JP2013004275A - Wiring harness - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wiring harness for a power system capable of securing the flexibility without deteriorating handling performance and of avoiding a transmission loss of a current caused by a skin effect even when a conductive part with a large cross sectional area is employed for preventing excessive heat generation.SOLUTION: A wiring harness 1 has a plurality of cylindrical power transmission parts laminated from inside to outside, and terminals provided for the power transmission parts. Each power transmission part has: a cylindrical conductive part 2 formed in a cylindrical shape by assembling a plurality of lead wires and configured by a braided wire and the like having the flexibility; and a cylindrical insulation part 3 formed in a cylindrical shape so as to cover an outer periphery of the cylindrical conductive part 2 and having the flexibility. The plurality of terminals are provided for the power transmission parts, and electrically connected to the cylindrical conductive parts 2. A core member 4 for keeping a shape of the power transmission parts 2 constant is incorporated inside a part of the innermost power transmission part 2.

Description

  The present invention relates to a wire harness.

  As shown in Patent Document 1, a conventional electric wire harness mounted on a vehicle has three insulated wires corresponding to three-phase alternating current phases or two insulated wires corresponding to single-phase alternating currents. It has a bundled structure. The insulated wire includes a conductive part through which a current flows and an insulating coating that covers the periphery of the conductive part.

  In addition, in a power system wire harness mounted on a conductive vehicle such as a hybrid vehicle or an electric vehicle, it is necessary to use a thick electric wire in order to prevent excessive heat generation when a large current flows.

Japanese Patent Laid-Open No. 2003-197037

  However, a wire harness employing a thick electric wire has a problem that it lacks flexibility and has poor handling performance. Furthermore, a wire harness employing a thick electric wire has a problem that current transmission loss due to the skin effect tends to increase.

  Even if a conductive part having a large cross-sectional area is employed to prevent excessive heat generation in a power wiring harness, the present invention ensures flexibility and does not impair handling performance, and the current due to the skin effect The purpose is to avoid transmission loss.

The wire harness according to the present invention includes a plurality of cylindrical power transmission units stacked from the inside to the outside, and further includes the following components.
(1) A 1st component is a conductive part which constitutes each power transmission part, and is a plurality of cylindrical conductive parts which are formed in the shape of a cylinder by combining a plurality of conducting wires, and have flexibility.
(2) A 2nd component is an insulation part which comprises each power transmission part, and is a some cylindrical insulation part which is formed in the cylinder shape which covers the outer periphery of a cylindrical electroconductive part, and has a softness | flexibility.
(3) The third component is a plurality of terminals provided for each power transmission unit and electrically connected to the cylindrical conductive unit.

It is also conceivable that the wire harness according to the present invention further includes the following constituent elements.
(4) The fourth component is a core member that is included inside a part of the innermost power transmission unit and holds the shape of the power transmission unit constant.

  In the wire harness according to the present invention, it is conceivable that the core member is formed in a flat bar shape that holds the cross-sectional shape of the power transmission unit flat.

  In the wire harness according to the present invention, it is conceivable that the inner cylindrical conductive portion has a larger total cross-sectional area in the cross section than the outer cylindrical conductive portion.

It is also conceivable that the wire harness according to the present invention further includes the following constituent elements.
(5) The fifth component is an insulated wire enclosed inside the innermost power transmission unit.

  In the wire harness according to the present invention, it is conceivable that the cylindrical conductive portion is formed of a braided wire having a flexibility by forming a plurality of conductive wires into a cylindrical shape.

It is also conceivable that the wire harness according to the present invention further includes the following constituent elements.
(6) A 6th component is a shield member which consists of a cylindrical braided wire which covers the outer side of the outermost power transmission part.

  In the wire harness according to the present invention, the cylindrical conductive portion is a portion made of, for example, a braided wire, and is formed into a cylindrical shape by combining a plurality of conductive wires and has flexibility. Therefore, even when the cylindrical conductive portion is formed with a large cross-sectional area to prevent excessive heat generation, flexibility is ensured and handling performance is not impaired. In addition, since the cylindrical conductive portion has a hollow structure, current transmission loss due to the skin effect is unlikely to occur.

  Moreover, in the wire harness mounted in a vehicle, a part is hold | maintained in the shape along a predetermined wiring path | route, and laying of a wire harness may become easier because another part has a softness | flexibility. In such a case, if the wire harness according to the present invention further includes a core member that keeps the shape of the power transmission unit constant, it is preferable that the handling performance of the laying is further increased.

  Moreover, if the wire harness which concerns on this invention is provided with the flat rod-shaped core member which hold | maintains the cross-sectional shape of a power transmission part flat, it will become easy to lay a power transmission part in the clearance gap with low height.

  Moreover, in the wire harness according to the present invention, the inner cylindrical conductive portion is less heat radiating than the outer cylindrical conductive portion. For this reason, it is desirable that the inner cylindrical conductive portion of the inner cylindrical conductive portion has a larger total cross-sectional area in the cross section than the outer cylindrical conductive portion. Thereby, the thermal balance of each of the plurality of cylindrical conductive parts is made uniform, and only a part of the cylindrical conductive parts can be prevented from being excessively heated.

  In addition, if the wire harness according to the present invention includes an insulated wire contained inside the power transmission unit, the insulated wire has a signal system to which a voltage lower than the voltage applied to the cylindrical conductive unit is applied. It can be used as an electric wire. Accordingly, it is possible to efficiently wire the power transmission unit and the signal insulated wire.

  Moreover, if the wire harness which concerns on this invention is equipped with the shielding member which consists of a cylindrical braided wire which covers the outer side of a power transmission part, the power transmission part can be shielded without impairing the flexibility of a wire harness.

It is a perspective view including sectional drawing of the 1st cable part which is a part of wire harness 1 concerning a 1st embodiment of the present invention. 2 is a perspective view including a cross-sectional view of a second cable portion that is a part of the wire harness 1. FIG. 1 is a perspective view of a wire harness 1. FIG. It is a perspective view of a core member with which wire harness 1 is provided. It is a perspective view including sectional drawing of the 1st cable part which is a part of wire harness 1A concerning a 2nd embodiment of the present invention. It is a perspective view including sectional drawing of the 2nd cable part which is a part of wire harness 1A. It is a perspective view of wire harness 1B concerning a 3rd embodiment of the present invention.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Each of the following embodiments is an example embodying the present invention, and is not an example of limiting the technical scope of the present invention.

<First Embodiment>
First, the configuration of the wire harness 1 according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 4. As shown in FIG. 1, the wire harness 1 includes a cable portion 10 and connection portions 50 provided at both ends of the cable portion 10. Moreover, the cable part 10 contains the 1st cable part 11 hold | maintained at the predetermined shape, and the 2nd cable part 12 which is not hold | maintained at a fixed shape but has flexibility. FIG. 1 is a perspective view including a cross-sectional view of the first cable portion 11, and FIG. 2 is a perspective view including a cross-sectional view of the second cable portion 12.

<Cable part>
As shown in FIGS. 1 and 2, the cable unit 10 includes three cylindrical power transmission units stacked from the inside to the outside. Each power transmission unit includes a cylindrical conductive unit 2 and a cylindrical insulating unit 3. Hereinafter, the cylindrical conductive part 2 and the cylindrical insulating part 3 are collectively referred to as a power transmission part 2. Each of the three cylindrical conductive parts 2 is referred to as a first cylindrical conductive part 21, a second cylindrical conductive part 22, and a third cylindrical conductive part 23 in order from the inside to the outside. Similarly, each of the three cylindrical insulating portions 3 is referred to as a first cylindrical insulating portion 31, a second cylindrical insulating portion 32, and a third cylindrical insulating portion 33 in order from the inside to the outside.

  That is, in the cable part 10, the first cylindrical insulating part 31 is formed so as to cover the outer periphery of the first cylindrical conductive part 21, and the second cylindrical conductive part 22 covers the outer periphery of the first cylindrical insulating part 31. The second cylindrical insulating part 32 is formed so as to cover the outer periphery of the second cylindrical conductive part 22, and the third cylindrical conductive part 23 is formed so as to cover the outer periphery of the second cylindrical insulating part 32. The three cylindrical insulating portions 33 are formed so as to cover the outer periphery of the third cylindrical conductive portion 23.

  The cylindrical conductive part 2 is a conductive part that forms a part of each of the power transmission units 2 and 3 and is formed into a cylindrical shape by combining a plurality of conductive wires. Since the cylindrical conductive part 2 has a structure in which a plurality of conducting wires are combined in a cylindrical shape, it has flexibility, and can be easily bent and crushed to be deformed into a flat shape. For example, the cylindrical conductive portion 2 is a braided wire formed into a cylindrical shape by knitting an annealed copper conductor.

  Each cylindrical conductive portion 2 is a power line that connects a three-phase motor and an inverter circuit in an electric vehicle and through which a large current flows when a high voltage is applied. That is, the three cylindrical conductive parts 2 transmit the current of each phase in the three-phase alternating current. Therefore, the total cross-sectional area of the conducting wire in the cross section of each of the three cylindrical conductive portions 2 is sufficiently large so as not to generate excessive heat. In the following description, the total cross-sectional area of the conducting wire in each cross section of the cylindrical conductive portion 2 is referred to as a conducting wire total cross-sectional area.

  In the present embodiment, the inner cylindrical conductive portion 2 is formed to have a larger total cross-sectional area than the outer cylindrical conductive portion 2. That is, the total lead cross-sectional area of the third cylindrical conductive portion 23 is the smallest, the total lead cross-sectional area of the second cylindrical conductive portion 22 is larger than the total lead cross-sectional area of the third cylindrical conductive portion 23, The conducting wire total cross-sectional area of the cylindrical conductive part 21 is larger than the conducting wire total cross-sectional area of the second cylindrical conductive part 22.

  Further, the cylindrical insulating portion 3 is a flexible insulating portion that forms a part of each of the power transmission units 2 and 3 and is formed in a cylindrical shape that covers the outer periphery of the cylindrical conductive portion 2. The cylindrical insulating part 3 is a member that electrically insulates the cylindrical conductive part 2 on the inner side from the object existing on the outer side. For example, the cylindrical insulating portion 3 is a cylindrical member made of resin such as polyethylene, vinyl chloride, or polyamide-based nylon.

  Further, as shown in FIG. 1, the first cable portion 11 of the cable portion 10 is included inside the innermost power transmission unit 2, 3, and the shape of the power transmission unit 2, 3 is held constant. A core member 4 is provided.

  The perspective view shown in FIG. 4 shows an example of the core member 4. The core member 4 shown in FIG. 4 is a rod-like member having a flat cross section, and is linearly formed with a linear portion 41 formed into a linear shape, a twisted portion 42 formed by twisting, and a curved portion. And a curved portion 43 formed.

  As shown in FIG. 3, the core member 4 as shown in FIG. 4 is arranged inside the innermost power transmission units 2 and 3 in the first cable portion 11, so that a part of the cable portion 10 is used. The certain 1st cable part 11 is hold | maintained in the shape where the linear part, the twisted part, and the curved part continued. Furthermore, since the core member 4 is formed in a flat bar shape, as shown in FIG. 1, the cross-sectional shapes of the three power transmission units 2 and 3 in the first cable unit 11 are held flat.

  On the other hand, the 2nd cable part 12 of the cable parts 10 is not provided with the core member 4, and the inner side of the innermost power transmission part 2 * 3 is a cavity. Therefore, the 2nd cable part 12 which has the structure where the 3 power transmission parts 2 * 3 which have flexibility were piled up was secured as a whole, and as shown in FIG. 3, it bends and becomes a flat state. It is easy to deform.

<Connection part>
As shown in FIG. 1, each connection part 50 provided at both ends of the cable part 10 includes three terminals 5 provided for each of the three power transmission parts 2 and 3 and terminals made of an insulating material. And a fixed portion 6.

  The three terminals 5 are parts that are screwed to electrical components such as a motor or an inverter circuit. The three terminals 5 are electrically connected to each of the three cylindrical conductive parts 2 independently in the terminal fixing part 6. That is, the three terminals 5 include a first terminal 51 electrically connected to the first cylindrical conductive portion 21, a second terminal 52 electrically connected to the second cylindrical conductive portion 22, and a first terminal The third cylindrical conductive portion 23 and a third terminal 55 electrically connected are included. For example, the three terminals 5 are crimped or welded to each of the three cylindrical conductive parts 2 in the terminal fixing part 6.

  The terminal fixing portion 6 is a member that holds the three terminals 5 in a predetermined positional relationship. The terminal fixing portion 6 is a molded member made of, for example, polyamide, polypropylene, polybutylene terephthalate, ABS resin, polyethylene, or insulating resin in which they are mixed.

<Effect>
In the wire harness 1, the cylindrical conductive portion 2 is formed into a cylindrical shape by combining a plurality of conductive wires and has flexibility. Therefore, even when the cylindrical conductive portion 2 is formed with a large cross-sectional area to prevent excessive heat generation, flexibility is ensured and handling performance is not impaired. Moreover, since the cylindrical conductive part 2 has a hollow structure, current transmission loss due to the skin effect is unlikely to occur.

  Moreover, in the wire harness 1, the 1st cable part 11 is hold | maintained in the shape in alignment with the wiring path predetermined by the core member 4, and the 2nd cable part 12 has a softness | flexibility. Thereby, the handling performance of laying the wire harness 1 is further increased.

  Moreover, since the core member 4 of the wire harness 1 has a flat bar shape that holds the cross-sectional shape of the power transmission units 2 and 3 flat, it is easy to lay the first cable portion 11 in a gap having a low height. .

  Further, in the wire harness 1, the second cylindrical conductive part 22 on the inner side is worse in heat dissipation than the third cylindrical conductive part 23 on the outer side. On the other hand, the second cylindrical conductive portion 22 is formed to have a larger total cross-sectional area than the third cylindrical conductive portion 23, and the first cylindrical conductive portion 21 is more conductive than the second cylindrical conductive portion 22. The total cross-sectional area is formed large. As a result, the thermal balance of each of the three cylindrical conductive parts 2 is made uniform, and only a part of the cylindrical conductive parts 2 can be prevented from being excessively heated.

Second Embodiment
Next, a wire harness 1A according to a second embodiment of the present invention will be described with reference to FIGS. This wire harness 1A has a configuration in which some components are added as compared to the wire harness 1 shown in FIGS. 5 and 6, the same constituent elements as those shown in FIGS. 1 to 4 are denoted by the same reference numerals. Hereinafter, only different points of the wire harness 1A from the wire harness 1 will be described.

  5 is a perspective view including a cross-sectional view of the first cable portion 11 that is a part of the wire harness 1A, and FIG. 6 is a perspective view including a cross-sectional view of the second cable portion 12 that is a part of the wire harness 1A. FIG. The wire harness 1A includes a core member 4A that holds the first cable portion 11 in a fixed shape. The core member 4 </ b> A corresponds to the core member 4 in the wire harness 1.

  The wire harness 1 </ b> A includes a plurality of insulated wires 7 included in the innermost power transmission units 2, 3, i.e., the first cylindrical conductive unit 21, in addition to the configuration of the wire harness 1 </ b> A. In the example shown in FIGS. 5 and 6, three insulated wires 7 are included inside the first cylindrical conductive portion 21, but one insulated wire 7, two insulated wires 7, or four. An example in which the above insulated wire 7 is included inside the first cylindrical conductive portion 21 is also conceivable.

  The insulated electric wire 7 is an electric wire having a core wire made of a stranded copper wire and a cylindrical insulating coating covering the periphery of the core wire. The insulated wire 7 is a signal-type wire to which a voltage lower than the voltage applied to the cylindrical conductive portion 2 is applied and a current sufficiently smaller than the current flowing through the cylindrical conductive portion 2 flows.

  Further, as shown in FIG. 5, the core member 4 </ b> A of the wire harness 1 is formed with a groove 44 into which the insulated wire 7 is fitted. Thereby, the insulated wire 7 is held at a fixed position in the first cable portion 11.

<Effect>
By adopting the wire harness 1A, the same effect as that obtained when the wire harness 1 is employed can be obtained. Furthermore, the wire harness 1 </ b> A includes a signal-type insulated wire 7 included inside the power transmission units 2 and 3. Therefore, it is possible to efficiently wire the power transmission units 2 and 3 and the signal insulated wires 7.

<Third Embodiment>
Next, a wire harness 1B according to a third embodiment of the present invention will be described with reference to FIG. The wire harness 1B includes a core member 4A having a shape different from that of the core member 4 and a terminal fixing portion 6A having a shape different from that of the terminal fixing portion 6 as compared with the wire harness 1 shown in FIGS. The only difference is that 7, the same components as those shown in FIGS. 1 to 4 are given the same reference numerals. Hereinafter, only different points from the wire harness 1 in the wire harness 1B will be described.

  In the wire harness 1 </ b> B, the core member 4 </ b> A disposed in the first cable portion 11 includes a straight portion 41 that is formed in a rod shape that extends linearly, and a curved portion 43 that is curved. However, the twist part 42 is not formed in the core member 4A. The core member 4A having such a shape is also an example of the core member employed in the wire harness according to the present invention.

  Moreover, the connection part 50A is provided in the edge part of the wire harness 1B. The terminal fixing portion 6A constituting the connection portion 50A holds the plurality of terminals 5 in a state where they are arranged in parallel. The terminal fixing portion 6A having such a shape is also an example of the terminal fixing portion employed in the wire harness according to the present invention.

<Others>
It is also conceivable that the wire harnesses 1, 1 </ b> A, 1 </ b> B shown above include a shield member made of a tubular braided wire in addition to the tubular conductive portion 2 such as a braided wire that functions as a power line. In this case, the shield member is formed of a cylindrical braided wire that covers the outer side of the outermost power transmission units 2 and 3, that is, the outer side of the third cylindrical insulating unit 33. If the wire harnesses 1, 1 </ b> A, 1 </ b> B are provided with such a shield member, the power transmission units 2, 3 can be shielded without impairing the flexibility of the wire harnesses 1, 1 </ b> A, 1 </ b> B.

  The shield member is grounded via conductive brackets or fourth terminals at both ends of the wire harnesses 1, 1 </ b> A, 1 </ b> B while being electrically insulated from each of the three cylindrical conductive portions 2. The

  Further, in the wire harnesses 1, 1 </ b> A, 1 </ b> B, the outermost power transmission units 2, 3 may be omitted. In this case, the 1st cylindrical conductive part 21 and the 2nd cylindrical conductive part 22 are electrically connected with respect to each of two lines of single phase alternating current via the 1st terminal 51 and the 2nd terminal 52, respectively. .

  It is also conceivable that the wire harnesses 1, 1 </ b> A, 1 </ b> B include four or more power transmission units 2, 3 stacked from the inside to the outside. It is also conceivable that the terminal fixing portions 6 and 6A are omitted from the wire harnesses 1 and 1A and 1B.

1, 1A, 1B Wire harness 2 Cylindrical conductive part (power transmission part)
3 Tubular insulation (power transmission)
4, 4A Core member 5 Terminal 6, 6A Terminal fixing part 7 Insulated wire 10 Cable part 11 First cable part 12 Second cable part 21 First cylindrical conductive part 22 Second cylindrical conductive part 23 Third cylindrical conductive part 31 1st cylindrical insulation part 32 2nd cylindrical insulation part 33 3rd cylindrical insulation part 41 linear part 42 twist part 43 bending part 44 groove | channel 50 connection part 51 1st terminal 52 2nd terminal 55 3rd terminal

Claims (7)

A wire harness comprising a plurality of cylindrical power transmission sections stacked from the inside to the outside,
A plurality of cylindrical conductive portions that are conductive portions constituting each of the power transmission units, and are formed into a cylindrical shape by combining a plurality of conductive wires, and have flexibility,
A plurality of cylindrical insulating portions that are each an insulating portion that constitutes each of the power transmission units, and are formed in a cylindrical shape that covers an outer periphery of the cylindrical conductive portion;
A plurality of terminals provided for each of the power transmission units and electrically connected to the cylindrical conductive unit;
A wire harness comprising:   The wire harness according to claim 1, further comprising a core member that is included inside a part of the innermost power transmission unit and that holds the shape of the power transmission unit constant.   The wire harness according to claim 2, wherein the core member is formed in a flat bar shape that holds the cross-sectional shape of the power transmission unit flat.   The wire harness according to any one of claims 1 to 3, wherein a total cross-sectional area of the conductive wire in a cross section is formed larger in the inner cylindrical conductive portion than in the outer cylindrical conductive portion.   The wire harness in any one of Claims 1-4 further equipped with the insulated wire enclosed by the inner side of the innermost power transmission part.   The wire harness according to any one of claims 1 to 5, wherein the cylindrical conductive portion is formed of a braided wire having a flexibility formed by knitting a plurality of conductive wires.   The wire harness in any one of Claims 1-6 further provided with the shielding member which consists of a cylindrical braided wire which covers the outer side of the outermost power transmission part.

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