelled wire.

[0097] A respective guide groove 54 extends between two guide pins 8, preferably in a straight line. A respective guide groove 54 can be divided into several partial grooves, in particular when a secondary strand 48 branches off from the main strand 46. At branching points, where the conductors 14 are guided around a respective guide pin 8 and thus angled, two partial grooves and thus also two ribs 52 adjoin one another. In particular, a guide pin 8 is arranged between each two consecutive ribs 52 / partial grooves arranged at an angle to one another. The ribs 52 define, in particular, a predetermined grid dimension between them. The ribs run parallel to one another, so that the grid dimension is always constant.

[0098] Viewed in cross-sectional profile, the ribs 52 taper upwards, forming a sort of insertion funnel between two ribs 52 for inserting the respective conductor 14. Preferably, each rib 52, viewed in cross-sectional profile, has a base region of a defined width, to which a conical head portion adjoins at the top. This also leads to a lower required force input during the joining process by reducing the contact area.

[0099] FIG. 7 shows a simplified side view of an assembly device 4 with the laminate composite 20 inserted therein, in the manner of an exploded view. Based on FIG. 7, a preferred variant of the lamination process for forming the laminate composite 20 and the wiring harness 2 is described below:

[0100] In addition to the previously described carrier 6, the mounting device 4 also has a laminating plate 56 which is placed on the carrier 6.

[0101] From the illustration in FIG 7, it can first be seen that the ribs 52 for forming the structured surface and for individually guiding the individual conductors 14 are attached to the carrier. The guide pins 8 and the positioning pins 50 can also be seen. These are preferably arranged outside the carrier layer 10 and the cover layer 18 and therefore do not penetrate them. Corresponding to the guide pins 8, recesses 58 are formed in the lamination plate 56, and corresponding to the positioning pins 50, positioning recesses 60 are formed. These are each designed as depressions in the manner of blind holes, but can alternatively also be designed as through holes. In the exemplary embodiment, a spring element 62 in the form of a helical spring is also placed on each of the positioning pins 50.

[0102] The individual steps for forming the laminate composite 20 are as follows:

[0103] First, the carrier layer 10, particularly in the form of a nonwoven layer, is placed on the carrier 6. The carrier layer 10 conforms to the surface structure formed by the ribs 52. In the area of ​​the ribs 52, these form a corrugated or crenellated guide structure—viewed in cross-section.

[0104] The simplified illustration in FIG. 7 shows that the ribs 52 pierce the carrier layer 10. This can be provided alternatively; however, the carrier layer 10 preferably rests merely on the ribs 52 without being pierced by them. A head region of the ribs 52 is preferably not sharp-edged, so that the carrier layer 10 can be placed over the ribs 52 without being pierced. In contrast, the guide pins 8 pierce the carrier layer 10.

[0105] In a second step, the conductors 14 are inserted into the individual guide grooves 54 formed by the ribs 52.

[0106] According to a preferred, but not mandatory, embodiment, the conductors 14 are enamelled wires.

[0107] In the third step, the cover layer 18 is applied, which is again designed in particular as a nonwoven layer. The guide pins 8 pierce the cover layer 18.

[0108] The lamination plate 56 is then placed on top and aligned and guided relative to the carrier 6 by the positioning pins 50. The lamination plate 56 is a heatable plate that is heated for lamination. The lamination plate 56 is then pressed against the carrier 6 with a predetermined pressing force, so that the two layers 10, 18 are pressed against each other with the conductors 14 interposed. Unlike the carrier 6, the lamination plate 56 preferably has a flat surface that comes into contact with the cover layer 10.

[0109] This is followed by the actual lamination process, in which the two layers 10,18 undergo thermal bonding under the influence of heat and pressure and are thus firmly bonded to one another.

[0110] After this thermal bonding, the lamination plate 56 is lifted off again, with the spring force of the spring elements 62 providing support for this.

[0111] In the final step, the formed laminate composite 20 is finally lifted off the carrier 6. The invention is not limited to the exemplary embodiments described above. Rather, other variants of the invention can also be derived therefrom by those skilled in the art without departing from the scope of the invention.

[0112] List of reference symbols

[0113] 2 wiring harness

[0114] 4 Mounting device

[0115] 6 carriers

[0116] 8 guide pins

[0117] 10 carrier layers

[0118] 12 Passage opening

[0119] 14 ladders

[0120] 16 Bend

[0121] 18 top layer

[0122] 20 laminate composite

[0123] 22 Breakthrough

[0124] 24 shielding foil

[0125] 26 connecting element

[0126] 28 vehicle door

[0127] 30 wet areas

[0128] 32 Dry area

[0129] 34 Door module

[0130] 36 Interior paneling

[0131] 38 Outer sheet

[0132] 40 cell contact system

[0133] 42 Battery

[0134] 44 battery cells

[0135] 46 Main strand

[0136] 48 side strand

[0137] 50 positioning pin

[0138] 52 ribs

[0139] 54 guide groove

[0140] 56 Laminating board

[0141] 58 recess

[0142] 60 Positioning recess

[0143] 62 spring element

Claims

Claims Method for producing an electrical cable harness (2), in which - a mounting device (4) is provided which has a carrier (6) with guide pins (8) arranged thereon, - a carrier layer (10) is placed on the carrier (6), wherein the carrier layer (10) has a plurality of through-openings (12) for a guide pin (8) each, and the guide pins (8) are each guided through a respective through-opening (12) through the carrier layer (10), - several conductors (14) are arranged on the carrier layer (10) according to a desired laying pattern and for this purpose at least some of the conductors (14) are guided around the guide pins (8), - a cover layer (18) is applied and laminated to the carrier layer (10) so that a laminate composite (20) is formed in which the conductors (14) are fixed between the cover layer (18) and the carrier layer (10) according to the laying pattern, - the laminate composite (20) is subsequently removed from the carrier (6) and pulled off the guide pins (8). Method according to the preceding claim, in which, when the carrier layer (10) is placed on it, it is perforated by the guide pins (8) to form the through-openings (12). Method according to one of the preceding claims, in which the cover layer (18) also has through-openings (12) for the guide pins (8), and the guide pins (8) are guided through the cover layer (18) when the cover layer (18) is placed on the carrier layer (10). Method according to one of the preceding claims, in which, in particular before the laminate composite (20) is removed from the carrier (6), an additional shielding film (24) is applied at least in regions to the cover layer (18). Method according to one of the preceding claims, in which the carrier layer (10) has an opening (22), wherein at least some of the conductors (14) are exposed in the region of the opening (22) and the opening (22) forms a contact zone for the conductors (14). Method according to one of the preceding claims, in which a film with an adhesive layer is used as the carrier layer (10) and the conductors (14) are placed onto the adhesive layer. Method according to one of the preceding claims, in which the carrier has a structured surface which has a guide structure for the conductors (14), wherein the carrier layer (10) adapts to the structured surface when placed on the structured surface so that the guide structure is impressed on the carrier layer (10). Method according to the preceding claim, in which the conductors (14) are guided individually through the guide structure.Method according to one of the two preceding claims, in which the guide structure has a plurality of individual guide grooves (54) which run in particular parallel to one another, the guide grooves (54) being formed in particular by free spaces between ribs (52) applied to an upper side of the carrier. Method according to the preceding claim, in which the guide grooves (54) have a constant grid dimension, in particular in the range between 1.5 mm and 5 mm. Method according to one of the preceding claims, in which, for laminating the cover layer (18) on the carrier layer (10), a laminating plate (56), in particular a heatable one, is placed so that the two layers, namely the carrier layer (10) and the cover layer (18), lie between the carrier (6) and the laminating plate (56) and are in particular pressed against one another. Method according to the preceding claim, in which the laminating plate (56) has recesses (58) in which the guide pins (8) are received when the laminating plate (56) is placed on top. Method according to one of the two preceding claims, in which the carrier (6) or the laminating plate (56) has positioning elements (50) and, correspondingly, the laminating plate (56) or the carrier (6) has corresponding positioning recesses (60) into which the positioning elements (60) engage for aligning the laminating plate (56) relative to the carrier (6). Method according to one of claims 11 to 13, in which spring elements (62) are attached to the positioning elements (50), which exert a spring force that presses the carrier (6) and the laminating plate (56) apart.Electrical cable harness (2), in particular produced according to a method according to one of the preceding claims, which comprises a laminate composite (20) with a carrier layer (10), with a cover layer (18) laminated thereto, and with a plurality of conductors (14) arranged between the two films (10, 18) and held according to a desired laying pattern, wherein at least some of the conductors (14) have at least one bend (16) and the carrier layer (10) has a through-opening (12) in the region of each bend (16), along which the conductor (14) runs in some areas circumferentially. Cable harness (2) according to the preceding claim, in which the cover layer (18) likewise has a through-opening (12) in the region of each bend (16), wherein the through-openings (12) of the cover layer (18) are aligned with those of the carrier layer (10).Cable set (2) according to one of the two preceding claims, in which the laminate composite (20) has a corrugated surface structure in the region of the conductors (14) at least on the carrier layer (10). Cable harness (2) according to the preceding claim, in which the conductors (14) are guided individually between the carrier layer (10) and the cover layer (18). Cable harness (2) according to one of the two preceding claims, in which at least one of the two layers (10, 18) has an opening (22) at which a plurality of conductors (14) are exposed, so that a contact zone for contacting a connection element is formed. Cable harness (2) according to the preceding claim, in which, in the region of the contact zone, a connection element (26) is connected to the laminate composite (20), via which connection element the conductors (14) are electrically contacted. Cable harness (2) according to one of claims 15 to 20, which is arranged as a separating element between a wet area (30) and a dry area (32) in a motor vehicle. Cable set (2) according to one of claims 15 to 21, which is at least part of a cell contacting system (40) for contacting battery cells (44) of a battery (42).

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