Cable harness and method for producing a cable harness

Abstract

The cable harness (2) according to the invention is provided in particular for a vehicle and has a plurality of lines (4) which are attached to a flexible support (8), wherein, at least on one of the lines (4), an electrical component (6), in particular a contact connector, is attached which is at least temporarily fixed to the support (8) by material of the support (8) in such a way that the at least one component (6) can be moved during subsequent assembly of the cable harness (2), specifically in particular in an insertion direction (28) for insertion into an electrical component (26). As a result, the at least one component (6) is fixed in position and is accessible for later, in particular automated, final assembly of the cable harness (2), for example on a support module, and can be automatedly inserted, for example, into a corresponding mating connector.

Description

[0001] Description

[0002] Cable harness and method for producing a cable harness

[0003] The invention relates to a cable harness, in particular for a vehicle, and a method for producing such a cable harness.

[0004] A cable harness typically comprises a number of cables laid according to a predefined routing pattern. Components, particularly contact connectors, are typically pre-assembled and attached to the cables.

[0005] Such a cable set is used particularly in the automotive sector to connect electrical components to the vehicle's electrical system.

[0006] The vehicle electrical system is often divided into different zones or modules, with each zone connected via a module-specific cable harness. For example, the cable harness might be for a door module, a tailgate module, a roof module (ceiling panel), an instrument panel module, etc. In these variants, the cable harness is typically attached to the body panel and / or to a carrier module on which electrical components such as electric motors, speakers, control units, etc. are mechanically mounted. These electrical components are connected via the cable harness.

[0007] The assembly of the cable harness on such a carrier module is often complex and difficult to automate. One reason for this is, among other things, that the cable harness is typically very flexible and, moreover, often has a complex routing structure. Based on this, the object of the invention is to provide a cable harness that can be assembled easily and, in particular, automatically, and can be attached in particular to such a carrier module or to the body.

[0008] The object is achieved according to the invention by a cable harness, in particular for a vehicle, comprising a plurality of lines mounted on a support layer of a flexible support according to a predetermined installation structure, and comprising at least one component mounted on the lines, in particular a contact plug, which is at least temporarily fixed to the support by the material of the support. The fixation is such that the at least one component is movable during subsequent assembly of the cable harness, in particular in a plug-in direction for insertion into an electrical component.

[0009] For this purpose, in particular a partial area of ​​the at least one component is accessible for later, in particular automated, assembly and can in particular be grasped.

[0010] By fixing at least one component, it is fixed to the carrier at a defined position.

[0011] In this case, fixation is understood to mean, on the one hand, direct fixation in which the component itself is held by carrier material.

[0012] On the other hand, fixation also refers to indirect fixation, in which the component itself is not directly held by the carrier material, but rather, in particular, the cable connected to the component. This is, for example, sandwiched between two layers of the carrier or otherwise held firmly to the carrier. This fixation of the cable connected to the component indirectly fixes the component. The carrier material is preferably a textile material, in particular a nonwoven. The carrier therefore preferably has at least one carrier layer made of a nonwoven.

[0013] In addition, a variant is also provided in which the fixation is carried out indirectly and, in addition, at least partly also directly.

[0014] During subsequent assembly, the preferred procedure is generally such that the carrier is first positioned and, for example, fixed on a carrier module or on a body component, and then the at least one component is moved into a final assembly position. Specifically, when the component is designed as a contact plug, the contact plug is moved toward a mating plug and plugged into it. Therefore, the component is preferably movable in a plug-in direction. The movement of the component therefore occurs in particular in a plug-in direction, i.e., the mobility is oriented in the plug-in direction.

[0015] The mobility or movement is preferably relative to the carrier. In this variant, the component is therefore only temporarily fixed and / or only loosely fixed, allowing it to be moved relative to the carrier. It is removed, for example, from a holder or fixture formed by the carrier, which is designed, for example, like a pocket or a retaining tab.

[0016] In a preferred embodiment, the movement occurs together with at least one part or section of the carrier. For this purpose, the component is held on the part / section of the carrier or at least the carrier layer and is moved together with it. This part of the carrier is also referred to below as the connecting section. This connecting section can therefore be moved relative to the rest of the carrier, i.e. to a remaining part of the carrier, and in particular can be bent out of a plane formed by the carrier. Preferably, a part or section of the carrier or the carrier layer is moved along, while other areas of the carrier remain stationary. The carrier generally preferably has flexibility and / or elasticity. This allows the part / section of the carrier to be moved along with the component during assembly.

[0017] When the component is fixed with a retaining tab, the component is gripped together with the retaining tab and moved in the plug-in direction.

[0018] If, within the meaning of this application, it is required that the component is movable during a later assembly of the cable harness, this is understood in particular to mean that the component can be moved at least relative to such a remaining carrier section, which is preferably fixed to the carrier module or the body component and held stationary there.

[0019] Preferably, the previously described partial area of ​​the component is freely accessible, i.e., not covered by the carrier material. In this freely accessible area, the component can be actuated and, in particular, gripped, and, in particular, removed from the fixture and moved to the desired final assembly position.

[0020] Alternatively, the component is temporarily covered by the carrier material and embedded, for example. However, this is done in such a way that the component can still be moved into the desired final position during subsequent assembly.

[0021] For example, the component is only loosely covered by carrier material in the form of loose tabs so that the component can be easily grasped.

[0022] The component is preferably only temporarily surrounded by the carrier material. A pocket is specifically designed, for example a closed pocket or, alternatively, an open pocket, whereby one side of this pocket can be opened for assembly or is open. The (temporarily closed) side is temporarily closed, for example, by a reversible closure mechanism, such as a hook and loop fastener. Alternatively, a predetermined breaking point is defined, for example by only a point-like and thus easily separable welding of two layers of the carrier material. Such a predetermined breaking point is particularly designed in such a way that it is broken open when the component is moved during final assembly. Alternatively, it is broken open / cut open using a suitable tool, such as a cutting element. In particular, the component is, for example, indirectly gripped and pulled by the cables connected to it, or if necessary.also pulled / pushed in other ways relative to the carrier so that the predetermined breaking point breaks open and the component can be moved specifically in the plug-in direction and in particular connected to an electrical component.

[0023] Overall, the carrier ensures that the component is secured close to the final assembly position, so that when the carrier is placed on the carrier module / body component for final assembly, the component is in the immediate vicinity of its final assembly position. At the same time, the fixation also ensures that the component is securely secured to the carrier during transport, for example.

[0024] The cable harness typically has a branched structure with a plurality of such components distributed across the carrier. In particular, each of these components is fixed to the carrier by the carrier material and thus held in a defined position.

[0025] A respective fixation formed by the carrier material is - as already explained above - designed such that preferably the aforementioned partial area of ​​the component is accessible, so that this partial area is accessible for an actuating element, in particular of an automated assembly device. The actuating element is in particular a gripping tool, for example of a robot. Alternatively or additionally, the component is pushed into a desired final assembly position by a corresponding punch. In the simplest variant, at least / only one side of the component is accessible, so that such a punch can, for example, push the component out of the fixation. In any case, the partial area of ​​the at least one component is therefore freely accessible for the actuation of such a tool.Preferably, the partial region - in the case of the component being designed as a contact plug - is arranged on a rear section of the component opposite a front end face, wherein the free end face is designed as a contact face for plugging in contact with a mating plug.

[0026] The freely accessible part of the component is, for example, at least one fifth, preferably at least one quarter or even one third of the component.

[0027] It should also be emphasized that the respective component is directly or indirectly fixed to the carrier by the material of the carrier itself. Therefore, no additional retaining elements are attached to the carrier that, for example, encompass the component to secure it.

[0028] There are various options for securing the at least one component to the carrier, which can also be combined with one another. Preferably, the at least one component is secured to the carrier using one of the variants described below. Different components can be secured using different variants.

[0029] According to a first preferred basic variant of the invention, as claimed in preferred embodiments in claims 2-12, the carrier is designed as a two-layer structure with two carrier layers, namely a lower base layer and an upper cover layer, between which the lines are sandwiched. The two carrier layers are connected to one another along the at least one line to which the electrical component is attached, specifically at least over a portion of the line in the vicinity of the electrical component. This measure achieves the previously mentioned indirect fixation of the component by the line connected to the component being fixed in place between the two carrier layers, particularly and at least in the vicinity of the component. The term "near area" is understood to mean the area of ​​the line starting from the component up to, for example, a distance of 5 cm from the component.

[0030] Furthermore, a partial section of at least one of the two carrier layers, which covers an end section of the at least one line with the component attached to the end, can be at least partially separated from the remaining carrier, such that the component is movable relative to the remaining carrier. By at least partially separating the partial section of the at least one carrier layer, the original indirect fixation is removed, and the component can be grasped during subsequent assembly for the desired contact and electrically and mechanically connected to a mating component.

[0031] In a preferred embodiment, the section that can be separated from the rest of the carrier comprises both carrier layers and the cable held between the two carrier layers. In this variant, the section forms a connection section that creates a sandwich-like structure from the two carrier layers with the cable. This section is therefore free and movable relative to the remaining carrier in the manner of an elongated tab. In this variant, it should be emphasized that the two carrier layers of the connection section are connected to one another in the region of the connection section, so that the component continues to be held to the connection section by the carrier layers in the connection section.

[0032] The two carrier layers generally preferably have the same or at least largely the same size and / or have the same or at least largely the same outer contour. In this case, "largely the same" is understood in particular to mean that the two carrier layers are congruent except for a difference of, for example, 10% or a maximum of 20% of the total area. To connect the two carrier layers, strip-shaped connecting regions are preferably formed on both sides of a respective line and along the respective line, along which the two carrier layers are connected to one another.

[0033] Therefore, in the preferred embodiment, no full-surface connection of the two carrier layers is provided, but only along the strip-shaped connecting areas. Because the two carrier layers are connected to each other on both sides of a respective line, the line, and indirectly the component, is fixed to the carrier.

[0034] The connection is achieved, for example, by a material-to-material bond, such as welding or gluing. Alternatively or additionally, the two carrier layers are joined together by a mechanical connection, such as a textile process such as sewing, knitting, etc. The strip-shaped connection area is formed, for example, by a continuous, elongated (material-to-material) connection point or by a plurality of individual, e.g., point-shaped connection points along a line.

[0035] In a preferred embodiment, the support is generally designed to cover a large area, with the cables preferably being laid only in partial sections of the support, and the support therefore also having surface sections where no cables are laid. Therefore, the support's geometry does not follow the cable laying structure.

[0036] In a preferred embodiment, it is provided that the two carrier layers are connected to one another along the lines and additionally at their edges, in particular via the strip-shaped connecting areas. If required, the two carrier layers can also be connected to one another in free surface sections in which no lines are laid, specifically by strip-shaped connecting areas. With a view to a simple at least partial separation of the partial section, in an expedient further development, prepared predetermined separation lines are formed, on which at least one material weakening is formed, for example in the form of a perforation. In a preferred embodiment, the predetermined separation lines are cutting lines along which the material of the carrier layer has already been severed (material weakening to zero, i.e. as a cut). The predetermined separation lines are defined in advance, e.g.before the cables are laid, for example, through the aforementioned perforation or, in particular, through punching to create the cutting lines. By weakening the material, at least a reduced bonding force is achieved between the section and adjacent sections of the carrier material. This allows the section to be easily separated from the rest of the carrier during subsequent assembly, particularly without additional aids (tools). In particular, no cutting tool is required for separation.

[0037] If the intended separation lines are formed by cutting lines, the section is preferably connected to the remaining carrier layer via connecting webs, which are then severed during separation. These can also be severed without a cutting tool and have a material weakening.

[0038] Alternatively, a cutting tool is used to separate the section or at least the connecting webs, for example, if the tear-off forces are too high to separate it at the specified separation line. Such a cutting tool can also be used to cut free sections, i.e., remove sections of the carrier layer. These sections to be cut free are also bordered by such specified separation lines, specifically cutting lines.

[0039] Preferably, the subsection is further permanently connected to the remaining support in a base section. The subsection is further connected to the remaining support in the base section. Especially in the configuration with the sandwich-like connecting section, this ensures that a connection to the support remains intact. With regard to subsequent, particularly automated, assembly, at least one of the two support layers at least partially covers the component, so that the component is at least partially exposed and can be grasped, particularly by a robot.

[0040] Preferably, the two carrier layers are not connected to one another in the region of the component. This means that after the separation of at least one carrier layer, the component is at most covered by a loose tab made of the carrier material. This can, for example, be easily folded down so that the component is accessible. This also applies, for example, to the embodiment with the sandwich-like connection section. A section of the carrier layer covering the component is therefore, for example, part of the separated subsection. In the embodiment with the sandwich-like connection section, two loose carrier tabs are created in the region of component 2.

[0041] Alternatively or additionally, the detachable section does not extend over the component or only partially extends over it. Therefore, when the section is separated, especially the connecting section, the component is automatically exposed.

[0042] As an alternative to such loose tabs that are still connected to the subsection, it is also possible to completely separate sections of the carrier material in the area of ​​the component, for example, again along the predetermined separation lines described above. The carrier material covering the component can therefore be removed, for example, by tearing it off, making the component accessible.

[0043] In a preferred embodiment, at least one of the carrier layers, in particular the base layer, has an at least partially or completely detachable section in the region of the component, which, after at least partially separating from the remaining carrier layer, can be at least folded down or completely removed. This at least partially detachable section in the region of the component is designed in particular in addition to the previously described detachable partial section / connecting section. Therefore, there are, in particular, two different detachable sections.

[0044] This measure offers the particular advantage that the section in the component area can be folded down or completely removed during production, thus preventing the component from being covered by the carrier material. This is particularly useful for securing the component to a bracket during cable harness production and cable routing, allowing the cables to be laid along a desired routing geometry until this geometry is secured by the sandwich structure subsequently formed between the two carrier layers.

[0045] Preferably, at least one of the carrier layers, in particular the upper cover layer, is cut out in the region of the components, preferably only in the region of the component, so that the component is exposed. The exposed component allows it to be easily gripped, for example, by the aforementioned robot, particularly during subsequent assembly.

[0046] Preferably, the carrier further comprises a plurality of at least partially cut-out openings which are arranged one after the other along the lines and can be guided through the guide pins.

[0047] These openings are used during production for inserting the guide pins, which are attached to the previously mentioned mounting board. The guide pins serve as an installation aid for laying the cables along the desired installation structure. The guide pins are therefore inserted through the two support layers during assembly. Once the support with the sandwiched support layers has been completed, the support is then removed from these guide pins and thus from the mounting board. The previously described strip-shaped connecting areas, which connect the two support layers, in particular on both sides of a respective cable, run in particular along a line formed by these openings. Each opening interrupts a respective strip-shaped connecting area, so that it is divided into a plurality of sections.that a plurality of strip-shaped connecting regions is formed, each of which runs between two adjacent openings and is also spaced apart by them.

[0048] A second basic variant with further sub-variants of the invention is explained in more detail below. This second basic variant with further sub-variants is the subject of claims 13-25.

[0049] Unless technically impossible, the two basic variants can be combined with each other; in particular, individual features of one basic variant can be combined with the other basic variant.

[0050] A characteristic distinguishing feature of this second basic variant from the first basic variant is that only one (large-area) carrier layer is provided (which, as in the first basic variant, can also be referred to as the base layer). Therefore, there are no two large-area carrier layers sandwiched together. In the second basic variant, at most, a number of fixing layers are formed, which, in particular, only partially cover the carrier layer.

[0051] According to a preferred first variant of this second basic variant, at least one retaining tab is partially cut free from the carrier layer, so that the retaining tab is still connected to the remaining carrier layer by a base side. The retaining tab is placed around the at least one component, with the retaining tab being folded or bent accordingly for this purpose. A fastening section of the retaining tab is then again connected, at least at certain points, to the remaining carrier layer, i.e., fastened to it. The connection of the fastening section to the remaining carrier layer is achieved, for example—similar to the connection of the two carrier layers according to the first basic variant—by gluing, welding, sewing, or using clamps, etc.

[0052] In this first variant (the second basic variant), the carrier layer is pre-cut accordingly during a pretreatment process so that the retaining tabs can be removed from the carrier along cutting lines. These cutting lines are created, for example, by mechanical cutting, for example, using a knife, or alternatively by punching or laser cutting.

[0053] The component is fixed using the strip-shaped retaining tab, for example.

[0054] According to a preferred variant, the component is partially inserted through an opening in the carrier layer. The opening is formed, for example, by cutting free and forms a cut-free opening. The component is preferably then secured with the aid of the retaining tab. This retaining tab spans, for example, in particular a rear partial section of the component. The opening is designed, for example, such that the component is held in it with a form-fitting fit. The component is preferably oriented perpendicular to the carrier and the carrier layer. When designed as a contact plug, for example, this is guided through the carrier layer with its contact or plug-in area at the front.

[0055] This opening has, for example, a T-shape or an H-shape and is therefore in particular designed as a slot with at least one transverse slot (T-shape) or two transverse slots (H-shape) at the end.

[0056] According to a preferred development, a plurality of retaining tabs are formed from a cut-out section. For this purpose, for example, an elongated tab is first cut free and then reconnected to the remaining carrier layer at several spaced-apart locations to form at least two separate retaining areas. In this case, sections of the cut-free tab are swollen up so that an insertion space / retaining area is formed into / through which the respective component or also the cables can be inserted or passed through. In particular, two retaining tabs arranged next to one another are formed, one retaining tab receiving the component and a section of the cables attached to the component being guided through the other retaining tab.

[0057] In a useful embodiment, the at least one retaining tab forms a pocket that is open only on one side and in which the at least one component is located. The pocket generally has a bottom and side wall regions that surround the at least one component.

[0058] In a preferred embodiment, according to a second variant, an opening with two differently sized opening areas, i.e. with a large opening area and a small opening area, is formed in the carrier layer. These two opening areas are preferably connected to one another via a connection formed by an opening slot. The at least one component is guided at least partially through the large opening area and then moved laterally into the small opening area and is held there in a form-fitting manner. In this embodiment, the at least one component is therefore held in a form-fitting manner in the small opening area in an opening formed according to the keyhole principle, in that an edge of the opening and thus material of the carrier encompasses a section, for example a constriction, of the at least one component.Specifically, it has a widened holding area or projection, which is engaged behind by the opening edge.

[0059] In a further preferred embodiment, according to a third variant of the second basic variant, the carrier is formed in two layers, and in particular only partially in two layers, namely with the carrier layer and with a fixing layer attached thereto, in particular only in certain regions. The at least one component is mounted in a pocket formed between the carrier layer and the fixing layer. The at least one component is therefore usually completely surrounded by the fixing layer and the carrier layer except for an opening on one side. The at least one component can be pulled out of this pocket if necessary.

[0060] In this variant, the component is also accessible for later assembly. It is therefore only temporarily fixed in the formed pocket and removed from it during subsequent assembly. The component is preferably oriented parallel to the carrier layer.

[0061] To form the pocket, the fixing layer is typically puffed up, essentially gathered, creating a free space for inserting the pocket. The carrier layer is usually smooth and flat in this area. This puffing is further secured by sections of the fixing tab being secured to the carrier layer at the sides of the puffing.

[0062] The fixing layer preferably does not completely cover the carrier layer and is therefore only formed in certain regions. This means that some sections of the carrier layer are not covered by the fixing layer. In particular, the aforementioned partial area of ​​the at least one component is not covered by the fixing layer and thus remains freely accessible.

[0063] For example, several different fixing layers are distributed across the carrier layer.

[0064] Alternatively, the fixing layer can also cover the entire carrier layer, with several recesses preferably being formed in the fixing layer through which the components are accessible. This design is then comparable, at least in some areas, to the first basic variant.

[0065] Preferably, the fixing layer is designed differently from the carrier layer. Preferably, both layers consist of the same material, for example, the same nonwoven. However, this is not mandatory. In particular, the two layers differ in terms of their material thickness and / or their basis weight. Preferably, the fixing layer is thinner or has a lower basis weight than the carrier layer. The thickness or basis weight differs, for example, by at least a factor of two or three. For example, the carrier layer, particularly when designed as a nonwoven, has a basis weight in the range of 70 g / m 2 up to 240 g / m 2 The fixing layer then has a basis weight of 35 g / m 2 up to 120 g / m 2 A special combination of 140 g / m 2 for the carrier layer and 40 g / m 2for the fixing layer. Alternatively to this different design, the carrier layer and fixing layer are identical in terms of their material properties, particularly their thickness and their basis weight. In this case, the basis weights are, for example, in the range of 60 g / m 2 up to 100 g / m 2 .

[0066] The two layers consist primarily of PET, PP or a mixture thereof.

[0067] The previously mentioned properties of the carrier layer on the one hand and the fixing layer on the other hand in the second basic variant also apply in particular to the two carrier layers of the first basic variant. Preferably, the two carrier layers of the first basic variant are made of the same material, in particular the same nonwoven, and have, for example, the same basis weights.

[0068] In a useful further development, the fixing position leaves a line section of the at least one line that adjoins the component free. This means that the at least one component dips into the pocket with its front end first. The line section directly adjacent to the component is therefore not fixed. This has the advantage that the at least one component can be gripped and mounted during subsequent assembly on the carrier module. The unfixed line section allows assembly tolerances to be easily compensated for. In a preferred embodiment, the at least one component is a contact plug that extends in a plug-in direction and that has plug contacts, such as contact pins or contact sockets, on a front end in the plug-in direction for electrical connection to a mating plug.

[0069] The at least one carrier layer of the carrier is preferably a textile carrier such as a nonwoven or a woven fabric. If the carrier consists of multiple layers, preferably all layers consist of a textile material such as a nonwoven or a woven fabric. The material of the carrier is therefore formed by the nonwoven or the woven fabric. Alternatively, the carrier as a whole or at least one carrier layer, and in particular both carrier layers, can also consist of a film. The advantage of a textile carrier is that the textile material also provides damping and / or insulation.

[0070] Conveniently, at least one component is only temporarily fixed and can be removed from its fixed position. During assembly, the respective component is therefore also removed from this fixed position. In the final assembled state, i.e., in particular when mounted in the motor vehicle, this is reflected in the fact that the previously formed fixing areas, such as the retaining tabs and pockets, are free and unoccupied. These therefore serve only to fix the components in defined positions on the carrier in order to simplify assembly and, in particular, the formation of plug connections between the contact plugs and the electrical components to be connected.

[0071] Alternatively, the components remain in their respective fixed positions. Due to the flexibility of the carrier, it is also possible in this case to transfer the respective component into the desired final assembly position and, for example, to connect it to a mating connector. By fixing the components to the carrier, they are each held in their intended position on the carrier and distributed across the carrier. In addition to this positionally correct fixing, a preferred embodiment also provides for orientationally correct fixing. This means that at least one component, in particular the contact connector, is fixed to the carrier in such a way that during later assembly it is already oriented in the plug-in direction, for example, and in particular no longer needs to be rotated.

[0072] In particular, a preferred embodiment provides that the at least one component is oriented at an angle, i.e., at an angle other than zero, obliquely to the carrier. Specifically, the component is oriented perpendicularly to the carrier. When using a contact plug as a component, the plugging direction is angular, for example, obliquely and, in particular, perpendicularly to the carrier. The front end of the contact plug is oriented away from the carrier. Alternatively, it is oriented, for example, toward the carrier.

[0073] According to a useful embodiment, a securing area is formed from the material of the carrier and by folding or bending, which secures the at least one component in its fixed position against accidental falling or slipping out. The securing area forms a positive locking device or obstacle, so that the at least one component remains in the fixed position even when the cable set moves. The securing area forms, for example, a stop for the component.

[0074] To create the security area, one of the following options is preferred:

[0075] According to a first option, which is used in particular in connection with the retaining tab described above, the securing area is designed in multiple layers, namely by partially cutting free from the carrier layer and bending and folding the cut-free part, which is then connected in particular to the remaining carrier layer, for example by gluing, sewing, welding, clamping, etc. The securing area is designed in particular opposite the retaining tab.

[0076] According to a second option, the securing area is again designed in several layers, but without cutting free, but simply by folding the carrier layer.

[0077] According to a third option, the securing area is formed by lateral compression and the resulting bulging of the material of the supporting layer. Specifically, based on the free-cutting variant, the cut-out section is first folded over and then compressed from both edges, creating a bulge in the center. The two edges are then fixed to the underlying supporting layer, thus securing the bulge created by the compression.

[0078] In the preferred embodiment with two differently sized opening areas, the securing area blocks a connection between the two opening areas. Specifically, the aforementioned opening slot between the two opening areas is blocked by the securing area. This blocks the connection area between the two opening areas. The securing area is in turn formed, in particular, by folding, particularly a cut-out section.

[0079] According to a preferred embodiment, the retaining tab is guided around the component and forms a protruding gripping tab, particularly for automated gripping. In particular, two opposing sections of the retaining tab are each wrapped around one half of the at least one component and joined at an upper side of the component and connected to one another, for example, by gluing, clamping, sewing, or welding. In a preferred embodiment, recesses or at least partially cut-out openings are further formed on the carrier, which can have different functions:

[0080] Holding elements, in particular holding forks or guide pins, are preferably guided through the recesses or openings. These are used for laying the cables on the support and along which the cables are / are guided during installation. The cables are usually inserted into holding forks. The holding forks are distributed and specify the installation geometry of the cables. Such holding forks are usually distributed on a mounting board, also referred to as an installation board, and protrude vertically from it. Overall, the cables and the electrical components connected to them are therefore guided by the holding forks at a distance from the installation board within a installation plane. The support is also arranged within this installation plane.

[0081] When using guide pins, the cables are laid between them. The support preferably rests directly on the installation board.

[0082] Alternatively, fixing elements are passed through the recesses / openings, through which the carrier can be attached to the carrier module or directly to a body component, and are also secured in the final assembly. The fixing elements are held in the recesses / openings in a form-fitting manner. The fixing elements are, for example, locking elements that are inserted into the recesses and held there. Corresponding receptacles for these fixing elements are provided on the carrier module.

[0083] According to a further preferred variant, an electrical component is at least partially guided through the recess, at least in the assembled state, wherein this electrical component is connected to the cable harness specifically via the at least one component in the assembled state. The electrical component is particularly attached to the carrier module or the body component.

[0084] Such a last-mentioned recess is preferably designed as a free recess adjacent to a respective retaining tab / pocket and is sufficiently large that at least the component can be guided through. When assembling the cable harness, the component is removed from the retaining tab / pocket, guided through the free recess and connected to the electrical component, or the component is connected to the component guided through the free recess. “Adjacent” is therefore also understood to mean that the recess is arranged so close to the retaining tab that the component with the cables connected to it can be moved up to the free recess. As a rule, this free recess is, for example, a maximum of 15 cm, a maximum of 10 cm, or a maximum of 5 cm away from the retaining tab.

[0085] In the initial state before assembly, several such free recesses are therefore formed in the carrier, and preferably each retaining tab is assigned (exactly) one free recess for each component.

[0086] The entire cable harness with the carrier generally serves to simplify the assembly of the cable harness, especially on the carrier module already mentioned several times or directly on a body component.

[0087] The cable harness with the carrier initially forms an intermediate product, which is typically transported from a cable harness manufacturing location to an assembly location.

[0088] At the assembly site, the carrier is attached to the carrier module or to the body component. This is followed by the particularly automated gripping of the components and their connection (plug connection) to the corresponding mating components on the carrier module / body component. In a preferred embodiment, the carrier is therefore attached to such a carrier module or a body component in the assembled state after assembly. The aforementioned electrical components are attached to the carrier module, which are electrically connected via the cable harness and connected to the rest of the vehicle's overall electrical system. For this purpose, the carrier is generally designed to be large-area, covering an area of, for example, at least 0.5 m 2 or even 1 m 2The carrier module is typically a door module, a tailgate module, a roof module, or even a dashboard module. Several electrical components are typically attached to this module, such as electric actuators (e.g., windshield wiper motors), speakers, control units, electric locks, or other actuators, as well as sensors.

[0089] The object is further achieved according to the invention by a method for producing the cable harness and in particular also for the subsequent assembly of the cable harness, wherein lines are attached to a carrier layer of a flexible carrier according to a predetermined laying structure and at least one component, in particular a contact plug, is attached to at least one of the lines. This at least one component is at least temporarily fixed to the carrier by material of the carrier, specifically in such a way that the at least one component is movable and in particular actuatable during assembly of the cable harness, specifically in such a way that the component is movable in a plug-in direction for insertion into the electrical component. For this purpose, in particular a partial area of ​​the at least one component remains accessible, so that the at least one component is accessible for later assembly of the cable harness and in particular can be grasped.

[0090] The advantages and preferred embodiments previously mentioned with regard to the cable set are also to be applied to the method.

[0091] To manufacture the cable harness, particularly according to the first basic variant, the following procedure is followed: First, the carrier layer is prepared, specifically placed on a mounting board. This board preferably has guide pins that protrude vertically and penetrate through the previously described partially cut-out openings.

[0092] The guide pins define a laying structure along which the branched structure of the cables is laid. The second carrier layer, known as the cover layer, is then applied, and the two carrier layers are connected to each other, particularly by strip-shaped connecting areas on both sides of the cables.

[0093] The two carrier layers are prepared carrier layers which, for example, have already been formed with the predetermined separation lines described above, for example through preparatory measures such as punching or perforating, or in which sections of the carrier material have already been removed.

[0094] At least one component is initially releasably secured using a bracket. The bracket is attached to the mounting board. This ensures that the component is initially secured to the mounting board for cable routing. To ensure this is done reliably, a section of the support layer in the area of ​​the component is at least partially cut out, allowing the section to be folded away and the component to be reliably inserted into the bracket attached to the installation board, where it is temporarily securely fixed.

[0095] The cable set prepared in this way, consisting of the carrier with the two carrier layers and the cables arranged between the carrier layers with the at least one component, forms an intermediate product for the subsequent assembly.

[0096] For assembly, the cable harness is preferably attached automatically to the carrier module, which has at least one electrical component that is electrically connected to the cable harness via the contact plug. For this purpose, the contact plug is automatically gripped and plugged into the electrical component, which is provided with a corresponding mating plug.

[0097] In the first basic variant described above, the detachable section is first separated from the remaining carrier. The component is then gripped, particularly automatically, with the help of a robot, moved relative to the remaining carrier, and connected to the mating component (mating connector). Preferably, the position of the component is identified in advance before gripping.

[0098] In particular in the second basic variant described above, the contact plug is preferably removed from its fixed position, for example from the retaining tab described above or the pocket described above, and is moved into the desired plug-in position and connected to the mating plug through the free recess described above.

[0099] The previously described free recess is located adjacent to the retaining tab, and the component is connected to the electrical component through this. The carrier module and thus the electrical components are therefore located on the side of the carrier facing away from the cables.

[0100] During assembly, the cable harness is preferably placed with the carrier first onto the carrier module or body component. The electrical components typically already attached there, at least the mating connectors, are accommodated in the free recesses, or the free recesses are positioned in the area of ​​the electrical components to be contacted, particularly in the area of ​​the mating connectors. The cables are arranged on the side of the carrier opposite the carrier module or body component.

[0101] The components / contact plugs are then gripped, removed from the retaining tabs / pockets, passed through the adjacent free recess to the electrical component, or plugged into the electrical component accommodated in the free recess.

[0102] For automated assembly, a suitably designed handling device, in particular a robot, is provided. This handling device has a suitable assembly tool, which is formed, for example, by a gripper or at least has one, via which the component is moved into the desired final position by the robot. For this purpose, in particular, the free portion of the at least one component is gripped and moved to the desired final position by the robot.

[0103] However, the prepared cable set with the carrier is also suitable for manual assembly and enables particularly ergonomic assembly, as the components are already fixed in the area of ​​the later assembly position.

[0104] Embodiments of the invention are explained in more detail below with reference to the figures, which show, in simplified representations:

[0105] FIG 1 is a plan view of a mounting board with a cable set mounted thereon with a carrier according to a second basic variant,

[0106] FIG 2A is a perspective, partial view of the carrier with cutting lines for partially exposing a retaining tab,

[0107] FIG 2B shows the section of the carrier shown in FIG 2A, wherein the cut-out retaining tab is formed into a pocket in which a contact plug is received,

[0108] FIG 3 a perspective, partial view of the carrier, with a partially cut-out retaining tab,

[0109] FIG 4A is a perspective partial view of the carrier with an opening formed according to the keyhole principle with a large opening area and a small opening area, FIG 4B is the section shown in FIG 4A after the assembly of a component and with a multi-layer securing area formed by folding for securing the component,

[0110] FIG 5A a front view of a contact plug fixed with a retaining tab, wherein a protruding gripping tab is formed

[0111] FIG 5B is a side view of FIG 5A,

[0112] FIG 6A is a perspective view of a carrier layer applied to a mounting board as a base layer for producing a cable harness according to a first basic variant,

[0113] FIG 6B is a perspective view analogous to FIG6B, wherein a further carrier layer is additionally applied as a cover layer,

[0114] FIG 6C shows a cable harness manufactured as an intermediate product with the two carrier layers, between which the cables are laid in a sandwich-like manner in a predetermined, branched laying structure.

[0115] In FIG 1, a cable harness 2 according to a second basic variant is shown, namely on a mounting board 3 (cable board), which is used as an aid for the formation of the cable harness 2.

[0116] A first basic variant of cable harness 2 is explained in conjunction with Figures 6A-6C. The two basic variants can, in principle, be combined with one another. Preferably, the first basic variant described in Figures 6A-6C is used without the fixing variants described in the second basic variant and Figures 1 to 5.

[0117] For both basic variants, the cable harness 2 generally has a branched installation structure with a large number of individual cables 4 that are combined to form a cable bundle. The cable harness 2 has different sections, also with branches, wherein the different sections have different numbers of cables 4. The individual cables 4 are, for example, individual wires. The cable harness 2 also has a plurality of components 6 connected to the ends of the cables 4, which are designed in particular as contact plugs. The cables 4 and the components 6 are attached to a flexible carrier 8. In all embodiments, the carrier 8 has at least one carrier layer 8A, which is preferably formed by a fleece.

[0118] As explained in more detail below, the individual components 6 are fixed to the carrier 8 by the material of the carrier 8 and thus held in place. In addition to being fixed in position, they are preferably also held in a defined orientation relative to the carrier 8.

[0119] Different fixation options for the second basic variant are described in more detail below using Figures 1 to 5.

[0120] The fixation is achieved in particular by retaining tabs 10 cut freely from the carrier material, which are placed around a respective component 6 and thus fix it, for example, by clamping. A cut-free opening 12 is therefore formed adjacent to each cut-free retaining tab 10. Each retaining tab 10 is also connected to the remaining carrier layer 8A via a base side.

[0121] In addition to the components 6, in the illustrated embodiment the cables 4 are also fixed by means of cut-out retaining tabs 10 or by retaining tabs bent over at the edges.

[0122] In addition to a fixation of the components 6 via the retaining tabs 10, FIG. 1 also shows, by way of example, a fixation via a fixing layer 8B of the carrier 8. This is attached to a section of the carrier layer 8A in some areas and connected to it, for example, by gluing, sewing, welding, or clamping.

[0123] One of the components 6 is inserted with its end face facing forward between the carrier layer 8A and the fixing layer 8B in a pocket 14 formed between these two layers. The pocket 14 is open in particular towards a central region of the carrier 8, i.e. the opening of the pocket is not oriented outwards towards an edge of the carrier 8. The fixing layer 8B is in particular designed and attached such that a line section 15 of the connected lines 4 adjoining the component 6 is free and is not covered by the fixing layer 8B, but rather is loose.

[0124] Alternatively, the adjoining cable section 15 is also covered by the fixing layer 8B. In this case—and generally—the fixing layer is designed or fixed in such a way that the cable section 15 is held loosely in the manner of a cable reserve, thus ensuring sufficient freedom of movement for the component 6 during assembly, so that the component 6 can be pulled out of the retaining tab 10 and brought into the desired mounting position.

[0125] According to one embodiment variant, the previously described retaining tabs 10 merely form retaining strips or also form pockets 14 into which a respective component 6 is inserted. The component is usually inserted into the pocket 14 with its front end facing forward.

[0126] A respective pocket 14 completely encloses a pocket space, except for a front pocket opening, into which the component 6 is inserted.

[0127] In the case of the strip-shaped retaining tabs 10 shown in FIG. 1, these are each placed circumferentially around the circumference of the respective component 6, so that the two opposite end faces are not covered.

[0128] With such retaining tabs 10, during assembly the respective component 6 is, for example, simply pushed through the strip-shaped retaining tab 10, in particular completely, and then connected to an electrical component 26.

[0129] The retaining tabs 10 or the pockets 14 are designed to fit precisely so that the respective component 6 is held in place by them. Additional securing elements are omitted. Alternatively, the respective component 6 is secured in the fixed position by a securing area 16.

[0130] For example, the securing region 16 is formed by a bulge, as indicated for one of the components 6 in FIG. 1. To form the securing region 16, a strip is first partially cut free from the carrier layer 8A. The cut-free strip is folded over and placed on the remaining carrier layer 8A in the direction of component 6. This cut-free and folded strip is then compressed inward from its two edges towards the center so that it bulges out in the center and thus forms the bulge. This ensures good form-fitting securing of component 6.

[0131] The securing area 16 is typically arranged generally opposite the retaining tab 10 or pocket 14. The securing area 16 therefore generally forms a positive locking mechanism formed by the carrier material, similar to a stop, against which the component strikes. This secures the component against unwanted, accidental falling out, for example, during transport.

[0132] The securing area 16 is preferably arranged generally between the carrier layer 8A and the line section 15 connected to the respective component 6, i.e., the line section 15 is not covered by the securing area 16. This allows the component 6 to be easily grasped during subsequent assembly and, for example, pulled backwards out of the pocket 14. Due to the flexible carrier material, the securing area 16 can be easily overcome by the assembly forces exerted.

[0133] Further design variants of the securing area are explained below in different variants, also in connection with FIG 2B or FIG 4B. The components 6 are fixed in a defined position on the carrier 8 and preferably also in a predetermined orientation. In principle, however, a partial area 18 of the component 6 is freely accessible. This partial area 18 is actuated during later assembly with a suitable actuating tool, for example a gripper, in particular gripped and transferred to a desired final assembly position, in particular the component 6 designed as a contact plug is gripped and plugged into a corresponding mating plug. The fixation by the retaining tab 10 / the pocket 14, for example also by the described securing areas 16, is overcome here, for example by the securing areas 16 being pushed away or any frictional connection that may have formed is overcome.

[0134] In the case of the strip-shaped retaining tabs 10, the component is pressed through, for example, using a stamp as an actuating tool.

[0135] The support layer 8A further comprises various recesses 20, which form holes, for example, formed by punching. These serve, for example, to accommodate and hold retaining forks 22, on which the cables 4 and the support 8 are placed. These are attached to the mounting board 3 and protrude from it, particularly vertically.

[0136] Furthermore, fixing elements 24, for example in the form of fastening pins or fastening clips, are preferably inserted into such recesses 20 and held there. These serve to fasten the carrier 8 and thus the cable harness 2, for example, to a carrier module. Finally, recesses 20 can also be designed to accommodate electrical components 26, such as a control unit.

[0137] Also worthy of note are so-called free recesses 20A. These are recesses 20A which are free and unoccupied before the cable harness 2 is mounted on a carrier module or a body component. They are formed adjacent to a respective retaining tab 10 or pocket 14. They serve to contact a respective component 6 with a respective electrical component 26 through the free recess 20A during assembly. For this purpose, the component 6 is pushed at least partially through the carrier 8, for example with a partial area first, and thus guided to the opposite side of the carrier 8. Alternatively, the electrical component 26 dips at least partially into this free recess 20A from the opposite side and partially through it and is connected to the component 6.

[0138] In FIG. 1, the electrical components 26 located there later after assembly as well as the course of the cables 4 are indicated by dashed lines in these free recesses 20A.

[0139] Figures 2A and 2B show a variant in which a retaining tab 10 is partially cut free, which then forms a pocket 14 by folding and turning. Edges of the retaining tab 10 are connected to the carrier 8, for example, by welding. A component 6 designed as a contact plug is inserted into this pocket 14.

[0140] Furthermore, a securing area 16 is formed opposite the pocket 14. For this purpose, a part, also referred to as a securing tab, is cut out similarly to the retaining tab 10. This securing tab is folded over, so that the securing area 16 is formed in multiple layers by the carrier layer 8A and the additional securing tab placed on top.

[0141] FIG 3 shows an embodiment in which a component 6 is partially inserted through a recess 20 of the carrier layer 8A and then secured by means of a folded-over retaining tab 10. In this embodiment, the strip-shaped retaining tab 10 is guided transversely across a (rear) end face of the component 6. The retaining tab 10 runs somewhat spaced from the remaining carrier layer 8A, so that a type of pocket 14 is also formed by the recess 20 and the retaining tab 10. It is also noteworthy in this embodiment variant that the component 6 is held oriented perpendicular to the carrier 8.

[0142] Component 6 is in turn designed as a contact plug and extends in a longitudinal direction, which is also a plug-in direction 28. Plug contacts 40, for example in the form of contact sockets or contact pins (see FIG. 5A) are formed on the front end face 30 (seen in the plug-in direction 28). This front end face 30 therefore defines a plug-in area of ​​the contact plug. During subsequent final assembly, the contact plug is therefore plugged into a correspondingly complementary mating plug in the plug-in direction 28. The lines 4 are typically arranged on the side of the carrier layer 8A opposite the end face 30 and are suitably connected to the rear area of ​​component 6 (not shown in FIG. 3).

[0143] Alternatively, the component 6 is oriented with the front end face 30 facing in the direction of the retaining tab 10, ie inserted with this end face 30 facing into the formed pocket 14.

[0144] Figures 4A and 4B show a variant in which an opening 32 is formed in the carrier layer 8A, with a large opening region 32A and a small opening region 32B, which in the exemplary embodiment are connected to one another by a slot-shaped connection 32C. A component 6 is inserted into this opening 32. For this purpose, it is first inserted into the large opening region 32A and then transferred laterally into the small opening region 32B, which is designed such that it positively engages behind the component, in particular a widened holding region 34 designed in the manner of a projection. In particular, the component 16 has, for example, a constriction which is encompassed by the opening edge of the small opening region 32B.

[0145] In this embodiment, a securing region 16 is preferably also formed. For this purpose, the carrier layer 8A is folded entirely, i.e., without any partial cutting. Due to the resulting fold, the securing region 16 is again formed in multiple layers, with the securing region running transversely to the connection 32C and thus blocking it.

[0146] The various layers of the securing area 16 are in turn firmly connected to one another in a suitable manner, for example at fixing points 36.

[0147] Figures 5A and 5B show a variant in which the retaining tab 10 is formed by two opposing tab sections, each of which extends halfway around the circumference of the component 6 and which are reunited and connected to one another at the top of the component 6. They project upwards together, thereby forming a gripping tab 38. This gripping tab 38 is used during final assembly for gripping by the handling device (robot), so that the carrier 8 can be gripped and positioned together with the component 6 by a gripper.

[0148] In this embodiment, the preferred procedure is to first place component 6 in the desired mounting position, so that, in particular, component 6 is positioned opposite the mating connector. Subsequently, component 6 is pushed through the retaining tab 10 from behind in the plug-in direction 28, so that the desired plug connection with a mating connector is formed.

[0149] In connection with Figures 6A to 6C, the preferred first basic variant of the cable set 2 and the production of the cable set 2 are explained in more detail below.

[0150] In a first step, a prepared carrier layer 8A, also referred to as the base layer, is applied to the mounting board 3. This layer has a plurality of openings 42, which are partially cut-out areas through which guide pins 44 are individually passed. The guide pins 44 are fastened to the mounting board 3 and protrude perpendicularly from it. The guide pins 44 define a routing path for the various cables 4. In the exemplary embodiment, a main line and secondary lines branching off from it can be seen. At least one component 6 is connected to the end of one of these (secondary) lines 4.

[0151] The prepared carrier layer 8A already has predetermined separation lines 46, along which a partial section 48 can be separated from the remaining carrier layer 8A. These are formed, for example, as perforations or preferably via cutting lines where the carrier material has already been severed. In this case, too, the partial section 48 is connected to the remaining carrier layer 8A via connecting webs 47, which are formed in particular in the area of ​​component 6. If the partial section 48 is subsequently separated, only these connecting webs 47 still need to be severed, provided the predetermined separation lines 46 are designed as cutting lines.

[0152] The partial section 48 is generally connected to the remaining carrier layer 8A via a foot section 49. The partial section 48 is generally formed in a strip-like manner, widening particularly in the front region, specifically in the region of component 6, so that it is preferably formed in an approximately T-shaped manner.

[0153] The front end of the detachable section 48 extends as far as the component 6, wherein in the exemplary embodiment a front section of the component 6 extends beyond the detachable section 48.

[0154] Furthermore, a holder 50 is attached to the assembly board 3, to which the component 6 is temporarily fixed for production. For this purpose, the holder 50 has, in particular, a receptacle that is preferably designed to complement the outer contour of the component 6, so that the component 6 is received and fixed in the holder with a form-fitting fit. The holder 50 is arranged below the carrier layer 8A. For reliable fixation, the carrier layer 8A has a section 52 in the region of the component 6 that can be at least partially separated from the remaining carrier layer 8A. This separable section 52 is in turn defined by predetermined separation lines 46.

[0155] Furthermore, it is clearly visible that the predetermined separation lines 46 (in particular material weakening such as perforation) of this detachable section 52 in the exemplary embodiment extend into the partial section 48. Essentially, the detachable partial section 48 and the detachable section 52 are two different sections of the carrier layer 8A. As an alternative to prepared predetermined separation lines 46, the detachable section 52 is already separated from the remaining carrier layer 8A, for example, along this drawn line, for example by a cutting operation, e.g., by a punching operation beforehand.

[0156] The detachable section 52 is either folded down or completely removed. In both cases, the component 6 can be inserted into the holder 50 and secured there without the intermediate layer of the carrier material of the carrier layer 8A.

[0157] The cables 4 are each laid along the guide pins 44, wherein the cables 4 are preferably each guided between two opposite guide pins 44.

[0158] In the next step, another carrier layer 8C, also referred to as the cover layer, is applied. This is again preferably a nonwoven layer. It is preferably the same size as the lower carrier layer 8A. The cover layer 8C also has openings 42 through which the guide pins 44 protrude.

[0159] In the exemplary embodiment, the cover layer 8C has a cutout 54 in the area of ​​component 6, so that component 6 is not covered by the carrier material. A portion of the cover layer 8C is therefore cut out. After the cover layer 8C has been applied, the two carrier layers 8A, 8C are connected to one another. This is done in particular via linear or strip-shaped connecting areas 56, along which the two carrier layers 8A, 8C are joined, for example, by means of a material bond (ultrasonic welding or high-frequency welding).

[0160] It should be emphasized that such connection areas 56 are formed on both sides of the path of a respective cable 4, so that each cable 4 is fixed in place on the support 8. Through the connection areas 56 on both sides, the respective cable 4 is simultaneously routed / guided within the support 8 along a desired installation path. In contrast, the component 6 is not directly fixed to the support layers 8A, 8C, but is only held in the desired position indirectly via the connected cable 4.

[0161] In the exemplary embodiment, the connecting regions 56 are formed next to the lines 4 between two adjacent openings 42.

[0162] The two carrier layers 8A, 8C are additionally connected to each other at the edges and all around by further connecting areas 56.

[0163] Finally, the exemplary embodiment provides for the free surface areas of the carrier 8, in which no lines 4 run, to be additionally connected to one another. In the exemplary embodiment, closed connecting areas 56, for example, forming an oval, are formed for this purpose.

[0164] In the exemplary embodiment, the upper carrier layer 8C also has predetermined separation lines 46. These run outside the strip-shaped connecting regions 56. The predetermined separation lines 46 of the two carrier layers 8A, 8C therefore lie one above the other, or the carrier 8 has predetermined separation lines 46 across both carrier layers 8A, 8C, via which a sandwich-like section can be separated from the remaining carrier 8. This sandwich-like section is referred to as the connecting section 58. It thus forms a type of cable tail, which, after being separated from the remaining carrier 8, can be moved relative to it.

[0165] The cable harness 2 prepared in this way with the carrier 8 with the two sandwiched carrier layers 8A, 8C and in the intermediate arranged cables 6 as well as the (indirectly) held component 6 is subsequently removed from the mounting board 4 and forms an intermediate product which is transported to an assembly location.

[0166] It should be emphasized that component 6 is at least partially exposed. In the exemplary embodiment, this is achieved in particular by the fact that the upper carrier layer 8C has the cutout 54. This enables, in particular, mechanical gripping of component 6.

[0167] In order to be able to move these relative to the remaining carrier 8, the previously described connecting section 58 is separated from the remaining carrier along the intended dividing line 46 and then guided to a mating component. In the foot region 49, the connecting section 58 and the subsections 48 of the two carrier layers 8A, 8B remain connected to the remaining carrier 8 or to the remaining carrier layer 8A, 8B. For this purpose, the connecting section 58 is bent out of the plane of the carrier 8 and can then be moved in the plug-in direction toward the mating component.

[0168] Preferably, the cable set 2 comprises a plurality of such components 6, each of which is movable by means of such a connection section 58.

[0169] The remaining carrier 8 itself is usually fixed and secured to a suitable carrier, for example directly to a body component, as already described for the second basic variant.

[0170] As an alternative to separating the entire sandwich-like connection section 58, it is also possible to separate only a partial section 48, for example, of the upper carrier layer 8C, allowing the component 6 and the cable 6 connected to it to be grasped and moved. This design variant requires that the predetermined separation lines 48 extend between the connection areas 56 and the cable 4, so that the separated partial section 48 is no longer connected to the lower carrier layer 8A.

[0171] List of reference symbols

[0172] 2 cable sets

[0173] 3 mounting board

[0174] 4 lines

[0175] 6 Component

[0176] 8 carriers

[0177] 8A support layer (base layer)

[0178] 8B Fixing position

[0179] 8C additional carrier layer (top layer)

[0180] 10 retaining tab

[0181] 12 cut-out opening

[0182] 14 bag

[0183] 15 line sections

[0184] 16 Security area

[0185] 18 sub-area

[0186] 20 recesses

[0187] 20A free recess

[0188] 22 holding forks

[0189] 24 Fixing element

[0190] 26 electrical component

[0191] 28 Plug-in direction

[0192] 30 front side

[0193] 32 Opening

[0194] 32A large opening area

[0195] 32B small opening area

[0196] 32C connection

[0197] 34 Holding area (projection)

[0198] 36 Fixation point

[0199] 38 Grab handle

[0200] 40 plug contact

[0201] 42 openings 44 guide pins

[0202] 46 dividing lines

[0203] 47 Connecting bridge

[0204] 48 Section 49 Foot Section

[0205] 50 bracket

[0206] 52 detachable section

[0207] 54 Excerpt

[0208] 56 Connection area 58 Connection section

Claims

Claims 1. Cable harness (2), in particular for a vehicle, with a plurality of lines (4) which are attached to a carrier layer (8A) of a flexible carrier (8) according to a predetermined laying structure and with at least one electrical component (6) attached to at least one of the lines (4), which is at least temporarily fixed to the carrier (8) by material of the carrier (8) in such a way that the at least one component (6) is movable during later assembly of the cable harness (2), in particular in a plug-in direction (28) for plugging into an electrical component (26).

2. Cable set (2) according to the preceding claim, wherein the carrier (8) is designed in two layers with two carrier layers (8A, 8C), namely with a lower base layer and an upper cover layer, between which the lines (4) are sandwiched, wherein the two carrier layers (8A, 8C) are connected to one another along the at least one line (4), wherein a partial section (48, 58) of at least one of the two carrier layers (8A, 8C), which covers an end section of the at least one line (4) with the component (6) attached to the end thereon, can be at least partially separated from the remaining carrier (8), so that the component (6) is movable relative to the remaining carrier (8).

3. Cable set (2) according to the preceding claim, wherein the partial section (48, 58) has both carrier layers (8A, 8C) with the cable (4) held therebetween and forms a movable connection section (58).

4. Cable set (2) according to one of claims 2 to 3, wherein the two carrier layers (8A, 8C) are connected to one another on both sides of a respective line (4) and along the respective line (4) at, in particular, strip-shaped connecting regions (56).

5. Cable set (2) according to the preceding claim, wherein the carrier (8) is designed to have a large area and lines (4) are laid only in partial areas, wherein the two carrier layers (8A, 8C) along each of the lines (4) are connected to one another by the connecting areas (56) and additionally the two carrier layers (8A, 8C) are connected to one another at the edges and in particular circumferentially via further, in particular strip-shaped, connecting areas (56).

6. Cable set (2) according to one of claims 2 to 5, wherein prepared predetermined separation lines (46) are formed for separating the partial section (48, 58), on which at least one material weakening is formed.

7. Cable set (2) according to one of claims 2 to 6, wherein the partial section (48, 58) is permanently connected to the remaining support (8) via a foot section (49).

8. Cable set (2) according to one of claims 2 to 7, wherein at least one of the carrier layers (8A, 8C) does not completely cover the component (6) such that the component (6) can be gripped.

9. Cable set (2) according to one of claims 2 to 8, wherein the carrier layers (8A, 8C) are not connected to one another in the region of the component (6).

10. Cable set (2) according to one of claims 2 to 9, wherein at least one of the carrier layers (8A, 8C), in particular the base layer, has in the region of the component (6) a section (52) which can be at least partially separated from the remaining carrier layer (8A, 8C), which section can be at least folded down after the at least partial separation from the remaining carrier layer (8A, 8C).

11. Cable set (2) according to one of claims 2 to 10, wherein at least one of the carrier layers (8A, 8C), in particular the upper cover layer, is cut out in the region of the component (6) so that it is exposed.

12. Cable set (2) according to one of claims 2 to 11, wherein the carrier has a plurality of at least partially cut-out openings (42) which are arranged one after the other along the lines (4) and can be guided by the guide pins (44), wherein preferably between two adjacent openings (42) the carrier layers (8A, 8C) are connected to one another in particular in a line 13. Cable set (2) according to one of the preceding claims, wherein at least one retaining tab (10) is partially cut out of the carrier layer (8A), is placed around the at least one component (6) and is then again connected at least at points to the carrier layer (8A).

14. Cable set (2) according to the preceding claim, wherein the at least one retaining tab (10) forms a pocket (14) which is open only on one side and in which the at least one component (6) is located.

15. Cable set (2) according to claim 1, wherein an opening (32) with two differently sized opening areas (32A, 32B) is formed in the carrier layer (8A) and the at least one component (6) is guided at least partially through the large opening area (32A) and is displaceable by lateral displacement into the small opening area (32B) and is held there in a form-fitting manner.

16. Cable set (2) according to claim 1, wherein the carrier (8) is preferably only partially formed in two layers with the carrier layer (8A) and a fixing layer (8B) attached thereto, wherein the at least one component (6) is fixed in a pocket (14) formed between the carrier layer (8A) and the fixing layer (8B), wherein the fixing layer (8B) is preferably formed differently than the carrier layer (8A), in particular is thinner and / or has a lower basis weight.

17. Cable set (2) according to the preceding claim, wherein the fixing layer (8B) leaves free a line section (15) of the at least one line (4) adjoining the component (6).

18. Cable set (2) according to one of the preceding claims, wherein the at least one component (6) is a contact plug which extends in a plugging direction (28) and which has plug contacts (40) for electrical plug connection to a mating plug on a front end face (30) in the plugging direction (28).

19. Cable set (2) according to one of the preceding claims, wherein the carrier layer (8A) is a textile material such as a fleece or a woven fabric.

20. Cable set (2) according to one of the preceding claims, wherein the at least one component (6) is only temporarily fixed and can be removed from its fixed position.

21. Cable set (2) according to one of the preceding claims, wherein the at least one component (6) is fixed in a defined orientation with respect to the carrier (8) and in particular at an angle thereto.

22. Cable set (2) according to one of the preceding claims, wherein a securing region (16) is formed with the material of the carrier (8) and by folding, wherein the securing region (16) secures the at least one component (6) in its fixed position.

23. Cable set (2) according to the preceding claim, wherein - the securing area (16) is multi-layered and formed by partially cutting it free from the carrier layer (8A) and then folding it, - the securing area (16) is multi-layered and formed by folding the carrier layer (8) without cutting free, - the securing area (16) is formed by compressing and thereby bulging the material of the carrier layer (8A), - in an embodiment according to claim 4, the securing area (16) blocks a connection between the two opening areas (32A, 32B).

24. Cable set (2) according to one of the preceding claims and according to claim 13 or 14, wherein the retaining tab (10) is guided around the component (6) and forms a protruding gripping tab (38) for in particular automated gripping.

25. Cable set (2) according to one of the preceding claims, in which recesses (20, 20A) or at least partially cut-out openings are formed in the carrier (8), through which optionally - holding elements, in particular holding forks (22), for laying the cables (4) on the support (8) are guided through, or - fixing elements (24) are passed through, which are designed to fasten the carrier (8) to a carrier module or to a body component, - in the assembled state, the component and / or an electrical component (26) is guided through, wherein the corresponding recess (20A) in the carrier (8) is formed as a free recess (20A) in the initial state next to a retaining tab (10).

26. A method for producing a cable harness (2), in particular according to one of the preceding claims, in which lines (4) are attached to a carrier layer (8A) of a flexible carrier (8) according to a predetermined laying structure, wherein at least one component (6), in particular a contact plug, is attached to at least one of the lines (4), wherein the at least one component (6) is at least temporarily fixed to the carrier (8) by material of the carrier (8) in such a way that the at least one component (6) is movable during later assembly of the cable harness (2), in particular in a plug-in direction (28) for plugging into an electrical component (26).

27. Method according to the preceding claim, wherein the carrier (8) is formed in two layers with two carrier layers (8A, 8C), namely with a lower base layer and an upper cover layer, between which the lines (4) are inserted in a sandwich-like manner, wherein the two carrier layers (8A, 8C) are connected to one another along the laying structure, wherein a partial section (48, 58) of the carrier, in which an end section of the line (4) with the component (6) attached to it at the end is received, is partially separated from the remaining carrier (8) and in particular forms a connecting section (58) which is movable relative to the remaining carrier (8).

28. Method according to one of the two preceding claims, in which the carrier (8) is placed on a mounting board (3) on which a holder (50) is formed, to which the component (6) is releasably fixed during the manufacture of the cable harness (2).

29. Method according to one of claims 26 to 28, in which the cable harness (2) is attached automatically to a carrier module or a body component which has at least one electrical component (26) which is electrically connected to the cable harness (2) by means of the contact plug, wherein for this purpose the contact plug is automatically gripped and plugged onto the electrical component (26) in the plugging direction (28).

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