DE102004023334A1 - Cable set, especially for motor vehicle, has cable bundle fed at least partly along cable path through stable shaped molded part consisting of expanded polymer material, especially expanded polypropylene - Google Patents

Abstract

The cable set (2) has a bundle of cables (4) containing a number of individual cables (6), whereby the cable bundle is fed at least partly in a stable shaped molded component (12) along a cable path through the molded part, whereby the molded part consists of an expanded polymer material, especially expanded polypropylene. The molded part may fully enclose the cable set.

Description

The The invention relates to a cable set, in particular for a motor vehicle.

One Cable set usually has a trunk group, consisting of a number of individual lines, each of the Individual lines in turn is formed from at least one conductor and a conductor sheath. Such cable sets are used for example in Motor vehicle area laid both in the interior and in the engine compartment. Due to the usually tight installation space is the course of the Cable set structurally fixed. For easy installation to enable are therefore often used so-called rigid cable harnesses that already have a geometry corresponding to the intended course. Due to the dimensional stability So the course of the trunk group is given.

Around the dimensional stability to reach the trunk group with a dimensionally stable shell, for example, a foamed or surrounded by cast material.

When Foam material is usually a so-called PUR foam used, depending on the application area, a different density can have. The foaming of the trunk group with PUR foam leads to an increase the total weight of the cable set. Especially in the automotive industry tremendous efforts are being made to reduce weight. In addition, the foaming requires a trunk group a suitable foaming tool or a suitable foaming mold, for the high investment costs are.

alternative for the generation of dimensional stability by foaming partly in the body parts to be laid depressions or Channels incorporated, in the then the trunk group is inserted. However, the arrangement of these channels is usually costly and thus costly.

Of the Invention is based on the object, an improved dimensionally stable Specify cable set.

The The object is achieved by a cable set, especially for a motor vehicle, comprising a cable bundle comprising a number of individual lines, wherein the trunk group at least partially in a dimensionally stable mold component along a through the mold component predetermined line course out and wherein the mold member is made of an expanded polymeric material, in particular consists of an expanded polypropylene.

to Formation of the dimensionally stable cable set is therefore to achieve the dimensional stability and shaping for the trunk group resorted to a so-called expanded polymer material, as for example for shock absorption in vehicle bumpers or for thermal insulation for insulating packaging or insulating boxes is used. The latter usually exist from an expanded polystyrene. This is by the knowledge assumed that the expanded polymer materials, in particular expanded polypropylene (EPP), for the requirements of a dimensionally stable cable set have suitable properties and therefore for training of the molded component for guidance of the trunk group suitable. By using an expanded polymer material Compared to a PUR foamed cable set, this is a clear Saves weight. Another advantage besides the low Tare weight of the molded component is also in the manufacturing technology simple and therefore inexpensive Production of the molded component. The cable set therefore offers - in view of on the requirements for a dimensionally stable cable set - comparable Features Cost advantages in the production and by the weight saving about that also benefits in the later Use, for example by reducing fuel consumption of a motor vehicle.

Next The advantage of the low weight is also the good insulating or damping property emphasize the material, so that the molded part as a multifunctional Part can be trained and in addition to the function of shaping for the trunk group expediently also a damping or Dämmfunktions takes over. Here, preferably, the outer contour of the mold component to the respective requirement for the damping or insulation adapted, i. the molded component does not necessarily give the outer geometry of the trunk group again.

The Use of the cable set is not in the field of application limited the automotive industry. The cable set can in principle in diverse Application areas are used. Another preferred application Here is in particular the arrangement of the cable set in one Home appliance, such as a refrigerator, a dishwasher Etc.

In general, in the production of a component made of an expanded polymer material, the procedure in principle such that a granular, dry granules of the expanded polymer material is introduced into a mold, which subsequently ßend is acted upon, for example, with hot steam. As a result, the individual granules at least partially swell somewhat and in particular cake together, so that they form a dimensionally stable shaped component. For example, an EPP molded component produced in this way has a density of approximately only 80 kg / m ³ . In contrast, a conventional PUR foam part has an approximately 10-fold higher density of about 700 kg / m ³ .

According to one expedient development encloses the molded part the cable set full, i.e. the cable set is enclosed radially and the mold component acts in the manner of a cable sheath, which has an all-round protective function for the Trunk group takes over. In this case, the procedure is preferably such that the trunk group placed in a corresponding shape with a predetermined line course and subsequently is enveloped with the polymer material to form the mold component.

According to one expedient further development, the mold component from at least formed two interconnected shell molds or shell halves, into the trunk group is inserted. To form the dimensionally stable cable set is in this embodiment first in a first step, the formed from the shell halves mold component produced and then gets into the shell halves the trunk group engaged for the formation of the cable set. This is in comparison to the production of the mold component with already in the mold inserted cable bundle manufacturing technology easier to realize, in particular the requirements of the mold for the production of the mold component lower.

Prefers grip the shell molds form-fitting into each other and are in particular by Verklipsen, ie by the Forming a positive connection, fastened together. After inserting of the trunk group Therefore, the two half-shells are clipped by simply Aneinand fastened together without requiring a special tool would.

Preferably the mold component already has an integrated branch on that of the trunk group a part of the trunk group branches off into a side branch. At the junction so divides the trunk group on. Due to the integration in the mold component is also a ensures a stable turn, i.e. through the branch is the angle and thus the direction of the branched off-line.

According to one Particularly advantageous development, the mold component comprises a Support plate as well a channel in which the trunk group is routed. The carrier plate as part of the mold component here is also from the expanded Polymer material. The carrier plate Here, in particular one of the shape and the course of the trunk group independent Design and geometry. This makes the advantageous Possibility, assign the mold component a variety of other functions. the Molded components are therefore preferably assigned further functions. So it is, for example, as a laying aid instead of the usual Cable boards used, i. the carrier plate forms a template, Based on which the individual lines to form the trunk group and the Wiring harnesses are laid. Here the advantage is achieved that after laying the single lines, the cable set is ready for installation is. Furthermore, it is provided that the carrier plate for automatic assembly of the cable set is used. Due to the fixed geometry the carrier plate is this namely easily gripped by a robot arm and can be attached to a predefined installation position for example, in a household appliance or in a motor vehicle to be built in.

the Molded part with the carrier plate will be next to the cable management especially an insulation or damping function assigned. Because of the expanded polymer material namely are very good insulation and attenuation values reachable. Such a molded component with carrier plate is therefore suitable for example, as internal side wall paneling with integrated trunk group for soundproofing in a household appliance or in the automotive sector. Especially in the automotive sector Here is the thermal insulation function of additional Advantage. Furthermore, the mold component is expediently for Arrangement provided in a motor vehicle door and serves here in particular for separating a wet area from a dry area, so that under circumstances the for this separation usually provided release film lapsed is. At the same time or alternatively be on or in the mold component integrated further elements and functional components.

For a simple Manufacturing and easy laying is convenient one in the manner of a guide channel formed recess integrated in the carrier plate, in the the trunk group is inserted is.

Preferably is after inserting the trunk group to the all-encompassing of the trunk group the recess covered with a channel top. Here are the Channel top and the support plate preferably positively in one another and are in particular by Verklipsen together in a simple manner attached.

in the With regard to the multifunctional design of the molded component is suitably provided that this has a fastener. The fastening element is for attachment of the molded component a supporting structure, for example in the motor vehicle or on Home appliance, intended. Alternatively, the fastener is for attachment a functional component provided on the mold component itself. Such a thing Functional component is for example integrated in a motor vehicle door Loudspeaker, an electronic control unit or also elements for prefabrication of the cable set. Such an element is for example a holding element for one Plug that struck at the end of the cable bundle in the formation of the cable set will or for one already at the trunk group battered plug, the final assembly of the holding element removed and connected to a corresponding mating connector is, for example, the harness with the rest of the electrical system of a motor vehicle connect to.

Conveniently, is provided here that the fastener in the Molded part includes integrated insert, which in particular made of a sturdy, inherently rigid material, such as plastic or metal exists to obtain sufficient mechanical stability.

embodiments The invention will be explained in more detail below with reference to the drawings. It each show in schematic representations:

1 an illustration of a cable set with a wire bundle, which is surrounded in a partial region by a molded part made of an expanded polymer material,

2a . 2 B a formed from two half-shells mold component in a plan view of the two half-shells or in a front view,

3a . 3b a molded component with a support plate and integrated cable bundle with plugs in a plan or in a side view

4a a molded component with incorporated recesses and with a plurality of channel upper parts, which are provided to cover the guide channel in different sub-areas in a plan view and

4b the carrier plate with the integrated guide channels according to 4a in a side view.

A cable set 2 according to 1 includes a trunk group 4 , which consists of a large number of individual single lines 6 composed. Each individual line 6 has at least one conductor and a conductor insulation. The individual lines serve here for energy or data transmission. The trunk group 4 includes a main strand 8th , which in the embodiment in a total of three secondary strands 10 divides. The single lines 6 of the main strand 8th are in the front area by bands 11 held together.

The trunk group 4 is in a partial area of a molded component 12 surrounded, which in the embodiment of 1 from two half-shells 12A . 12B is formed. The mold component 12 here has one to the trunk group 4 matched geometry and is seen in cross-section approximately circular. The mold component 12 Covered in the embodiment, only a portion of the trunk group 4 and is designed in the manner of a guide channel. The mold component 12 has a high dimensional stability, so that it the line course for the trunk group 4 sets. The mold component 12 this includes several branches 14 at which the secondary strands 10 depart. Due to the dimensional stability of the molded component 12 is the departure direction of the secondary strands 10 established. End to two of the branches 14 are plugs 16 molded, wherein the molded component 12 to the plug 16 enough.

The formed in the manner of a guide channel or a protective sheath molded component consists of an expanded polymer material. As expanded polymer material here in particular expanded polypropylene (EPP) is set. Its density can be set in particular in a range of 20 to 100 kg / m ³ . In addition to excellent damping behavior, EPP also has a high level of wear resistance and good resistance to acids, alkalis and oils. Also EPP has a good thermostability. These features make EPP suitable for use with harnesses 2 particularly suitable.

Another suitable expanded polymer material is expanded polyethylene (EPE), whose density can be adjusted in particular in a range between 25-70 kg / m ³ . Another popular expanded polymer material is expanded polystyrene (EPS), which is used in particular for packaging. Compared to EPP and EPE, however, EPS has lower temperature resistance and less resistance to solvents.

For the production of the molded component 12 Of expanded polymer material is usually a Granules of the expanded polymer material are placed in a mold and in particular subjected to steam, so that the granules still slightly swell and baked together to form the dimensional stability.

For the formation of the cable set 2 with the mold component 12 In principle, there are two production methods to choose from: According to the first method, the bundle of wires becomes 4 placed in a mold, then the granules are filled and subjected to steam, so that an integral, circulating around the wire bundle mold component is formed. Alternatively, according to the second method, the harness 2 manufactured in two production steps, wherein in the first step, the mold component produced and in the second step, the trunk group 4 inserted in the mold component and optionally with a further portion of the mold component 12 is closed. In particular, here is the mold component 12 from several parts, in particular the half shells 12A . 12B so that easy assembly is possible.

In 2a is one of the two half-shells 12A . 12B molded molding component shown. As can be seen, the two half-shells grip 12A . 12B at their frontal, mutually facing edges 15 positively in one another, wherein seen in cross section, the edges 15 each form a step profile. At the edges 14 Therefore, groove or guide grooves are provided which engage with each other. To further attach the two half shells 12A . 12B together they are held together in a variant with an adhesive tape or a cable tie. For this purpose, around the outer circumference of the half-shells 12A . 12B Be provided guide grooves. Laterally on the mold component 12 are still formed on the type of tabs fasteners 17 molded over which the entire cable set 2 is attached to predefined positions such as a motor vehicle body positionally accurate.

In the 3a . 3b and 4a . 4b is an alternative embodiment of a molded component 19 shown. And indeed, the shaped component points 19 in contrast to the molded component 12 as it is in the 1 . 2a . 2 B is shown, a support plate 18 on, in or on the trunk group 4 is guided. For this purpose, the shaped component 19 a channel 20 for the trunk group 4 on.

According to the embodiment of the 3a . 3b becomes the mold component 16 formed by that the trunk group 4 with already end-hinged plugs 16 is inserted into a mold and then surrounded with the expanded polymer material as described, so that a one-piece mold component 19 around the entire trunk group 4 with the integrally formed thereon support plate 18 formed. The channel 20 in which the trunk group 4 is guided, so is in the manufacture by the intervening trunk 4 shaped.

Due to the use of the expanded polymer material, the integration of the molded plug is already in the manufacturing process, ie the surrounding of the cable bundle 4 with the polymer material, easily possible. In contrast to PUR foam material, there is no risk that the expanded polymer material enters plug openings and, for example, damages the plug contacts or changes their position. Especially with floating mounted contacts in multi-pin connectors is a problem with the use of polyurethane foam, as the individual contacts are fixed by penetrating foam, so that the floating storage is repealed. The mold component 19 , as well as the mold component 12 , therefore, are in useful embodiments, each up to the plug 16 guided or even surrounded this, so that the expanded polymer material quasi forms a plug housing.

According to the embodiment according to the 4a . 4b becomes the mold component 19 initially without the trunk group 4 manufactured and has a recess formed in the manner of a branched guide channel 22 on, in which the trunk group 4 is inserted. The depression 22 is in the carrier plate 18 integrated. The end has the depressions 22 Recordings 24 on, for the arrangement of connector housings or plugs 16 are formed, the end of the cable bundle 4 are struck.

To the formation of the channel 20 which the trunk group 4 surrounds completely, are still several channel tops 26 provided to cover the depression 22 with the then already inserted trunk group 4 on the carrier plate 18 be attached from above. In the embodiment, this purpose in the carrier plate 18 laterally beside the depression 22 running slots 28 introduced, in the corresponding fastening webs 30 intervene on the lower edge of the channel tops 26 are arranged. These fastening bars 30 In this case, for example, are designed as hook-shaped elements, so that by insertion into the slots 28 and subsequent longitudinal displacement a positive engagement between the fastening webs 30 and the carrier plate 18 is trained. Alternatively, the slots 28 and the fastening webs 30 designed to form a snap connection, so that the channel upper parts 26 only on the carrier plate 18 need to be clipped.

• – Im Vergleich zu PUR-Schaumformteil sind vereinfachte Formwerkzeuge einsetzbar, so dass die Herstellungskosten geringer sind;
• – Ein im Vergleich zu PUR-Schaum deutlich geringeres Gewicht, was den Einsatz insbesondere im Kraftfahrzeugbereich besonders interessant macht;
• – Gute Schutzfunktion für das Leitungsbündel 4 aufgrund einer ausreichenden Thermostabilität, guten Verschleißfestigkeit und Widerstandsfähigkeit gegen Lösungsmittel, insbesondere bei EPP;
• – Ausreichende Formstabilität um den Leitungsverlauf des Leitungsbündels 4 festulegen insbesondere die positionsgenaue Festlegung der Abzweigungen 14 sowie der Positionen für die Stecker 16;
• – Durch Integration der Befestigungselemente 17 wird eine positionsgenaue Befestigung beispielsweise an einer Kraftfahrzeugkarosserie ermöglicht;
• – Insbesondere bei der Ausführungsvariante des Formbauteils 19 mit der Trägerplatte 18 können dem Formbauteil 19 neben der Funktion der Führung des Leitungsbündels 4 eine Vielzahl von weitergehenden Funktionen zugewiesen werden; Das Formbauteil 19 dient beispielsweise als Verlegehilfe, als Montagehilfe zur automatischen Befestigung mit einem Roboter und die Trägerplatte 18 dient als Dämm- oder Dämpfungselement oder als Trennelement, um zwei Räume voneinander zu trennen.

The advantages of using an expanded polymeric material to form the molded components 12 . 16 for the design of a dimensionally stable cable set 2 can be summarized as follows:

• - Compared to PUR foam molding simplified molds are used, so that the manufacturing cost is lower;
• - A significantly lower weight compared to PUR foam, which makes the use particularly in the automotive sector particularly interesting;
• - Good protection for the trunk group 4 due to sufficient thermostability, good resistance to wear and resistance to solvents, especially in EPP;
• - Sufficient dimensional stability around the line course of the trunk group 4 Specify in particular the positionally accurate determination of the branches 14 as well as the positions for the plugs 16 ;
• - By integration of the fasteners 17 a positionally accurate attachment, for example, on a motor vehicle body allows;
• - Especially in the embodiment of the molded component 19 with the carrier plate 18 can the mold component 19 in addition to the function of managing the trunk group 4 be assigned a variety of advanced functions; The mold component 19 serves as a laying aid, as an assembly aid for automatic attachment with a robot and the support plate 18 serves as an insulating or damping element or as a separating element to separate two rooms from each other.

2

cableset

4

trunk group

6

Single line

8th

main line

10

secondary line

11

tape

12

mold component

12A

half shell

12B

half shell

14

diversion

15

edge

16

plug

17

fastener

18

support plate

19

mold component

20

channel

22

guide channel

24

deepening

26

Channel shell

28

slot

30

fastening web

Claims (11)

Cableset ( 2 ) with a trunk group ( 4 ) comprising a number of individual cables ( 6 ), the trunk group ( 4 ) at least partially in a dimensionally stable molded component ( 12 . 19 ) along a through the mold component ( 12 . 19 ) predetermined line course is performed and wherein the molded component ( 12 . 19 ) consists of an expanded polymer material, in particular of an expanded polypropylene. Cableset ( 2 ) according to claim 1, wherein the molding component ( 12 . 17 ) the cable set ( 2 ) completely encloses. Cable set according to Claim 1 or 2, in which the molded component ( 12 ) of at least two interconnected shell molds ( 12A . 12B ) is formed, in which the trunk group ( 4 ) is inserted. Cableset ( 2 ) according to claim 3, wherein the shell molds ( 12A . 12B ) interlock positively and are fastened in particular by clipping together. Cableset ( 2 ) according to one of the preceding claims, in which the molded component ( 12 . 19 ) a branch ( 14 ), at which of the trunk group ( 4 ) a secondary strand ( 10 ) of the trunk group ( 4 ) branches off. Cableset ( 2 ) according to one of the preceding claims, in which the molded component ( 19 ) a carrier plate ( 18 ) as well as a channel ( 20 ), in which the trunk group ( 4 ) is arranged. Cableset ( 2 ) according to claim 6, wherein the carrier plate ( 18 ) for forming at least part of the channel ( 20 ) a channel-like depression ( 22 ), in which the trunk group ( 4 ) is inserted. Cableset ( 2 ) according to claim 7, wherein the channel-like recess ( 22 ) with the inserted trunk group ( 4 ) at least in a partial area with at least one channel upper part ( 26 ) is covered. Cableset ( 2 ) according to claim 8, wherein the channel top part ( 26 ) and the carrier plate ( 18 ) interlock positively and are fastened in particular by clipping together. Cableset ( 2 ) according to one of the preceding claims, in which the molded component ( 12 . 19 ) at least one fastening element ( 17 ) has for fastening the molded component ( 12 . 17 ) on a supporting structure or for fastening a functional component on the molded component. Cableset ( 2 ) according to claim 10, wherein the Fastening element ( 17 ) comprises an integrated into the mold component insert.