Wiring Harness

Abstract

To provide an improved wiring harness. The wiring harness (1010) includes a cable bundle (1020) having a cable (1025) and an outer jacket (1030). The outer jacket (1030) includes a first outer jacket portion (1400), a second outer jacket portion (1405), and a transition portion (1410), the first outer jacket portion (1400) having a first horizontal length (b1) in a first direction of the longitudinal length of the first outer jacket portion (1400), and the second outer jacket portion (1405) having a second horizontal length (b2) in a second direction of the longitudinal length of the second outer jacket portion (1405). The transition portion (1410) is disposed between the first outer jacket portion (1400) and the second outer jacket portion (1405), the first outer jacket portion (1400) having a first outer surface (1415), the second outer jacket portion (1405) having a second outer surface (1420), and a transition surface (1425) that is inclined relative to the first outer surface (1415) and the second outer surface (1420). The inclination has an angle (α1) of less than 45°.

Description

[Technical field]

[0001] The present invention relates to a wiring harness. [Background technology]

[0002] Wiring harnesses with individual cables for connecting various components in a motor vehicle are known. In this context, the cables are laid on a mounting plate and wound on a winding tape. Wiring harnesses are substantially manufactured manually, so that the manufacture of wiring harnesses is particularly expensive. Summary of the Invention [Problem to be solved by the invention]

[0003] SUMMARY OF THE PRESENT EMBODIMENT It is an object of the present invention to provide an improved wiring harness. [Means for solving the problem]

[0004] This object is achieved by a wiring harness for a motor vehicle according to claim 1. Advantageous embodiments are set forth in the dependent claims.

[0005] It has been found that an improved wiring harness for motor vehicles can be provided if the wiring harness comprises a cable bundle with at least two cables and an outer jacket. At least a part or parts of the cable bundle are embedded in the outer jacket. In this way, it is possible to dispense with laborious winding of the cable bundle. Furthermore, the outer jacket ensures that the wiring harness can be bent and guided particularly easily around tight radii. Furthermore, the individual cables of the cable bundle are protected by the outer jacket.

[0006] In another embodiment, the jacket has an indicator element on the outside, the indicator element being routed parallel to the cable bundle for indicating the position of the cable bundle, the indicator element extending over substantially the entire longitudinal length of the jacket, and at least one portion or portions of the indicator element being configured to correspond to the geometric configuration of the holding device of the mold. The first ridge is a simple means of indicating the alignment of the cable bundle on the jacket, which allows a particularly rapid installation of the wiring harness in the vehicle.

[0007] In another embodiment, the indicator element has a first ridge, which is a bead-shaped configuration and / or the indicator element has a cut-out on the outside of the jacket, which allows the cable bundle to be found particularly quickly in the jacket when repairing the wiring harness.

[0008] In another embodiment, the first ridge extends substantially the entire longitudinal length of the envelope.

[0009] In another embodiment, the wiring harness has a first fastening element, at least one part or parts of which are embedded in the jacket. The first fastening element is configured to hold at least one of the cables of the cable bundle in a defined position. In this way, the heating of the wiring harness can be fixed in a defined manner, thereby reliably avoiding even localized overheating of the wiring harness. This makes it possible to avoid irreversible damage to the wiring harness in a simple manner.

[0010] In another embodiment, the wiring harness has a second fastening element having a first engagement portion embedded in the housing and a second engagement portion configured to engage a vehicle component of the automobile to fasten the wiring harness to the vehicle component.

[0011] In another embodiment, the jacket comprises a first layer, a second layer and preferably a third layer, the cable bundle being embedded in the first layer, the first layer comprising a first material, the second layer comprising a second material, the second material preferably having a different elasticity, preferably higher, than the first material, the second layer preferably having a rectangular configuration or a ribbed structure, the second layer preferably having a surface with a predetermined surface structure on the side facing the first layer, the second layer preferably having a flat configuration on the side facing away from the first layer, the third layer preferably being arranged on the side of the second layer facing away from the first layer, the third layer comprising at least one material, the third material comprising an adhesive and / or having a third elasticity different, preferably lower, than the first and / or second elasticities, which allows the second layer to act as a protection for the cable bundle, thereby avoiding possible damage to the cable bundle, for example due to sharp edges of the vehicle body.

[0012] In another embodiment, the first layer is configured to be narrower than the second layer in a direction transverse to the cable bundle, the first layer is configured to engage a recess in a vehicle component, the first layer preferably having a trapezoidal cross-section and the second layer preferably having a substantially rectangular cross-section.

[0013] In another embodiment, the outer jacket has a second ridge, the wiring harness can pass through a feed-through opening in the vehicle component, the second ridge extends at an angle to a longitudinal length of the cable bundle, the second ridge is configured to form a separation, preferably a liquid-tight separation, between two spaces in the vehicle component in at least one portion or portions, the second ridge has a ridge contour, and the second ridge is configured to press the ridge contour against a feed-through opening contour of the feed-through opening to provide a substantially liquid-tight separation between the spaces.

[0014] In another embodiment, the jacket has a second ridge, which extends at an angle to the longitudinal length of the cable bundle, and which is configured to form, at least in one or more parts, a separation, preferably a liquid-tight separation, between two spaces in the vehicle component, and which has a ridge contour, which is configured to press the ridge contour against a recess contour of a recess in the vehicle component to provide a frictional connection between the recess and the second ridge and to frictionally fasten the wiring harness in the recess, which allows fastening the wiring harness in the motor vehicle in a particularly simple manner.

[0015] In another embodiment, the jacket has a first jacket portion and a second jacket portion, the first jacket portion having a first width relative to a first direction of a longitudinal length of the first jacket portion, and the second jacket portion having a second width relative to a second longitudinal length of the second jacket portion, the first width being greater than the second width.

[0016] The jacket has a transition section. The transition section is arranged between a first jacket part and a second jacket part. The first jacket part has a first outer side and the second jacket part has a second outer side. The transition section has transition surfaces that are inclined relative to the first outer side and the second outer side. The inclination has an angle, the angle having 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°.

[0017] However, the object is also achieved by automotive vehicle components.

[0018] It has been found that an improved vehicle component of a motor vehicle can be provided, if the vehicle component has a structure with at least one recess with a recess contour and a wiring harness as described above, where at least the second ridge engages in the recess, the second ridge being at least partially arranged in the recess under prestress, preferably under compression, and the second ridge presses the ridge contour against the recess contour to provide a frictional connection between the wiring harness and the vehicle component. This allows a particularly efficient use of the installation space available inside the vehicle component of the motor vehicle. Furthermore, rattling of the wiring harness against the structure of the vehicle component is avoided by surface-to-surface contact with the structure.

[0019] In another embodiment, the wiring harness is arranged in the recess and the structure has a surface adjacent to the recess, which surface and the top surface are of stepless configuration and which preferably extend in a common plane. In this way, the wiring harness can be laid in the vehicle requiring a particularly small installation space, while at the same time the fixing of the wiring harness can be ensured in a simple manner. Furthermore, catching of other components of the vehicle on the wiring harness when mounting it on the structure is avoided.

[0020] However, the object is also achieved by a mold for manufacturing a wiring harness.

[0021] It has been recognized that an improved mold for manufacturing wiring harnesses can be provided when the mold has a wall and an opening, the wall defining at least laterally a mold cavity, the mold cavity being adjacent at an upper portion to the opening.

[0022] The upwardly opening mold allows the cables to be laid particularly easily during the production of the wiring harness without having to be pulled around pins, which results in the wiring harness being particularly quickly produced. Furthermore, the cables can also be laid automatically by a robot, so that the production costs are further reduced by automation.

[0023] In another embodiment, the mould has a retaining device, which is arranged in at least one or more parts on the wall and covers the opening, the retaining device is of plate-type and / or brush-type construction, the retaining device comprises a material capable of reversible elastic deformation, and the retaining device can be reversibly bent at least 70°, preferably 90°, preferably into the mould cavity, thereby avoiding a situation where the cable laid in the mould cavity can be accidentally pulled out. Also, floating of the cable in the mould cavity during foaming of the jacket is avoided.

[0024] In this case, it is particularly advantageous if the wall has a wall base and the holding device is arranged, at least in one or more parts, parallel to the wall base.

[0025] In another embodiment, the wall comprises a first wall portion and a second wall portion, the first wall portion being arranged opposite the second wall portion, the retaining device comprising a first retaining element and a second retaining element, the first retaining element being arranged on the first wall portion and the second retaining element being arranged on the second wall portion, the first retaining element and the second retaining element each terminating with a free end above the opening and closing the mould cavity in at least one or more portions, and the first wall portion and / or the second wall portion preferably comprising a wavy contour shape in at least one or more portions.

[0026] In another embodiment, the free ends of the first and second retaining elements are spaced apart and / or the first and second retaining elements are arranged in an overlapping manner over the opening.

[0027] In another embodiment, the first wall portion has a first wall region and a second wall region, the first wall region being arranged substantially parallel to the second wall portion and the second wall region extending in an offset manner from the first wall region in a direction away from the second wall portion, such that the mold cavity has a widened portion and the second wall region is configured to correspond to the first ridge contour and / or the second ridge contour.

[0028] In another embodiment, an opening is provided in the wall, the opening being configured as a through opening and arranged in a bottom wall of the mold, the bottom wall defining the mold cavity at the bottom, the opening being configured to receive at least a portion of the first and / or second fastening element of the wiring harness and / or an ejector for removing the wiring harness from the mold is configured to reach through the opening, the opening being preferably configured to correspond to the ejector, so that the wiring harness can be particularly easily removed from the mold by machine.

[0029] In another embodiment, an opening is provided in the wall, the opening configured to receive at least a portion of the first and / or second fastening elements of the wiring harness.

[0030] In another embodiment, the wall has a first wall portion, a second wall portion and a wall transition portion, the first wall portion being preferably arranged lower than the second wall portion and the wall transition portion being arranged between the first wall portion and the second wall portion, the wall transition portion being arranged at an incline to the first wall portion and the second wall portion, the incline preferably having an angle which is less than 45°, in particular less than 30°, in particular less than 20°, in particular less than 15°, in particular less than 10°, whereby cracks in the wiring harness at the transition between the first wall enclosure and the second wall enclosure are avoided.

[0031] In another embodiment, the first wall portion and the second wall portion are arranged in two planes arranged parallel to each other.

[0032] In another embodiment, the retention device is configured to be along the wall and interrupted in some portion or portions and / or continuous.

[0033] In another embodiment, the retainer comprises silicone as a material. Additionally or alternatively, the wall comprises at least one of the following materials: polytetrafluoride, polyoxymethylene.

[0034] These materials have a particularly low surface tension compared to the jacketing materials, which ensures reliable release of the wiring harness after the jacket has hardened. In particular, the use of these materials for the walls also ensures that a large number of wiring harnesses can be produced on the same mold without the need for further cleaning or reworking steps to produce an additionally required master.

[0035] In another embodiment, the wall has a wall surface facing the mold cavity, and the wall surface is laser polished in at least one portion or portions, particularly to reduce any scoring that may be present due to the mold cavity being milled into the mold, thereby ensuring that the wiring harness can be molded and removed from the mold.

[0036] In another embodiment, the wall is contoured, at least in one or more parts, in a wavy and / or ribbed and / or planar manner, which allows the wiring harness to be optimally adapted to the geometric boundary conditions in the vehicle in a simple manner.

[0037] In another embodiment, a sealing element is arranged at one longitudinal end of the wall to at least partially prevent the emergence of the envelope from the mold cavity.

[0038] In another embodiment, the mould comprises a first mould part and a second mould part. The first mould part has a first engagement element at one longitudinal end. The second mould part has a socket at a longitudinal end of the second mould part facing the longitudinal end of the first mould part, which is adapted to correspond to the first engagement element. The first engagement element engages with the first socket and securely connects the first mould part with the second mould part, the engagement element and the socket being arranged with respect to each other such that engagement of the engagement element in the socket prevents longitudinal disengagement, the engagement element and the first mould part being preferably integral and of a materially single construction. This allows the mould to be particularly easily expanded or applied.

[0039] In another embodiment, the mold is configured to be fastened to a mounting plate of a mold system.

[0040] However, the object is also achieved by a mould system.

[0041] It has been found that an improved mould system can be provided when the mould system comprises a mould and a mounting plate, the mould being constructed as described above, the mould having a further engagement element on its side facing the mounting plate and the mounting plate having at least one grid with a plurality of further sockets on its side facing the mould, or the mould having a further socket on its side facing the mounting plate and the mounting plate having a grid with a plurality of further engagement elements on its side facing the mould, the further engagement element and the further socket being arranged in a corresponding manner to one another, the further engagement element engaging with one of the further sockets and connecting the mounting plate in a positive and reversibly separable manner with the mould and the other further sockets of the grid remaining free, or the one of the further engagement elements engaging with the further socket and connecting the mounting plate in a positive and reversibly separable manner with the mould and the other further engagement elements of the grid remaining free, the further engagement elements being preferably integral and of a single material construction with the mould or with the mounting plate.

[0042] As a result, the mold can be particularly quickly attached to the mounting plate or the mold system can be particularly quickly adapted to the different wiring harnesses being manufactured.

[0043] However, the object is also achieved by an improved method. Advantageous embodiments are set forth in the dependent claims.

[0044] According to the invention, it has been found that an improved method for manufacturing a wiring harness as constructed above can be provided, whereby a mould as constructed above is provided, at least one cable of the cable bundle is laid in the mould cavity, the holding device is reversibly deformed and opened from a closed position in a first region, preferably by a means that is bent into or away from the mould cavity, such that the opening is free in at least one part or parts in the first region and the holding device remains in a closed position in a second region and closes the opening, the cable is laid in the mould cavity through the first region, the means is moved along the mould cavity, after removal of the means the holding device is relaxed again to close the mould cavity, and at least one material of the jacket is introduced into the mould cavity, the material flows in the direction of gravity during the process time of the jacket material and thereby surrounds the cable of the cable bundle in at least one part or parts.

[0045] In another embodiment, when the cable is laid in the first region, the first and second retaining elements are reversibly bent away from the closed position by said means, preferably into or outwardly away from the mold cavity or in the longitudinal direction of the mold cavity, and after removal of said means the retaining elements bend back to the closed position, again closing the opening.

[0046] In another embodiment, after introduction of the jacket material into the mold cavity, a cover is placed on the retaining device, the cover at least partially preventing the retaining device from flexing open on the side facing away from the mold cavity.

[0047] In another embodiment, the jacket material is first introduced into the mold cavity above the first wall portion, and then at a later time into the mold cavity above the second wall portion and further into the mold cavity above the wall transition portion.

[0048] In another embodiment, the jacketing material is applied in a wavy manner in the transverse direction with respect to the cable bundle between the first and second wall, thus ensuring a reliable embedding of the cable bundle in the surrounding wall.

[0049] The invention is explained in more detail below with the aid of the figures. [Brief description of the drawings]

[0050] [Figure 1A] FIG. 2 shows a detail of a cross-sectional view of a vehicle component of a motor vehicle according to a first embodiment. [Figure 1B] FIG. 1B shows a detailed plan view of the vehicle component shown in FIG. 1A. [Diagram 2] FIG. 4 shows a cross-sectional view of a vehicle component according to a second embodiment. [Figure 3A] FIG. 11 shows a detail of a cross-sectional view of a vehicle component of an automobile according to a third embodiment. [Figure 3B] FIG. 3B shows a detailed cross-sectional view of an evolution of the vehicle component shown in FIG. 3A. [Figure 3C] FIG. 3B shows a detailed cross-sectional view of an evolution of the vehicle component shown in FIG. 3A. [Figure 3D] FIG. 3B shows a detailed cross-sectional view of an evolution of the vehicle component shown in FIG. 3A. [Figure 3E] 3B shows a longitudinal cross-sectional view of an extension of the vehicle component shown in FIG. 3A. [Figure 4A] FIG. 11 shows a detail of a cross-sectional view of a vehicle component of an automobile according to a fourth embodiment. [Figure 4B] FIG. 4B shows a detailed cross-sectional view of an evolution of the vehicle component shown in FIG. 4A. [Diagram 5] FIG. 2 shows a longitudinal cross-sectional view of the wiring harness. [Figure 6] FIG. 13 is a perspective view of a wiring harness according to another embodiment. [Figure 7] FIG. 13 is a perspective view of a wiring harness according to another embodiment. [Figure 8] FIG. 13 is a perspective view of a wiring harness according to another embodiment. [Figure 9A] FIG. 9 illustrates a perspective view of a die system for manufacturing at least one of the wiring harnesses shown in FIGS. 1-8. [Figure 9B] FIG. 9B shows a plan view of the mold system shown in FIG. 9A. [Figure 10] FIG. 9C shows a perspective view of a first mold part of the mold shown in FIGS. 9A and 9B according to a first embodiment. [Figure 11A] 11 shows a cross-sectional view of the mold shown in FIG. 10 taken along the cross-sectional plane AA shown in FIG. [Figure 11B] 11 shows a cross-sectional view of a modification of the mold shown in FIG. 10 taken along the cross-sectional plane AA shown in FIG. [Figure 12] 11 shows a cross-sectional view of a first mould section according to a second embodiment taken along the cross-sectional plane AA shown in FIG. 10. [Figure 13] FIG. 13 shows a perspective view of a first mould section according to a third embodiment. [Figure 14] FIG. 2 shows a detailed perspective view of the mold. [Figure 15] FIG. 15 shows a perspective view of an extension of the mold shown in FIGS. 9A to 14. [Figure 16] FIG. 16 shows a perspective view of an extension of the mold shown in FIGS. 9A to 15. [Figure 17] FIG. 17 shows a detailed perspective view of an extension of the mold shown in FIG. [Figure 18] FIG. 13 shows a perspective view of a first mould section according to a fourth embodiment. [Figure 19] 19 shows a perspective view of a mold including the mold parts shown in FIG. 18. [Figure 20] FIG. 2 shows a perspective view of a wall in an evolved form. [Figure 21] 21 shows a perspective view of a wall in a modification of the embodiment shown in FIG. 20. [Figure 22] FIG. 13 shows a perspective view of a mold according to another embodiment. [Diagram 23] 13 shows a longitudinal cross-sectional view of a mold according to another embodiment. [Figure 24] FIG. 13 shows a perspective view of a mold according to another embodiment. [Diagram 25]FIG. 13 shows a perspective view of a mold according to another embodiment. [Figure 26] FIG. 13 shows a perspective view of a mold according to another embodiment. [Figure 27] FIG. 2 shows a perspective view of a first fastening element according to a first embodiment. [Figure 28] FIG. 13 shows a perspective view of a first fastening element according to a second embodiment. [Figure 29] FIG. 13 shows a perspective view of a first fastening element according to a third embodiment. [Diagram 30] FIG. 13 shows a perspective view of a first fastening element according to a fourth embodiment. [Diagram 31] FIG. [Diagram 32] FIG. 4 shows a perspective view of a second fastening element according to a second embodiment. [Diagram 33] 1 shows a flow chart of a method for manufacturing a wiring harness. [Diagram 34] 4 shows a plan view of the mould system during a third method step. [Diagram 35] 35 shows a cross-sectional view along the cross-sectional plane DD shown in FIG. 34. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0051] 1A shows a detail of a cross-sectional view of a vehicle component 1000 of an automobile according to a first embodiment. The vehicle component 1000 comprises a structure 1005 and a wiring harness 1010. The structure 1005 can be, for example, a car body, a deep-drawn part, a roof lining, a door panel, a middle panel, a soundproof bulkhead or a cockpit. The structure 1005 can be, for example, made of sheet metal or plastic. However, the structure 1005 can also be a plastic structure, a carpet or similar. The structure 1005 comprises a bearing surface 1015. The bearing surface 1015 faces the wiring harness 1010.

[0052] The wiring harness 1010 includes a cable bundle 1020 that includes a number of cables 1025. The cables 1025 serve to conduct electrical signals or currents between two points. The cables 1025 are arranged to extend in approximately the same direction as each other. In this arrangement, a connection system may be provided at each end of the wiring harness 1010 for electrically connecting the wiring harness 1010 to another electrical device. The cables 1025 of the cable bundle 1020 are embedded in a jacket 1030 of the wiring harness 1010. The jacket 1030 has an outer surface 1035 on the outside that has a jacket contour.

[0053] The outer jacket 1030 preferably comprises at least one of the following materials: polyurethane, silicone, foam, closed cell foam, open cell foam, silicone foam, polyurethane foam. The wiring harness 1010 rests on the bearing surface 1015 by the outer surface 1035. In this arrangement, an adhesive layer can be additionally provided between the bearing surface 1015 and the outer surface 1035 to materially connect the wiring harness 1010 to the structure 1005.

[0054] In this arrangement, there is freedom of choice regarding the cross-section of the jacket 1030, which should preferably be selected to correspond to the geometric configuration of the bearing surface 1015. At the same time, it is particularly advantageous if the bearing contour and the jacket contour are identical in one or more parts, thereby ensuring a particularly good surface-to-surface contact between the wiring harness 1010 and the structure 1005.

[0055] It is particularly advantageous if the jacket 1030 comprises an indicator element 1038. The indicator element 1038 advantageously comprises a first ridge 1036 on the upper surface 1037 of the wiring harness 1010. The first ridge 1036 protrudes above the upper surface 1037. The first ridge 1036 is preferably of a bead-shaped configuration and preferably extends parallel to the cable bundle 1020 at least in one or more portions. The indicator element 1038 can be arranged centrally with respect to the first maximum lateral length b1. This makes it possible to indicate the route of the cables 1025 of the cable bundle 1020 in a simple manner. The indicator element 1038 can furthermore be used to indicate a given side for the insertion of the wiring harness 1010 into the structure 1005, which allows a particularly quick installation of the wiring harness 1010 during the assembly of the vehicle. Additionally or alternatively, it is contemplated that the indicator 1038 may include a cutout 1040 (shown in dashed lines in FIG. 1A ) in the upper surface 1037. The cutout 1040 may serve, for example, to indicate a particular type of wiring harness 1010.

[0056] FIG. 1B shows a detailed plan view of the vehicle component 1000 shown in FIG. 1A.

[0057] The indicator element 1038 extends over substantially the entire longitudinal length of the wiring harness 1010. This makes it possible to determine in a particularly simple manner the insertion position of the cable bundle 1020 in the jacket 1030. This is particularly advantageous when the jacket 1030 is of a particularly thick configuration, so that neither tactile nor visual perception of the cable bundle 1020 in the jacket is possible.

[0058] 2 shows a cross-sectional view of a vehicle component 1000 according to a second embodiment. The vehicle component 1000 is constructed substantially identically to the vehicle component 1000 shown in FIGS. 1A and 1B. The structure 1005 has a first space 1100 and a second space 1105. A bulkhead 1110 is provided between the first space 1100 and the second space 1105. The bulkhead 1110 has an opening 1115. The wiring harness 1010 passes through the opening 1115.

[0059] The wiring harness 1010 is constructed in such a way that it is substantially identical to the wiring harness 1010 illustrated in Figures 1A and 1B. In addition, the jacket 1030 of the wiring harness 1010 has a second ridge 1120. The second ridge 1120 extends transversely to the longitudinal length of the cable bundle 1020. At least in the region of the second ridge 1120, the jacket 1030 advantageously comprises a flexible material. The second ridge 1120 has a ridge contour 1121. The second ridge 1120 is disposed in the opening 1115 and fills the opening 1115. The second ridge 1120 is preferably pressed / compressed into the opening 1115. As a result, the second ridge 1120 presses the ridge contour 1121 against the opening contour 1122 of the opening 1115 at its periphery, fluidically sealing the first space 1100 from the second space. Furthermore, noise transmission by the second ridge 1120 between the first space 1100 and the second space 1105 is thereby avoided. It is particularly advantageous here if the second ridge 1120 is arranged to surround the cable bundle 1020. It may be particularly advantageous if the second ridge 1120 has a triangular configuration in cross section. This makes it possible to dispense with the use of a grommet at the opening 1115.

[0060] FIG. 3A shows a cross-sectional view of a vehicle component 1000 of an automobile according to a third embodiment in detail. The vehicle component is similar in configuration to the vehicle component 1000 shown in FIGS. 1 and 2. The difference is that the wiring harness 1010 has a first layer 1200 and a second layer 1205. The second layer 1205 is disposed below the first layer 1200, between the first layer 1200 and the structure 1005. The cable bundle 1020 is embedded in the first layer 1200. In this arrangement, the first ridge 1036 is adjacent to the first layer 1200. The first layer 1200 preferably includes a first material, and the second layer 1205 preferably includes a second material. It is also possible that the first layer 1200 and the second layer 1205 include the same material. In this case, the second material may have a different elasticity than the first material. Thereby, it is advantageous that rattling of the cable bundle 1020 can be avoided by the particularly elastic properties of the second layer 1205 of the structure 1005 when the elasticity of the second material is greater than that of the first material.

[0061] Furthermore, it is also advantageous if the elasticity of the second material of the second layer 1205 is less than that of the first material, thereby causing the second layer 1205 to form a kind of plate that effectively protects the cable bundle 1020 from possible damage.

[0062] In this embodiment, the second layer 1205 is rectangular in cross-section. Other configurations of the second layer 1205 are also contemplated. Thus, the second layer 1205 may be, for example, semicircular, elliptical, U-shaped, C-shaped, cylindrical, or any other configuration.

[0063] 3A, it is also conceivable that the second layer 1205 has a ribbed structure in the longitudinal direction of the wiring harness 1010. This allows the wiring harness 1010 to be particularly well guided around radii, while at the same time the second layer 1205 may provide a high level of protection for the cable bundle 1020.

[0064] Figure 3B shows a detailed cross-sectional view of an evolution of the vehicle component 1000 shown in Figure 3A. The wiring harness 1010 has substantially the same configuration as the wiring harness 1010 shown in Figure 3A. The difference is that the second layer 1200 has a predetermined surface structure 1215 on the surface 1220 facing the first layer 1200. The surface structure 1215 is, for example, a wavy configuration. This increases the size of the surface 1220 of the second layer 1205, improving the adhesion of the first layer 1205 to the second layer 1200 compared to the configuration shown in Figure 3A.

[0065] 3C shows a cross-sectional detail of an evolution of the vehicle component 1000 shown in FIG. 3A, with the difference being that the first layer 1200 is thinner than the second layer 1205 in the direction transverse to the cable bundle 1020.

[0066] FIG. 3D shows a detail of a cross-sectional view of a development of the vehicle component 1000 shown in FIG. 3A. In addition, the jacket 1030 has a third layer 1210. The third layer 1210 is arranged on the side of the second layer 1205 facing away from the first layer 1200 and is connected to said second layer. The third layer 1210 comprises a third material with a third elasticity. The third elasticity is preferably smaller than the first elasticity and / or the second elasticity. The third layer 1210 is preferably configured as an impact plate or as an adhesive layer. In the case of the configuration as an impact plate, it is advantageous that damage to the cable bundle 1020 can be avoided by the third layer 1210, while at the same time vibrations can be particularly effectively damped by the second layer 1205. In this embodiment, by way of example, the layers 1200, 1205, 1210 are arranged in a rectangular shape of the same width at the layer overlap. The layers 1200, 1205, 1210 may have different widths or configurations.

[0067] 3E shows a longitudinal cross-sectional view of an extension of the vehicle component 1000 shown in FIG. 3A. The second layer 1200 is provided with a rib structure 1225. The rib structure 1225 has ribs 1230 and rib recesses 1235 longitudinally disposed between and longitudinally separating the ribs 1230. The rib recesses 1235 each have a recess bottom surface 1240 spaced apart from the cables 1025 of the cable bundle 1020.

[0068] Figure 4A shows a detail of a cross-sectional view of a vehicle component 1000 of an automobile according to a fourth embodiment. The vehicle component 1000 is of substantially the same configuration as the vehicle component 1000 shown in Figures 1A to 3E. The structure 1005 has a groove-type recess 1300 having a recess contour 1305. By way of example, the recess 1300 has a rectangular configuration. The recess 1300 can be introduced into the structure 1005, for example, during a pressing operation.

[0069] The wiring harness 1010 is of substantially the same configuration as the embodiment shown in FIG. 3A. The wiring harness 1010 is placed in a recess 1300. In this arrangement, the jacket 1030 has a second ridge 1120. The second ridge 1120 is preferably formed circumferentially, preferably surrounding the cable bundle 1020 on three sides, and preferably of a layered configuration. The second ridge 1120 has a ridge contour 1121. The material of the second ridge 1120 is preferably elastic and integral with the material of the jacket 1030 and is materially unitary. In the unmounted state, the ridge contour 1121 of the second ridge 1120 is preferably larger than the recess contour of the recess 1300 in this case.

[0070] When the wiring harness 1010 is mounted, the second ridge 1120 and its material are compressed, so that the second ridge 1120 presses its ridge contour 1121 against the recess contour of the recess 1300, thereby frictionally connecting the wiring harness 1010 to the recess 1300 of the vehicle component 1000 by means of the second ridge 1120. This makes it possible to accommodate the wiring harness 1010 in the structure 1005 of the vehicle component 1000 in a particularly space-saving manner.

[0071] In particular, it is advantageous in this case for the structure 1005 to have a surface 1310 adjacent to the recess 1300, and the top surface 1037 of the wiring harness 1010 is configured in such a way that there is substantially no transition or step with respect to the surface 1310. The top surface 1037 and the surface of the structure 1005 are preferably in a common plane. In the case of the wiring harness 1010, it is then possible to omit the second ridge 1120, in which case the wiring harness 1010 fills the recess 1300 substantially completely. It is also possible to provide the second ridge 1120 only in one or more longitudinal portions, the outer cover 1030 being, for example, arranged at a distance from the recess contour 1305 in the remaining area (without the second ridge 1120).

[0072] FIG. 4B shows a cross-sectional view of a development of the vehicle component 1000 shown in FIG. 4A.

[0073] The configuration shown in Fig. 4B is essentially a combination of the configuration of the wiring harness 1010 shown in Fig. 3C and the configuration of the vehicle component 1000 shown in Fig. 4A. The difference is that the vehicle component 1000 has, in addition to the structure 1005, a retaining structure 1006 disposed on the upper surface at a distance from the recess 1300. Only the first layer 1200 engages the recess 1300, while the second layer 1205 is disposed outside the recess 1300 between the retaining structure 1006 and the structure 1005. The retaining structure 1006 preferably has a retention force F H 1205, thereby securing the wiring harness 1010 to the structure 1005. The retaining structure 1006 can be secured to the structure 1005. The retaining structure 1006 can also be a separate vehicle subassembly from the structure.

[0074] 5 shows a longitudinal section of the wiring harness 1010. The jacket 1030 of the wiring harness 1010 has a first jacket part 1400, a second jacket part 1405 and a transition part 1410. The transition part 1410 is arranged between the first jacket part 1400 and the second jacket part 1405 in the longitudinal direction of the wiring harness 1010. The first jacket part 1400 has a first outer side surface 1415 and the second jacket part 1405 has a second outer side surface 1420. The outer sides 1415, 1420 are preferably arranged parallel in two planes that are offset relative to each other at different heights. In this case, by way of example, the outer sides 1415, 1420 are of a flat configuration. Other configurations of either of the outer sides 1415, 1420 are also conceivable. The transition part 1410 has a transition surface 1425. The outer sides 1415, 1420 and the transition surface 1425 can be arranged below the wiring harness 1010, laterally on the wiring harness 1010 or on the top side of the wiring harness 1010. The transition surface 1425 is arranged at an incline with respect to the first outer side 1415 and the second outer side 1420. The incline has an angle α1, which 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°. This avoids cracks in the jacket 1030 at the transition between the first jacket part 1400 and the second jacket part 1405. Of course, it is also conceivable to omit the transition part 1410. Also conceivable is the transition surface 1425 which is of a curved configuration instead of the flat configuration shown in FIG. 5. In this case, in particular a convex or concave curvature is conceivable.

[0075] Due to the offset outer surfaces 1415, 1420, the first jacket part 1400 has a first horizontal length b1 in a first direction of the longitudinal length of the first jacket part 1400, and the second jacket part 1405 has a second horizontal length b2 in a second direction of the longitudinal length of the second jacket part 1405, where the first horizontal length b1 is greater than the second horizontal length b2.

[0076] 5 is the same as the second direction of the length. The first direction of the length may be different from the second direction of the length, and the transition portion 1410 may, for example, have a curved configuration. This configuration of the wiring harness 1010 has the advantage that the wiring harness 1010 can flexibly adapt in terms of its width to the installation space available in the structure 1005.

[0077] FIG. 6 shows a perspective view of a wiring harness 1010 in another embodiment.

[0078] The wiring harness 1010 has a similar configuration to the wiring harness 1010 shown in Figures 1 to 5. The difference is that the outer surface 1035 is configured with a wavy contour shape 1500 as shown. The contour shape 1500 has a first contour shape portion 1505 and a second contour shape portion 1510. As an example, the first contour shape portion 1505 is configured to be wider in the vertical direction than the second contour shape portion 1510. Preferably, the first contour shape portion 1505 has a concave configuration and the second contour shape portion has a convex configuration. The first and second contour shapes portions 1505, 1510 alternate in the vertical direction.

[0079] FIG. 7 shows a perspective view of a wiring harness 1010 in another embodiment.

[0080] The wiring harness 1010 has substantially the same configuration as the wiring harness 1010 shown in Fig. 6. The difference is that the first contour shape portion 1505 and the second contour shape portion 1510 are configured to have the same width.

[0081] FIG. 8 shows a perspective view of a wiring harness 1010 in another embodiment.

[0082] The wiring harness 1010 has substantially the same configuration as the wiring harness 1010 shown in Fig. 6. The difference is that the contour shape 1500 is substantially rectangular, the first contour shape portion of the wiring harness 1010 shown in Fig. 6 has a substantially flat configuration, and the second contour shape portion 1510 is configured as a recess in the outer surface 1035.

[0083] FIG. 9A shows a perspective view of a mold system 10 for manufacturing at least one of the wiring harnesses 1010 shown in FIGS. 1-8.

[0084] The mold system 10 preferably includes a mold 15 and a mounting plate 20. By way of example, the mounting plate 20 is flat. The mold 15 may include a first mold part 16 and at least one second mold part 17, each of which abuts at one longitudinal end 18 and is disposed by its lower surface 19 on an upper surface 25 of the mounting plate 20, preferably in a common plane.

[0085] FIG. 9B shows a detailed plan view of the mold system 10 shown in FIG. 9A.

[0086] On the upper surface 25, by way of example, the mounting plate 20 has a grid 27 that includes a plurality of first sockets 142 that are identical to one another. The first sockets 142 are arranged in a regular pattern in the grid 27. For clarity, only a portion of the first sockets 142 are shown in FIG. 9B.

[0087] FIG. 10 shows a perspective view of the first mold part 16 of the mold 15 according to the first embodiment shown in FIGS. 9A and 9B.

[0088] To facilitate easier description of mold 15, reference is made below to coordinate system 26. Coordinate system 26 is preferably configured as a right-handed system, having an x-direction (horizontal length direction), a y-direction (length direction), and a z-direction (height direction).

[0089] The mold 15 has a wall 30, an opening 35 and a holding device 40. The wall 30 defines a mold cavity 45. During the production of the wiring harness 1010, the cable bundle 1020 and the jacket 1030 are introduced into the mold cavity 45 by the opening 35. The opening 35 is located on the top surface and adjoins the mold cavity 45. In this embodiment, by way of example, the mold cavity 45 is configured with a rectangular cross section. It is also possible that the mold cavity 45 is configured in any other way and has a different cross section. Thereby, for example, mold cavities 45 that are (in one or more parts) polygonal, triangular, round, circular and / or elliptical in configuration are also conceivable.

[0090] The wall 30 has a first wall portion 50, a second wall portion 55 and a wall bottom portion 60. The wall bottom portion 60 is disposed between the first wall portion 50 and the second wall portion 55. The first wall portion 50 and the second wall portion 55 laterally define a mold cavity 45. The wall bottom portion 60 defines the mold cavity 45 at the bottom. The opening 35 is preferably disposed above the wall bottom portion 60.

[0091] The first wall 50 has a first wall surface 61 facing the mold cavity 45, the second wall 55 has a second wall surface 62 facing the mold cavity 45, and the wall bottom 60 has a wall bottom surface 63 facing the mold cavity 45. In this embodiment, by way of example, the first and second wall surfaces 61, 62 extend parallel to each other. The wall bottom surface 63 is arranged perpendicular to the first wall surface 61 and the second wall surface 62. The wall bottom surface 63 and / or the walls 61, 62 may also be arranged in a different way. Thus, the first wall surface 61 can be arranged obliquely relative to the second wall surface 62. It is also conceivable that the first wall surface 61 and the second wall surface 62 are directly adjacent to each other and the wall bottom surface 60 is omitted, so that the mold cavity 45 has, for example, a triangular cross section.

[0092] It is particularly advantageous here if at least one of the wall surfaces 61, 62 and / or the wall bottom surface 63 is laser polished at least in one or more parts. This can ensure a particularly good surface finish. Furthermore, scoring and / or grooves, which arise for example by introducing the mould cavity 45 into the base material for producing the mould 15 by machining, are at least partially removed by laser polishing. This ensures a particularly long-term stable mould 15, which allows a large number of wiring harnesses 1010 to be produced without the need for additional preparation of the mould 15.

[0093] In contrast to a flat configuration of the wall surfaces 61, 62 and / or the wall base 63, it is also possible for the wall surfaces 61, 62 and / or the wall base 63 to be contoured in a wavy and / or ribbed manner, at least in one or more portions.

[0094] The holding device 40 comprises a first holding element 65, a second holding element 70, a first contact pressure element 75, a second contact pressure element 80 and a first fastening means 85. By way of example, the first holding element 65 and the second holding element 70 are preferably configured symmetrically with respect to a plane of symmetry 86 passing through the center of the mould cavity 45. The plane of symmetry 86 is preferably configured as a YZ plane. It is also possible to configure the first holding element 65 and the second holding element 70 differently from each other.

[0095] The moulds 15 are positively connected to the mounting plate 20 by second fastening means 135, which in this embodiment have, by way of example, at least one pin 140 configured as a first engagement element. In this case, the pin 140 is connected to the wall 30 and engages with its free longitudinal end 141 into a first socket 142 of the grid 27 of the mounting plate 20, said socket being configured to correspond to the pin 140. In order to provide a particularly simple mounting of the moulds 15 to the mounting plate 20, there is for this purpose preferably a multiplicity of pins 140, which are configured to correspond to the first sockets 142 and identically to one another, and which are connected to the wall 30. Depending on the arrangement of the moulds 15, the pins 140 each engage into a first socket 142 of the grid 27, while the other first sockets 142 of the grid 27 remain free. In this case, the engagement can be additionally non-positively ensured in order to prevent the moulds 15 from accidentally falling off the mounting plate 20, for example if the mould system 10 is supposed to be tilted. This can be accomplished, for example, by configuring the pin 140 and socket 142 as an transition or interference fit.

[0096] The second fastening means 135 can also be constructed differently. In particular, it is possible here to consider the second fastening means 135 being designed as a screw system.

[0097] The first sockets may be located on the lower surface 19 of the mold halves 16, 17. On the upper surface of the mounting plate 20, the mounting plate 20 preferably has a number of pins 140 configured as first engagement elements.

[0098] Instead of the first sockets 142, the grid 27 may alternatively have pins 140 configured as first engagement elements extending in the direction of the mould 15. In this alternative, the first sockets 142 are arranged in the mould 15, preferably in the wall 30. Depending on the alignment of the mould 15, some of the pins 140 of the grid 27 each engage in a first socket 142 in the mounted state of the mould 15 on the mounting plate 20, reversibly fixing the mould 15 to the mounting plate 20, as described above. The other pins 140 that do not engage in the first sockets 142 remain free (at least in the circumferential direction) and / or are covered (at the top surface) by the mould 15 at least in one or more parts.

[0099] FIG. 11A shows a cross-sectional view of the mold 15 shown in FIG. 10 along the cross-sectional plane AA shown in FIG. 10, with the holding elements 65, 70 in the closed position.

[0100] The first retaining element 65 is of a plate-type configuration and comprises a first part 90 and a second part 95. In this case, the first part 90 of the first retaining element 65 is arranged on the upper side of the first wall 50. The first contact pressure element 75 is arranged on the upper side of the first part 90. The first contact pressure element 75 is preferably non-positively connected to the first wall 50 by means of a first fastening means 85. In this case, the first fastening means 85 provides a first clamping force FS1, whereby the first contact pressure element 75 presses the first retaining element 65 against the upper side of the first wall 50. In this embodiment, the first contact pressure element 75 is configured, by way of example, to be exactly the same width as the first wall 50 in the X-direction. Thereby it is possible to ensure that the first retaining element 65 is positively pressed in contact by the first contact pressure element 75. Furthermore, unwanted deformations of the first retaining element 65 can be avoided.

[0101] The first free end 100 of the first retaining element 70 ends above the opening 35. A second part 95 of the first retaining element 65 adjacent to the first free end 100 of the first retaining element 65 covers the opening 35 at the top. The second part 95 may preferably be of a wedge-shaped configuration, at least in one or more parts. In this regard, it is particularly advantageous if the first lower surface 105 of the first retaining element 65 is of a substantially flat configuration and the first retaining element 65 thickens at the top surface (Z-direction) from the free end 100 towards the first wall 50.

[0102] The second holding element 70 is preferably arranged at the same height on the opposite side with respect to the first holding element 65, i.e., for example, in a common XY plane. The second holding element 70 is arranged mirror-symmetrically with respect to the symmetry plane 86. The second holding element 70 is arranged on the upper surface of the second wall 55 and has a third part 110 and a fourth part 115, which for example are also of plate-shaped configuration. The third part 110 of the second holding element 70 rests on the upper surface of the second wall 55. The second contact pressure element 80 is arranged above the third part 110. The first fastening means 85 supplies the second contact pressure element 80 with a second contact pressure FS2, so that the second contact pressure element 80 presses the second part 110 against the upper surface of the second wall 55. In this case, for example, the second contact pressure element 80 is configured to have exactly the same width as the second wall 55. In this case, the first contact pressure element 75 and the second contact pressure element 80 laterally define a first gap 120 which is exactly the same width as the opening 35 .

[0103] The fourth portion 115 is adjacent to the second free end 130 of the second retaining element 70. Like the second portion 95, the fourth portion 115 is of a wedge-shaped configuration, with the second lower surface 125 of the second retaining element 70 being disposed in a common plane with the first lower surface 105 of the first retaining element 65. The second free end 130 terminates above the opening 35. At the top, the fourth portion 115 thickens from the second free end 130 towards the third portion 110.

[0104] In this regard, the fourth portion 115 is adjacent to the second free end 130 of the second retaining element 70 .

[0105] The first free end 100 is preferably arranged at a distance from the second free end 130 of the second holding element 70. In this case, the distance between the first free end 100 and the second free end 130 is preferably ten times smaller than the width of the opening 35 (with respect to the common XZ plane). As a result, the holding device (40) covers only a portion of the opening 35. Also, the first free end 100 and the second free end 130 may be in direct contact with each other.

[0106] It is particularly advantageous if the holding elements 65, 70 comprise a material that is particularly elastic and can be reversibly bent by at least 90°, preferably into the mould cavity 45. In this case, it is particularly advantageous if the holding elements 65, 70 comprise silicone as a material, which further makes it possible to configure the holding elements 65, 70 to follow the geometric configuration of the walls 50, 55.

[0107] FIG. 11B shows a cross-sectional view of a variation of the mold 15 shown in FIG. 10 taken along the cross-sectional plane AA shown in FIG.

[0108] The mold 15 is of substantially the same configuration as that shown in Figure 11A, except that the first retaining element 65 and the second retaining element 70 are of a brush-type configuration, in which the first retaining element 65 has a first brush 66 with a number of brush fibers 67, and the second retaining element 70 has a second brush 71 with a number of second brush fibers 72.

[0109] The brush fibers 67, 72 extend substantially in the transverse direction. In this case, the second part 95 and the fourth part 115 are wider than half the width of the opening 35 in the transverse direction (x-direction). As a result, the brushes 66, 71 reach the opposite brushes 66, 71, respectively, and completely close the upper opening 35. It is also possible to arrange the free ends 100, 130 at a distance from each other, as shown in Fig. 11A.

[0110] FIG. 12 shows a cross-sectional view of a first mould half 16 according to a second embodiment taken along the cross-sectional plane AA shown in FIG.

[0111] The mold 15 has a similar configuration to the mold 15 shown in Figures 9A to 11. The difference is that the second part 95 and the fourth part 115 of the holding elements 65, 70 are arranged to overlap partially above the opening 35. In this case, overlapping is understood to mean that the second part 95 and the fourth part 115 at least partially overlap when projected onto a common XY plane.

[0112] The wall 30 of the first mould part 16 is integral and of a single material construction. In this regard, the wall 30 advantageously comprises at least one of the following materials: polypropylene (PP), polytetrafluoride (PTFE), polyethylene (PE), preferably polyethylene with highly branched polymer chains (PE-LD), polyoxymethylene (POM). Additionally or alternatively, it is also conceivable that the wall 30 comprises a material having a particularly low surface tension with respect to polyurethane and / or silicone.

[0113] FIG. 13 shows a perspective view of a first mould section 16 according to a third embodiment.

[0114] First mold section 16 is of similar configuration to mold 15 shown in Figures 10 to 12, except that first mold section 16 has an enlarged longitudinal length as compared to the configuration shown in Figure 10.

[0115] The holding device 40 is designed to accommodate the enlarged longitudinal length. In this case, in order to enable the second fastening means 135 to be attached to the upper side of the wall 30, the holding device 40 is additionally provided with a first recess 145, preferably on the side facing away from the opening 35. In this case, by way of example, the first recess 145 in the holding device 40 extends across the holding elements 65, 70 and across the contact pressure elements 75, 80. The first recess 145 is of a narrower design in the X-direction, i.e. transverse to the longitudinal length of the mould 15 and of the holding device 40 in the region of the second fastening means 135.

[0116] Furthermore, the first fastening means 85 and the second fastening means 135 can be combined with each other, so that the mold 15 and the holding device 40 are fixed to the mounting plate 20 by the combined fastening means 85,135.

[0117] In addition, on both sides of the mold 15 shown in Figures 9A to 12, 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 cavity 45 at the longitudinal end 18. In this case, the sealing element 150 can be of a plate-type configuration. In this case, it is particularly advantageous if the sealing element 150 is arranged only at the longitudinal end 18 where the mold part 16 does not adjoin any other mold part 17. This makes it possible to avoid the appearance of the jacket 1030 at the longitudinal end 18 of the mold 15 during the production of the wiring harness 1010.

[0118] FIG. 14 shows a detailed perspective view of the mold 15.

[0119] The first mould section 16 may be constructed as shown in Figures 9A to 13. The mould 15 additionally has a cover 155 on the wall 30. The cover 155 is connected to the wall 30 of the first mould section 16 by a third fastening means 160. In this case, the cover 155 is placed on the upper surface of the holding device 40 (not shown in Figure 14) and prevents the holding elements 65, 70 from being bent upwards in a direction away from the mould cavity 45.

[0120] FIG. 15 shows a perspective view of a development of the mold 15 shown in FIGS. 9A to 14.

[0121] The mold 15 is of similar construction to the mold 15 shown in Figures 9A to 14, except that various modifications of the holding device 40 are shown in Figure 15.

[0122] The holding device 40 comprises a number of holding elements 65, 70 arranged at regular intervals in the longitudinal direction (x-direction). The holding elements 65, 70 are each connected to a wall 50, 55. The holding elements 65, 70 preferably extend perpendicular to the upper surface 165 of the wall 30. In these variations 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 surface 165 (xy-plane). Thus, for example, the holding elements 65, 70 can have a circular, rectangular, trapezoidal, elliptical and / or circular cross-section. It is also conceivable that the holding elements 65, 70 taper in the direction away from the upper surface 165 of the wall 30. In this case, it is particularly advantageous if the retaining elements 65, 70 have a wedge-shaped cross-section in the direction away from the upper surface 165 of the wall 30, the free ends 170 of the retaining elements 65, 70 being set back from the wiring harness 1010. This makes it possible to facilitate the insertion of the individual cables 1025 of the cable bundle 1020.

[0123] In this embodiment, the first retaining element 65 is in each instance arranged opposite the second retaining element 70, so that the first and second retaining elements 65, 70 are each arranged in a common XZ plane.

[0124] Of course, the first and second retaining elements 65, 70, respectively, can also be offset relative to each other.

[0125] Figure 16 shows a perspective view of a development of the mould 15 shown in Figures 9A to 15. For clarity, the holding device 40 is not shown in Figure 16.

[0126] The mould 15 is of similar construction to the mould 15 shown in figures 9A to 15, with the difference being that the wall 30 of the first wall region 50 has a first web 175 at its side and the second wall region 55 has a second web 180 at its side. The webs 175, 180 extend away from the mould cavity 45 and adjoin the underside 19 of the first mould section 16. Furthermore, each web 175, 180 is preferably provided with a number of first openings 185. In this case, the first openings 185 are preferably constructed as slotted holes. This allows a particularly precise positioning of the first mould section 16 in the longitudinal direction, so that it abuts with its longitudinal end 18 and the surface 190 adjacent thereto against a further end face 195 of a further mould section 17 arranged at the longitudinal end 18.

[0127] For the first opening 185, the second fastening means 135 preferably comprises a screw instead of a pin 140. It is also possible to connect the mould halves 16, 17 to the mounting plate 20 by means of a pin 140 fixed to the webs 180, 175, for example, as shown in Figure 10.

[0128] The cable bundle 1020 of the wiring harness 1010 is inserted into the mold cavity 45. In this case, by way of example, the cable bundle 1020 is held in place by the first fastening element 200, 205. The first fastening element 200 is supported by the wall 30 on the side facing away from the cable bundle 1020 and is embedded in the outer jacket 1030 of the wiring harness 1010.

[0129] Further details of the first fastening element 200 are shown in Figures 27-30.

[0130] FIG. 17 shows a detailed perspective view of a development of the mold 15 shown in FIG.

[0131] The mold 15 is of a similar construction to the mold 15 shown in FIG. 16. The difference is that the first mold part 16 has a second engagement element 205 and the second mold part 17 has a second socket 210 that is adapted to accommodate the second engagement element 205 in order to ensure a reliable connection of the first mold part 16 with the second mold part 17. In this case, the second engagement element 205 is arranged end-on at the longitudinal end 18 of the first mold part 16. The second engagement element 205 engages with the second socket 210, thereby ensuring a reliable coupling of the first mold part 16 with the second mold part 17. This makes it possible to form a reliable alignment of the mold parts 16, 17 relative to each other. In particular, this ensures that the mold cavity 45 extends in a straight line through the transition between the first mold part 16 and the second mold part 17, as shown in FIG. 17, so that leakage at the transition is avoided.

[0132] FIG. 18 shows a perspective view of a first mould section 16 according to a fourth embodiment.

[0133] In this case, the second engagement elements 205 are arranged on the end faces of the webs 175, 180. In this case, by way of example, two second engagement elements 205, each preferably arranged on the webs 175, 180, are provided on the end face 190 of the first mould part 16. In this case, the second engagement elements 205 have a trapezoidal cross section when cut in the xy plane, the second engagement elements 205 becoming thicker in the direction away from the end face 190 of the first mould part 16.

[0134] Figure 19 shows a perspective view of a mold 15 including a first mold part 16 shown in Figure 18 and a second mold part 17 configured to correspond to the first mold part 16. The second mold part 17 has a second socket 210 configured to correspond to the trapezoidally configured second engagement element 205 in Figure 18. The second engagement element 205 engages with the second socket 210. Due to the trapezoidal cross section of the second engagement element 205, the two mold parts 16, 17 can be attached and detached from each other only in the Z direction. This can ensure that no gaps are formed between the two end faces 190, 195 and that the mold cavity 45 is sealed at the end faces.

[0135] Furthermore, the configuration of the second socket 210 and the second engagement element 205 ensures that the mould parts 16, 17 can be reversibly attached to and detached from each other. In this way, the mould system 10 can be particularly quickly adapted to various configurations for the manufacture of the wiring harness 1010. This allows the set-up time of the mould system 10 to be reduced.

[0136] FIG. 20 shows a perspective view of a wall 30 in a development of the mold 15 shown in FIGS.

[0137] In this case, by way of example, the wall 30 is constructed with a low wall thickness, for example the wall 30 can be deep drawn.

[0138] The first wall section 50 has a first wall region 215 and a second wall region 220. By way of example, the first wall region 215 and the second wall region 220 are adjacent to each other in the vertical direction. The second wall section 55 is preferably configured symmetrically to the first wall section 50 with respect to the plane of symmetry 86 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 horizontal direction (x direction), and the third wall region 225 is preferably arranged opposite the first wall region 215 in the horizontal direction. The first wall region 215 and the third wall region 225 preferably extend parallel to each other. The second and fourth wall regions 220, 230 are, by way of example, configured in an arc.

[0139] The second wall region 220 is disposed at a setback relative to the second wall portion 55. For example, the fourth wall region 230 is disposed at a setback relative to the second wall region 220 such that the mold cavity 45 has a widened portion 235 between the second wall region 220 and the fourth wall region 230. The widened portion 235 can be used to form the second ridge 1120. It is also contemplated that at least one of the wall regions 215, 220, 225, 230 may have a different geometric configuration.

[0140] Figure 21 shows a perspective view of the wall 30 in a modification of the configuration shown in Figure 20. The difference is that the second and fourth wall regions 220, 230 are longer in the vertical direction (y direction) than in Figure 20. In this case, the second wall region 220 and the fourth wall region 230 form a widened portion 235 in the form of a slotted hole.

[0141] Furthermore, the wall 30 has a second opening 240 in the wall bottom 60 at the height of the second and fourth wall regions 220, 230 in the vertical direction. By way of example, the second opening 240 is of rectangular configuration and configured as a through hole in the wall bottom 60. In this case, the second opening 240 is configured to receive a second fastening element 400 (not shown). Further details of the second fastening element 400 are shown in Figures 31 and 32. The second opening 240 can also be arranged in the wall regions 50, 55.

[0142] The second opening 240 can also be configured to accommodate an ejector 245 (shown in dashed lines in FIG. 21 ) for ejecting the wiring harness 1010 from below out of the mold 15 after the wiring harness 1010 is produced in the mold 15. This makes it possible to avoid damage to the wiring harness 1010, and in particular to the jacket 1040, since the jacket 1040 is only subjected to a compressive load by the ejector 245 and is substantially not subjected to a tensile load. The ejector 245 can be applied directly to the jacket 1040 or to the second fastening element 400. If, during the production of the wiring harness 1010, no second fastening element 400 is inserted into the second opening 240, the mold cavity 45 is open towards the bottom by the second opening.

[0143] Fig. 22 shows a perspective view of a mould 15 in another embodiment. The walls 30 are of a similar configuration to the walls 30 shown in Figs. 20 and 21. With the difference, the walls 30 separate a number of mould cavities 45 which communicate with each other in a common area 241. In this respect, the geometric configuration shown in Fig. 22 is exemplary. The walls 30 can be configured in any other way. The opening of the mould cavities 45 into the common area allows the individual cable bundles 1020 and / or cables 1025 of the wiring harness 1010 to be branched or joined in a simple manner in the mould 15.

[0144] FIG. 23 shows a vertical cross-sectional view of a mold 15 in another embodiment. The mold 15 has a similar configuration to the mold 15 shown in FIGS. 9A to 22. The wall bottom 63 and / or the wall portions 55, 60 have a first wall portion 250, a second wall portion 255 and a wall transition portion 260. The wall transition portion 260 is arranged between the first wall portion 250 and the second wall portion 255 in the vertical direction. In this case, the first wall portion 250 is arranged lower than the second wall portion 255. In this case, the first wall portion 250 and the second wall portion 255 are each arranged to extend in planes that are offset with respect to each other, preferably parallel to each other. The wall transition portion 260 is arranged at an angle with respect to the first wall portion 250 and the second wall portion 255. It is advantageous if the inclination of the wall transition 260 has an angle α2, which has a value less than 45°, in particular less than 30°, in particular less than 20°, in particular less than 15°, in particular less than 10°. The wall portions 250, 255 and the wall transition 260 make it possible to form the jacket portions 1400, 1405 and the transition portion 1410 of the wiring harness 1010.

[0145] FIG. 24 shows a perspective view of a mold 15 in another embodiment.

[0146] The mold 15 has a similar configuration to the mold 15 shown in Figures 9A to 23. The difference is that the walls 61, 62 are configured in a wavy manner to correspond to the contour shape 1500 of the wiring harness 1010 shown in Figure 6.

[0147] Fig. 25 shows a perspective view of a mold 15 in another embodiment. The mold 15 has a similar configuration to the mold 15 shown in Fig. 24, and the walls 61 and 62 are configured in a wavy manner to correspond to the contour shape 1500 of the wiring harness 1010 shown in Fig. 7.

[0148] FIG. 26 shows a perspective view of a mold according to another embodiment.

[0149] The mold 15 has a configuration similar to that of the mold 15 shown in Figures 24 and 25, and the walls 61, 62 are configured in a ribbed manner to correspond to the contour shape 1500 of the wiring harness 1010 shown in Figure 8.

[0150] FIG. 27 shows a perspective view of a first fastening element 200 according to the first embodiment.

[0151] The first fastening element 200 comprises 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 at a distance from each other in the vertical direction on the fastening plate 300. In this embodiment, the fastening plate 300 is of a flat configuration by way of example. The fastening plate 300 can also be of a curved shape. The fastening plate 300 rests on the wall surface 61, 62 and / or the wall bottom surface 63 by means of an outer side 315 facing away from the fastening brackets 305, 310. The fastening brackets 305, 310 preferably have at least one laterally arranged bearing surface 311, 312 that rests on the associated wall surface 61, 62, respectively.

[0152] The first fastening bracket 305 has a third opening 320. The second fastening bracket 310 has a fourth opening 325. The third and / or fourth openings 320, 325 are configured to accommodate the cable bundle 1020 or one or more cables 1025 of the cable bundle 1020. The third and / or fourth openings 320, 325 may preferably be of a circular configuration. Other cross sections are also contemplated. In this case, the third and fourth openings 320, 325 are arranged opposite each other in the longitudinal direction.

[0153] 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 leads to the third opening 320. The second insertion opening 335 leads to the fourth opening 325. In this case, the insertion openings 330, 335 are arranged on opposite sides of the fastening brackets 305, 310 in the lateral direction (X direction). In this case, the insertion openings 330, 335 may preferably include a 90° arc portion. A stable fixation and positioning of the cable bundle 1020 and / or one or more cables 1025 of the cable bundle 1020 in the mold cavity 45 by the first fastening element 200 is thereby ensured.

[0154] FIG. 28 shows a perspective view of a first fastening element 200 according to the second embodiment.

[0155] The first fastening element 200 has a similar configuration to the embodiment of the first fastening element 200 shown in FIG. 27. The difference is that the fastening brackets 305, 310 are preferably of a hook-type configuration. The first fastening bracket 305 has a first bracket part 340 and a second bracket part 345. In this case, as an example, the first bracket part 340 is formed perpendicular to the fastening plate 300. The second bracket part 345 is oriented perpendicular to the first bracket part 340 and, as an example, is parallel to the fastening plate 300. The second fastening bracket 310 preferably has the same configuration as the first fastening bracket 305. The difference is that the second fastening bracket 310 is offset relative to the first fastening bracket 305 in the vertical direction (y direction). In this case, the second bracket part 345 of the second fastening bracket 310 extends in the direction of the second bracket part 345 of the first fastening bracket 305 (x direction) and is preferably arranged parallel to the first fastening bracket 305.

[0156] It is also possible for the second bracket portion 345 to have a wedge-shaped configuration on the side facing the fastening plate 300 adjacent the free end 349 of the second bracket portion 345, as shown in FIG.

[0157] FIG. 29 shows a perspective view of a first fastening element 200 according to a third embodiment.

[0158] The first fastening element 200 is of a similar configuration to the first fastening element 200 shown in FIG. 28. With the difference being that the second bracket part 345 of the first and / or second fastening bracket 305, 310 is arranged at an angle to the fastening plate 300. In this case, the second bracket part 345 extends obliquely downwards in the direction of the fastening plate 300. As a result, the angle between the first bracket part 340 and the second bracket part 345 is smaller than 90°. Furthermore, a support part 350 is provided between the first bracket part 340 and the fastening plate 300. In this case, the support part 350 has, on the side facing the second bracket part 345, a support surface 355, which is preferably configured to correspond to the cable bundle 1020 and / or one or more cables 1025 of the cable bundle, e.g. rounded. This allows the cable bundle 1020 to be particularly well fixed in the mould cavity 45 by the fastening brackets 305, 310.

[0159] FIG. 30 shows a perspective view of a first fastening element 200 according to the fourth embodiment.

[0160] The first fastening element 200 has a similar configuration to the first fastening element 200 shown in FIG. 28. The difference is that the first fastening bracket 305 and the second fastening bracket 310 are arranged at the same height in the vertical direction (y direction). Furthermore, the second bracket portion 345 of the first fastening bracket 305 tapers in the direction of the second bracket portion 345 of the second fastening bracket 310. In this case, the taper is preferably configured such that the second bracket portion 345 has a wedge-shaped design. The second bracket portion 345 of the second fastening bracket 310 has a similar configuration to the second bracket portion 345 of the first fastening bracket 305 and tapers in the direction of the second bracket portion 345 of the second fastening bracket 310. A second gap 360 is arranged between the second bracket portion 345 of the first fastening bracket 305 and the second bracket portion 345 of the second fastening bracket 310. The second gap 360 allows the cable bundle 1020 or the individual cables 1025 of the cable bundle 1020 to be inserted so that the cables 1025 of the cable bundle 1020 are surrounded by the fastening brackets 305, 310. This allows the cable bundle 1020 to be positioned in a predetermined position in the mold cavity 45.

[0161] FIG. 31 shows a perspective view of the second fastening element 400 .

[0162] The second fastening element 400 comprises a support plate 405, a first engagement portion 410 and a second engagement portion 415. By way of example, the first engagement portion 410 is arranged on the upper side of the support plate 405 in FIG. 31. The second engagement portion 415 is arranged on the lower side of the support plate 405. The support plate 405 is configured to taper outward in the direction of its border edge 420. The first engagement portion 410 has a fir-tree configuration and has at least one engagement plate 425 which extends obliquely relative to the support plate 405 and is preferably arranged over the entire surface of the first engagement portion 410. In this case, the engagement plate 425 is embedded in the jacket 1030 of the wiring harness 1010. The fir-tree configuration makes it possible to achieve a particularly good fixation of the wiring harness 1010 to the second fastening element 400 by the jacket 1030.

[0163] The second engagement portion 415 preferably has an outer rib-shaped structure 430. In this case, the second engagement portion 415 is configured to engage in an opening 1115 of the structure 1005 of the vehicle component 1000 of the motor vehicle. This allows the wiring harness 1010 to be fixed particularly well to the structure 1005.

[0164] In this case, it is particularly advantageous if the second opening 240 (see FIG. 21) is configured to correspond to the second engagement portion 415 and the support plate 405 is configured to be larger at the top side than the second opening 240. As a result, the support plate 405 acts as a sealing element and at the same time delimits the mold cavity 45, for example, at the bottom. Furthermore, the step in the jacket 1030 of the wiring harness 1010 is reduced by the support plate 405 tapering in the outward direction.

[0165] FIG. 32 shows a perspective view of a second fastening element 400 according to a second embodiment. In this case, the second fastening element 400 is a combination of the first fastening element 200 shown in FIG. 29 and the second fastening element 400 shown in FIG. 31. In this case, the fastening plate 300 of the first fastening element 200 is integral with the support plate 405 of the second fastening element 400 and is of a single material structure. As an example, the first engagement portion 410 is omitted. Furthermore, as an example, two first fastening elements 200 are disposed on the support plate 405. The positioning of the cable bundle 1020 and / or at least one cable 1025 in the mold cavity 45 can be guaranteed by the first fastening element 200. At the same time, the wiring harness 1010 can be reliably fixed to the structure 1005 by the second engagement portion 415 after the wiring harness 1010 is manufactured. At the same time, the support plate 405 preferably enters into a material interface with the jacket 1030 of the wiring harness 1010 .

[0166] Fig. 33 shows a flow diagram of a method for manufacturing a wiring harness 1010. Fig. 34 shows a plan view of the mould system 10 during a third method step and Fig. 35 shows a cross-sectional view along the section plane DD shown in Fig. 34.

[0167] The mould system 10 is provided in a first method step 3000. In this case, heating of the mould 15 is omitted, so that the mould 15 is substantially at room temperature. Also, the introduction of a release agent into the mould cavity 45, in particular into the walls 61, 62 and / or into the wall bottom 63, is omitted. This makes it possible to avoid a situation in which the cable 1025 comes into contact with the release agent, and the introduced jacket 1030 cannot adhere to the cable 1025.

[0168] In an optional second method step 3005, the first fastening element 200 and / or the second fastening element 400 are introduced into the mould cavity 45. During this process, the second engagement portion 415 is inserted into the second opening 240 until the support plate 405 rests on the wall bottom surface 63 or on the wall surfaces 61, 62. The first fastening element 200 is inserted such that it does not protrude from the mould 15 at the top and / or rests on the wall surfaces 61, 62 by means of the bearing surfaces 311, 312 or preferably sits on the wall bottom surface 63 at the bottom.

[0169] In a third method step 3010, individual cables 1025 of the cable bundle 1020 are inserted. During this process, the first and second retaining elements 65, 70 are reversibly deformed from a closed position in the first region 1605 by the means 1600 such that an insertion opening 1610 is formed between the retaining elements 65, 70. For example, the first and second retaining elements 65, 70 are bent into or away from the mould cavity 45. By way of example, the insertion opening is delimited longitudinally by the means 1600 and transversely by the first and second retaining elements 65, 70. The means 1600 may be a mechanical tool and / or a human finger and / or the cable 1025 to be inserted. By way of example, a portion of the means 1600 protrudes into the mould cavity 45 at the top.

[0170] In the second region 1615, which is adjacent to the first region 1605 on both sides in the longitudinal direction, the holding elements 65, 70 are in the closed position. In addition, the first and / or second fastening element 200, 400 optionally ensures a predefined position of a given cable 1025 of the cable bundle 1020 relative to further cables 1025 of the cable bundle 1020. The first and / or second fastening element 200, 400 can also position and fix the cable bundle 1020 in its position in the mould cavity. In particular, the heating of the cable bundle 1020 in the wiring harness 1010 can be precisely defined by a predefined arrangement of one or more cables 1025 in the cable bundle 1020. In particular, overheating of the wiring harness 1010 is avoided in this case. As a result, possible self-ignition of the wiring harness 1010, short circuits or other irreversible damage to the wiring harness 1010 is avoided.

[0171] In addition, the holding device 40 prevents the cable 1025 from slipping out of the mold cavity 45 in the second region 1615. The insertion opening 1610 allows at least one of the cables 1025 of the cable bundle 1020 to be inserted by moving the means 1600 in a longitudinal direction along the mold cavity 45 and, parallel thereto, inserting the cable 1025 to be inserted from above into the mold cavity 45 through the insertion opening 1610. During the movement of the means 1600, the holding elements 65, 70 open and bend in front of the means 1600 to form the insertion opening 1610, and after the means 1600 has passed, they return to their respective closed positions, closing the opening 35 of the mold cavity 45.

[0172] 10 to 15 allows the cable 1025 to be inserted particularly quickly, either manually or automatically, thereby making it possible to produce the wiring harness 1010 at particularly low cost. Furthermore, the insertion of the cable 1025 into the mould 15 by means of the holding device 40 is perceived as being particularly ergonomic.

[0173] In a fourth method step 3015, the material of the outer jacket 1030 is introduced into the mould cavity 45 at the top by the opening 35 in a low pressure process. For this purpose, the holding elements 65, 70 can once again be reversibly bent from their respective closed positions (e.g. into or away from the mould cavity 45) to introduce the material of the outer jacket 1030 into the mould cavity.

[0174] During this process, the second material for the formation of the second layer 1205 (see FIG. 3) is preferably introduced first, followed by the first material of the first layer 1200. Both the first and second materials are preferably free-flowing during introduction. During the processing time of the materials, the materials settle in the direction of gravity, enveloping the cables 1025 of the cable bundle 1020 in the process. The second material is deposited on the wall bottom surface 63, forming the second layer 1205. In this case, it is particularly advantageous if the first material is applied to the second material when the second material has already hardened and the processing time of the second material has preferably elapsed.

[0175] When at least a part of the mould 15 is constructed as shown in Fig. 5, it is particularly advantageous if the material is first introduced above the first wall portion 250 and, after the underlying first wall portion 250 has been filled, above the second wall portion 255 and into the second wall portion 255. Finally, the material is introduced above the wall transition portion 260. This procedure has the advantage that it prevents the material from flowing down from the second wall portion 255 through the wall transition portion 260 in the direction of the first wall portion 250.

[0176] It is particularly advantageous if, during the introduction of the material into the mould cavity 45, the material of the jacket 1030 is applied in a wave-like fluctuating manner in a plane parallel to the wall bottom surface 63 between the first wall 50 and the second wall 55. This ensures a reliable embedding of the cables 1025 of the cable bundle 1020 in the jacket 1030.

[0177] If the material is designed to foam during hardening, the holding device 40 additionally prevents the cable bundle 1020 from being pushed out of the mould cavity 45 at the top and fixes the cable bundle 1020 in the mould cavity 45. This ensures a safe encapsulation of the cable bundle 1020 by the jacket 1030. In this case, the first gap 120 allows the first ridge 1036 to be formed at the same time in a simple manner. In this case, the first ridge 130 can subsequently be formed at the respective free end 100, 130 which corresponds, at least in one or more parts, to the geometric configuration of the holding element 65, 70 (see Figs. 11A and 12). If the holding element 65, 70 has a brush-type configuration, the first ridge 1036 is generated in that during foaming, the material from the mould cavity 45 presses against the underside 105, 125 of the brush 66, 71, so that the brush 66, 71 is bent slightly upwards away from the mould cavity 45 (symbolically shown by a dashed line in Fig. 11B). The support element 1038 corresponds to the mark of the brush 66, 71. If the gap 120 is arranged between the brushes 66, 71, the material of the jacket 1030 pushes in particular into the gap 120, so that the first ridge 1036 in particular has a lateral brush mark of the brush 66, 71. It is also possible to generate the configuration of the support element 1038 as a notch 1040 by the brush 66, 71 in a particularly simple manner.

[0178] In a fifth method step 3020, the cover 155 is placed on the mould 15, which prevents the holding elements 65, 70 from bending upwards on the side facing away from the mould cavity 45. This ensures a particularly reliable geometrical configuration of the envelope 1030, in particular of the first ridge 1036, even when a foam material is used.

[0179] It should be noted that in addition to the above-mentioned method steps 3000, 3005, 3010, 3015, 3020, further method steps may be provided. It is also conceivable to omit some of the method steps 3000, 3005, 3010, 3015, 3020.

[0180] It should further be noted that the various configurations of mold 15 and / or mold portions 16, 17 described in Figures 9A-26 may be combined with each other. Also, the features of fastening elements 200, 400 may be combined with each other in different ways. Also, the features of wiring harness 1010 described in Figures 1-8 may be combined with each other. [Explanation of symbols]

[0181] 10 Mold System 15 Mold 16 1st mold part 17 Second mold part 18 Vertical edge 19 Underside of mold part 20 Mounting plate 25 Top of mounting plate 26 Coordinate Systems 27 Grid 30 Wall 35 Opening 40 Holding device 45 Mold Cavity 50 1st wall 55 2nd wall section 60 Wall bottom 61 First Wall 62 Second Wall 63 Wall bottom 65 1st holding element 70 Second holding element 75 First contact pressure element 80 Second contact pressure element 85 First fastening means 86 Symmetry Plane 90 First portion of first retaining element 95 Second part of first retaining element 100 First free end of first holding element 105 First lower surface of first holding element 110 Part 3 115 Part 4 120 Gap 125 2nd bottom surface 130 Second free end 135 Second fastening means 140 Pin (first engagement element) 141 Free end of pin 142 1st Socket 145 First recess 150 sealing element 155 Cover 160 Third fastening means 165 Top of wall 170 Free end of holding element 175 Web 1 180 Second Web 185 First Opening 190 End face of mold part 195 Further mold part end face 200 First fastening element 205 second engagement element 210 Second Socket 215 1st wall area 220 2nd wall area 225 Third wall area 230 4th wall area 235 Widening section 240 Second Opening 241 Common Area 245 Ejector 250 First wall section 255 Second wall section 260 Wall Transition Section 300 Fastening plate 305 First Fastening Bracket 310 Second Fastening Bracket 311 Bearing surface of fastening bracket 312 Bearing surface of fastening bracket 315 External surface 320 3rd Opening 325 4th Aperture 330 First insertion opening 335 Second insertion opening 340 First bracket part 345 Second bracket part 349 Free end of second bracket part 350 Support part 355 Support surface 360 Second Gap 400 Second fastening element 405 Support Plate 410 First engagement part 415 Second engagement part 420 Boundary edge 425 Engagement Plate 430 Structure 1000 Vehicle Components 1005 Structure 1006 Retention structure 1010 Wiring Harness 1015 Bearing surface 1020 Cable bundle 1025 Cable in a cable bundle 1030 Outer cover 1035 External surface 1036 1st protuberance 1037 Top surface 1038 Instruction element 1040 Notch 1100 1st space 1105 2nd space 1110 Bulkhead 1115 Opening 1120 Second bulge 1121 Ridge Contour 1122 Opening contour 1200 1st layer 1205 2nd layer 1210 3rd layer 1215 Surface structure 1220 Surface 1225 Rib structure 1230 Rib 1235 Rib recess 1240 Bottom surface of rib recess 1300 Recess 1305 Concave Contour 1310 Structural Surface 1400 1st outer covering part 1405 Second outer cover 1410 Transition 1415 Outer surface of first outer cover 1420 Outer surface of second outer cover 1425 Transition Surface 1500 Contour Shape 1505 First contour shape part 1510 Second contour shape part 1600 means 1605 1st area 1610 Insertion opening 1615 Second area 3000 1st method step 3005 Second method step 3010 Third method step 3015 4th method step 3020 5th method step a Distance b1 First horizontal length b2 Second horizontal length

Claims

1. A wiring harness (1010) for an automobile, comprising: at least one cable bundle (1020) having at least two cables (1025) and a jacket (1030); At least one portion or portions of the cable bundle (1020) are embedded in the jacket (1030) to eliminate wrapping the cable bundle (1020) with a winding tape; the outer jacket (1030) has a first outer jacket portion (1400), a second outer jacket portion (1405), and a transition portion (1410) disposed between the first outer jacket portion (1400) and the second outer jacket portion (1405) in the longitudinal direction of the wiring harness (1010); the outer cover (1030) is integrally constructed of a material including at least one of foam, closed cell foam, open cell foam, silicone foam, and polyurethane foam; The first outer cover portion (1400) has a first horizontal length (b1) with respect to a first direction of the vertical length of the first outer cover portion (1400), the second envelope portion (1405) has a second horizontal length (b2) in a second direction of the vertical length of the second envelope portion (1405); The first horizontal length (b1) is greater than the second horizontal length (b2), The first envelope portion (1400) has a first outer surface (1415); the second envelope portion (1405) has a second outer surface (1420); the first outer surface (1415) has a planar configuration; the transition portion (1410) has a transition surface (1425) that is inclined relative to the first outer surface (1415) and the second outer surface (1420) and has a flat configuration; and A wiring harness (1010), wherein the inclination of the transition surface (1425) has an angle, the angle being formed by the first outer surface (1415) and the transition surface (1425) and having a value of less than 45°, particularly less than 30°, particularly less than 20°, particularly less than 15°, particularly less than 10°, to avoid cracks in the transition portion (1410) between the first outer jacket portion (1400) and the second outer jacket portion (1405).

2. 2. The wiring harness (1010) of claim 1, wherein the first outer surface (1415) and the second outer surface (1420) are arranged parallel to each other in two planes offset from each other at different heights.

3. The wiring harness (1010) of claim 1, wherein the second outer surface (1420) has a flat configuration.

4. The wiring harness (1010) has an upper surface (1037); the first outer surface (1415) and the second outer surface (1420) and the transition surface (1425) are disposed on the underside of the wiring harness (1010) opposite the top surface (1037) of the wiring harness (1010); and The wiring harness (1010) of claim 1, wherein the top surface (1037) of the wiring harness (1010) is configured to be substantially free of any transitions or steps.

5. The wiring harness (1010) comprises a first fastening element (200), At least one portion or portions of the first fastening element (200) are embedded in the outer cover (1030); and 2. The wiring harness (1010) of claim 1, wherein the first fastening element (200) is configured to hold at least one of the cables (1025) of the cable bundle (1020) in place.

6. The wiring harness (1010) comprises a second fastening element (400), The second fastening element (400) has a first engagement portion (410) embedded in the outer cover (1030), and The wiring harness (1010) of claim 5, wherein the second fastening element (400) has a second engagement portion (415) configured to engage with a vehicle component (1000) of an automobile to fasten the wiring harness (1010) to the vehicle component (1000).

Images