JP5579215B2 - Wire harness and wire harness shield structure - Google Patents

Description

  The present invention relates to a shield technology for a wire harness routed in a vehicle or the like, particularly a high-voltage wire harness.

  In general, it is known that electromagnetic noise due to high-frequency current is generated from a wire harness (electric wire) that supplies a motor driving current of a hybrid vehicle. Various types of shield structures for electric wires have been proposed in the past to shield the electromagnetic noise and prevent the noise from being superimposed on signal lines of an ECU (Electric Control Unit) or the like (for example, Patent Document 1 and Patent Document 2).

  The shield structure of the electric wire described in Patent Document 1 is composed of a braided wire in which fine metal wires are knitted in a mesh shape, and is shielded using a tubular braided conductor that can be flexibly deformed. On the other hand, the shield structure of the electric wire described in Patent Document 2 includes a rigid electric wire having a single core wire and a metal shield case covering the outer periphery of the rigid electric wire in the range of the routing route that does not require flexibility as a cable. In the range of the routing route that is required to be flexible as a cable, a flexible electric wire having a core wire composed of a large number of conductive wires, and a flexible shield member covering the outer circumference of the flexible electric wire, The core wires of the rigid electric wire and the flexible electric wire are connected to each other.

JP 2010-40396 A JP 2006-156051 A

  However, in the case of the shield structure of Patent Document 1, since it is shielded by the braided conductor, the shield structure has a gap, and the shielding effect in the high frequency band becomes a problem.

  Further, in the case of the shield structure of Patent Document 2, the shield is shielded by a metal shield case covering the outer periphery of a rigid electric wire having a single core wire, but in order to exert a shielding effect against low frequency band noise. Therefore, it is necessary to reduce the electrical resistance of the shield. For this reason, it is necessary to increase the thickness of the metal shield case to some extent. However, if the thickness of the shield case is excessively increased, the flexibility is deteriorated and the weight and cost are increased. In addition, a flexible shield member that covers a flexible electric wire having a core wire composed of a large number of conducting wires, for example, when the flexible shield member is a metal braid, as described above, the reliability of the shielding effect at high frequencies is as described above. When using metal foil, metal plating, or metal tape, the same problem as the metal shield case covering the outer periphery of the rigid wire mentioned above occurs, and the shielding effect is exhibited in the low frequency band. However, a certain amount of shield thickness is required, and the balance with flexibility becomes a problem. In addition, it is necessary to connect the core wires of rigid and flexible wires to each other, and because the wires are divided into flexible and rigid parts, the structure is complicated, so the number of manufacturing processes and parts The number and cost will increase.

  In this way, it is very difficult to obtain a wide and high shielding effect from a low frequency band to a high frequency band with one shield form, and it is difficult to solve the problem when trying to have flexibility at the same time. Become.

  Therefore, the present invention has been made to solve the above-described problems, and has a high shielding effect in a wide frequency band, is excellent in flexibility, and has an electric wire structure that is simple and easy to manufacture. It is possible to provide a wire harness that is easy to handle and its shield structure.

  In order to achieve the above object, a wire harness according to the present invention includes one or more insulation-coated electric wires, and the insulation coating by being arranged along the longitudinal direction of the insulation-coated electric wires and grounding. It has one or more magnetic field cancellation conducting wires for canceling out a magnetic field generated by energization of an electric wire, and a metal layer covering the insulation coated electric wire and the magnetic field canceling conducting wire.

  The wire harness according to the present invention preferably includes a resin tube that houses the insulating coated electric wire and the magnetic field canceling lead, and the metal layer is preferably formed on an outer periphery of the resin tube.

  Moreover, it is preferable that the wire harness which concerns on this invention is arrange | positioned in parallel with the said insulation coating electric wire in the said conducting wire for magnetic field cancellation.

  Moreover, the wire harness which concerns on this invention may arrange | position the said magnetic field cancellation conducting wire twisted mutually with the said insulation coating electric wire.

  In the wire harness according to the present invention, the metal layer may be covered with a resin layer.

  In the wire harness according to the present invention, it is preferable that the magnetic field canceling lead is made of any one of copper, aluminum, a copper alloy, and an aluminum alloy.

  In the wire harness according to the present invention, a magnetic layer may be provided around at least a part in the longitudinal direction around the insulating coated electric wire and the magnetic field canceling conductor.

  Moreover, the wire harness which concerns on this invention may provide a magnetic layer in the surrounding surface between the said resin pipe | tube and the said metal layer, and at least one part of a longitudinal direction.

  Moreover, the shield structure of the wire harness according to the present invention is a shield structure of a wire harness using the above-described wire harness, and both end portions of the metal layer and the magnetic field canceling conductor are grounded. Features.

  In the wire harness of the present invention, a metal layer is provided around one or a plurality of insulation-coated wires, and one or a plurality of magnetic field canceling conductors along the longitudinal direction of the insulation-coated wires are provided in the metal layer. Because the structure is interpolated, the noise in the high frequency band can be reduced by the metal layer, and the magnetic field canceling conductor inserted in the metal layer along the longitudinal direction of the insulation-coated electric wire, for example, the terminal portion By grounding to the metal casing of the electrical / electronic equipment, it is possible to cancel the magnetic field generated when the insulated coated electric wire is energized, and as a result, the noise in the low frequency band can be reduced. Therefore, the wire harness and the shield structure of the wire harness according to the present invention can exhibit a shielding effect in a wide frequency band.

  In addition, when a metal layer having a metal pipe or metal sprayed on a resin tube is used, the wire harness can have flexibility over the entire area. In addition, when the exterior of the metal coating layer applied on the resin tube is further coated with a resin, the metal layer can be protected. Moreover, since the structure does not change between the middle part and the terminal part of the wire harness as in the conventional case, the structure is simple, and the weight is reduced, the number of manufacturing steps is reduced, and the handling and cost are excellent.

It is a partial notch figure which shows typically the shield structure of the wire harness which concerns on 1st Embodiment. It is AA sectional drawing of FIG. It is a top view which shows typically the modification of the shield structure of the wire harness which concerns on 1st Embodiment. It is a top view which shows typically the other modification of the shield structure of the wire harness which concerns on 1st Embodiment. It is AA sectional drawing of FIG. It is a top view which shows typically the shield structure of the wire harness which concerns on 2nd Embodiment. It is AA sectional drawing of FIG. It is a top view which shows typically the modification of the shield structure of the wire harness which concerns on 2nd Embodiment. It is AA sectional drawing of FIG. It is a graph which shows the shielding effect of the Example and comparative example of this invention.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

(First embodiment)
First, an example of the shield structure 1 of the wire harness concerning the 1st Embodiment of this invention is demonstrated. FIG. 1 is a diagram for explaining a shield structure 1 for a wire harness according to a first embodiment of the present invention, in which a top portion of a resin tube 5, a metal layer 6, and a resin layer 7 is cut away when viewed from above. FIG. 2 is a cross-sectional view taken along line AA of the wire harness 2 in FIG.

  As shown in FIG. 1 and FIG. 2, the shield structure 1 of the wire harness according to the embodiment includes an insulation coated electric wire 3, a magnetic field canceling lead 4, an insulation coated electric wire 3, and a magnetic field canceling lead 4. It has the wire harness 2 which consists of the resin pipe 5 to be accommodated, the metal layer 6 formed around the resin pipe 5, and the resin layer 7 covering the metal layer 6, and both ends of the metal layer 6 and the magnetic field canceling conductor 4. Is grounded to the metal casing 8 of the electric / electronic device.

  The insulation covered electric wire 3 and the magnetic field canceling conductive wire 4 are arranged substantially parallel to each other in the longitudinal direction. The insulated wire 3 has a core wire 9 covered with an insulator 10. A metal material such as copper, aluminum, a copper alloy, and an aluminum alloy can be used for the core wire 9 and the magnetic field canceling conductive wire 4 of the insulating coated electric wire 3. In the present embodiment, the number of the insulation-coated wires 3 and the magnetic field canceling conductive wires 4 is one, but a plurality of each may be used.

  The thickness and number of the magnetic field canceling conductive wires 4 can be designed as appropriate, but it is preferable to set the thickness and the number so as to cancel the magnetic field generated by energization of the insulating coated electric wire 3.

  The resin tube 5 is provided so as to collectively cover the periphery of the insulation covered electric wire 3 and the magnetic field canceling conductive wire 4 over the entire length in the longitudinal direction. As the resin tube 5, for example, a tube formed by extrusion molding using a flexible insulating material such as polyamide or polypropylene can be used. Although the thickness of the resin tube 5 can be designed as appropriate, it is preferably 10 μm to 400 μm from the viewpoint of securing the strength as the wire harness 2.

  The metal layer 6 is formed on the outer peripheral surface of the resin tube 5 by spraying a metal material having high conductivity such as copper, aluminum, a copper alloy, or an aluminum alloy, or performing electroless plating. The thickness of the metal layer 6 is within a range for obtaining a desired shielding effect, particularly a shielding effect for a frequency band of 100 kHz or more, preferably 1 MHz or more. It is desirable to design appropriately according to the resistance, the length and material of the shield, and the electrical resistance. However, it is desirable to set the shield thickness so that the electrical resistance of the shield is within 50 mΩ in the core wire 9 and the shield of 1 m.

  The resin layer 7 is formed by extrusion molding using polyolefin, polyvinyl chloride (PVC), or the like. The resin layer 7 may not be provided, but is preferably provided from the viewpoint of protecting the metal layer 6. The thickness of the resin layer 7 can be appropriately designed, but is preferably 1 mm to 3 mm from the viewpoint of protecting the metal layer 6.

  Both end portions of the metal layer 6 and the magnetic field canceling conductive wire 4 are grounded to a metal casing 8 of an electric / electronic device. As a result, in the low frequency band, due to the magnetic coupling between the insulated wire 3 and the magnetic field canceling lead 4, a current of the same level is induced in the magnetic field canceling lead 4 in the direction opposite to the insulating covered wire 3, and the noise is reduced. A magnetic field is generated from the magnetic field canceling lead 4 in a direction that cancels out the radiated magnetic field by the insulated coated electric wire 3 that contributes to Further, with respect to noise in a high frequency band, the insulation covered electric wire 3 and the magnetic field canceling conductive wire 4 are covered with the metal layer 6, thereby exhibiting a noise shielding effect. In this embodiment, both end portions of the metal layer 6 and the magnetic field canceling conductive wire 4 are grounded to the metal casing 8 of the electric / electronic device, but may be grounded to the body ground of the vehicle body. .

  As described above, according to the shield structure 1 of the wire harness according to the present embodiment, noise in the high frequency band can be reduced by the metal layer 6, and the magnetic field generated when the insulated coated electric wire 3 is energized by the magnetic field canceling lead 4 is canceled out. As a result, noise in the low frequency band can be reduced. Therefore, the shield structure 1 of the wire harness can exhibit a shielding effect in a wide frequency band.

  In addition, since the metal layer 6 is made by applying metal plating or thermal spraying onto the resin tube 5, the wire harness 2 can have flexibility over the entire area. Further, the outer peripheral surface of the metal layer 6 applied on the resin tube 5 is further covered with the resin layer 7, so that the metal layer 6 can be protected. Moreover, since the structure does not change between the middle part and the terminal part of the wire harness 2 as in the prior art and the structure is simple, it is excellent in terms of weight reduction, reduction in manufacturing process, handling and cost.

  Next, the modification of the shield structure 1 of the wire harness concerning the 1st Embodiment of this invention is demonstrated using FIG. FIG. 3 is a view for explaining the shield structure 1 ′ of the wire harness according to the modification of the first embodiment of the present invention, in which the upper part of the resin tube 5 and the metal layer 6 is cut away when viewed from above. FIG.

  Here, the difference from the shield structure 1 of the wire harness according to the first embodiment shown in FIGS. 1 and 2 will be described. In addition, in FIG. 3, the member which attached | subjected the code | symbol same as the code | symbol used by description of the connection structure of the wire harness 2 concerning the above-mentioned 1st Embodiment is the structure similar to the above-mentioned member.

  In the connection structure of the wire harness 2 according to the first embodiment described above, as shown in FIG. 1, the insulation-coated electric wire 3 and the magnetic field canceling lead 4 are arranged substantially parallel to each other in the longitudinal direction. In contrast to this, in the wire harness 2 ′ of the present modification, as shown in FIG. 3, the insulation-coated electric wire 3 and the magnetic field canceling conductive wire 4 are arranged to be twisted with each other. . Thereby, a higher noise reduction effect can be obtained.

  Next, another modified example of the shield structure 1 for the wire harness according to the first embodiment of the present invention will be described with reference to FIGS. 4 and 5. FIG. 4 is a view for explaining a shield structure 1 ″ for a wire harness according to a modification of the first embodiment of the present invention, and shows an upper portion of the resin tube 5, the magnetic layer 11 and the metal layer 6 as viewed from above. Fig. 5 is a cross-sectional view taken along line AA in Fig. 4.

  Here, the difference from the shield structure 1 of the wire harness according to the first embodiment shown in FIGS. 1 and 2 will be described. 4 and 5, members having the same reference numerals as those used in the description of the shield structure 1 of the wire harness according to the first embodiment described above have the same configuration as the above-described members.

  As shown in FIGS. 4 and 5, the wire harness 2 ″ of the present modification further includes a magnetic layer 11 on a part of the circumferential surface between the resin tube 5 and the metal layer 6 in the longitudinal direction. The magnetic layer 11 may be formed of a magnetic material core such as a magnetized ring-shaped ferrite, or may be formed by applying a magnetic material paint on the outer peripheral surface of the resin tube 5 or winding a magnetic material tape. The magnetic material may be a composite material including a magnetic material.

  Thereby, since the coupling coefficient, which is the degree of magnetic coupling between the insulated wire 3 and the magnetic field canceling lead wire 4, is improved as compared with the case where there is no magnetic layer, a higher magnetic field canceling effect can be exhibited.

  In this modification, the magnetic layer 11 is provided on the peripheral surface between the resin tube 5 and the metal layer 6 and in a part of the longitudinal direction. However, the magnetic layer 11 may be provided in the entire longitudinal direction.

(Second Embodiment)
Next, the shield structure 100 of the wire harness concerning the 2nd Embodiment of this invention is demonstrated using FIG. 6 and FIG. FIG. 6 is a view for explaining the shield structure 100 of the wire harness according to the second embodiment of the present invention, and is a partially cutaway view in which the upper part of the metal layer 600 and the resin layer 7 is cut away when viewed from above. It is. 7 is a cross-sectional view taken along line AA of the wire harness 200 in FIG.

  As shown in FIGS. 6 and 7, the shield structure 1 of the wire harness according to the present embodiment includes an insulating coated electric wire 3, a magnetic field canceling conductive wire 4, an insulating coated electric wire 3, and a magnetic field canceling conductive wire 4. A wire harness 200 composed of a metal layer 600 covering the periphery of the substrate and a resin layer 7 covering the metal layer 600, and both end portions of the metal layer 600 and the magnetic field canceling conductor 4 are connected to the metal casing 8 of the electric / electronic device. Is grounded.

  Here, the difference from the shield structure 1 of the wire harness according to the first embodiment shown in FIGS. 1 and 2 will be described. 6 and 7, members having the same reference numerals as those used in the description of the shield structure 1 of the wire harness 2 according to the first embodiment described above have the same configuration as the above-described members.

  In the first embodiment, the metal layer 6 is formed by performing electroless plating or thermal spraying on the outer peripheral surface of the resin tube 5 that houses the insulation-coated electric wire 3 and the magnetic field canceling conductive wire 4. In this embodiment, the metal layer 600 is composed of a metal pipe, a plurality of small-diameter conductors that are wound in a spiral manner so that no gap is generated around the outer periphery of the insulated coated electric wire 3 and the magnetic field canceling conductor 4. A braid of several wires bundled alternately and wound around the outer periphery of the insulated wire 3 and the magnetic field canceling conductor 4, and the insulated wire 3 and the magnetic field canceling conductor so that the edges of the tape-like metal overlap in a spiral shape Wrapped around the outer periphery of 4 without any gaps (wrap winding), wrapped around the outer periphery so that the metal foil is along the longitudinal direction of the insulation coated electric wire 3 and the magnetic field canceling conductor 4 Ones (Tatesoe) etc., or it is formed by a combination thereof.

  Both end portions of the metal layer 600 and the magnetic field canceling conductive wire 4 are grounded to the metal casing 8 of the electric / electronic device. The magnetic field generated when the insulation-coated electric wire 3 is energized by the magnetic field canceling conductive wire 4 can be canceled out. As a result, the noise in the low frequency band can be reduced. Therefore, the thickness of the metal layer 600 can reduce the noise in the high frequency band. Can be about. For this reason, while having a high shielding effect in a wide frequency band, it can have a certain degree of flexibility over the entire region. In addition, since the outer peripheral surface of the metal layer 600 is covered with the resin layer 7, the metal layer 600 can be protected. Further, the structure does not change between the middle part and the terminal part of the wire harness 200 as in the conventional case, and the structure is simple, so that it is excellent in terms of weight reduction, reduction in manufacturing process, handling and cost.

  Next, the modification of the shield structure 1 of the wire harness concerning the 2nd Embodiment of this invention is demonstrated using FIG. 8 and FIG. FIG. 8 is a view for explaining a shield structure 100 ′ for a wire harness according to a modification of the second embodiment of the present invention, in which the upper part of the metal layer 600 and the resin layer 7 is cut away when viewed from above. FIG. 9 is a cross-sectional view taken along line AA in FIG.

  Here, the difference from the shield structure 1 of the wire harness according to the second embodiment shown in FIGS. 6 and 7 will be described. In FIGS. 8 and 9, members denoted by the same reference numerals as those used in the description of the connection structure of the wire harness 200 according to the above-described second embodiment have the same configuration as the above-described members.

  As shown in FIGS. 8 and 9, the wire harness 200 ′ according to the present modification further includes a magnetic layer 11 ′ around the insulation-coated electric wire 3 and the magnetic field canceling conductive wire 4 and in a part in the longitudinal direction. The magnetic layer 11 'may be formed of a magnetic material core such as a magnetized ring-shaped ferrite, or may be formed by winding a magnetic material tape. The magnetic material may be a composite material including a magnetic material. In this modification, the magnetic layer 11 ′ is provided on a part of the insulation coated electric wire 3 and the magnetic field canceling conductor 4 in the longitudinal direction, but may be provided on the entire longitudinal direction.

(Example)
Next, examples of the present invention will be described, but the present invention is not limited to these examples.

  Wire harness connection structures according to the following examples and comparative examples were created, noise measurements were performed on the examples and comparative examples, and the shielding effect was calculated. The result is shown in FIG. The noise measurement method was an absorption clamp method using a spectrum analyzer R3132 manufactured by Advanced Test Co., Ltd. as a noise detection measuring instrument, and an absorption clamp KT-10 manufactured by Kyoritsu Electronics Co., Ltd. was used as the absorption clamp. The shielding effect was calculated by subtracting the radiation noise of each of the examples and comparative examples from the radiation noise in the case of only the insulated coated electric wire.

Example 1
One insulation-coated electric wire and one magnetic field canceling conductor are inserted into an aluminum pipe so as to be substantially parallel to each other along the longitudinal direction, and both ends of the end portions of the magnetic field canceling conductor and the aluminum pipe are inserted. Was grounded to a metal casing. A copper wire having a thickness of 0.5 sq, a length of 1 m, and an electric resistance of 0.035Ω was used as the core wire of the insulation-coated wire and the magnetic field canceling lead wire. In addition, a pipe having a length of 1 m, a thickness of 1 mm, and an inner diameter of 18 mm was used as the aluminum pipe. The metal casing is formed of an aluminum alloy plate (A5052), and the casing has an electric resistance of 0.0015Ω.

(Example 2)
The configuration was the same as that of Example 1 except that the insulated wire and the magnetic field canceling conductor were twisted together in the longitudinal direction.

Example 3
Instead of the aluminum pipe, the configuration was the same as in Example 2 except that the insulation-coated electric wire and the magnetic field canceling conductor were shielded by copper braiding. The magnetic field canceling lead and the copper braid were grounded to the metal casing at both ends of the terminal. As a copper braid, a braid of tin-plated annealed copper wire having a pitch of 100 6.5 mm ² , a striking number of 32 / a number of grips of 18 / a strand diameter of 0.12 mm was used.

(Comparative Example 1)
The configuration was the same as that of Example 1 except that the insulated wire and the magnetic field canceling lead were not shielded by an aluminum pipe. The magnetic field canceling conductor was grounded to the metal casing at both ends of the terminal.

(Comparative Example 2)
The configuration was the same as in Example 1 except that the magnetic field canceling lead was not inserted. The copper braid was grounded to the metal casing at both ends of the terminal.

  As shown in FIG. 10, in Examples 1 and 2, the magnetic field canceling conductor is disposed along the longitudinal direction of the insulation-coated electric wire, and both terminal portions thereof are grounded to the metal casing, and the magnetic field canceling is performed. Since the outer periphery of the conductive wire and the insulation coated electric wire is shielded with an aluminum pipe, the shielding effect is 80 dB or more in the frequency band of 10 kHz to 1 GHz, and the shielding effect is high in a very wide frequency band.

  In Example 3, since the outer periphery of the magnetic field canceling conductor and the insulation-coated electric wire is shielded by copper braiding, the shielding effect in the high frequency band was not as high as in Examples 1 and 2, but for magnetic field cancellation. Since the conducting wire is twisted with the insulated wire along the longitudinal direction of the insulated wire and both ends are grounded to the metal casing, the shielding effect is 80 dB in a frequency band of about 10 kHz to 10 MHz. Thus, the shielding effect is high in the low frequency to medium frequency band.

  On the other hand, since the outer periphery of the magnetic field cancellation conducting wire and the insulation coated electric wire was not shielded by the metal layer in Comparative Example 1, the shielding effect was not high. However, the magnetic field canceling conductor is arranged along the longitudinal direction of the insulation-coated electric wire, and both ends are grounded to the metal casing, and the shielding effect is obtained in the low to medium frequency band (about 10 kHz to 10 MHz). I understand that there is.

  Moreover, since the comparative example 2 uses the copper braid as a shield, the shielding effect can be confirmed over the entire measurement frequency. However, the higher the frequency, the lower the shielding effect, and the low frequency to medium frequency band (about 10 kHz to 10 MHz). ), The shielding effect is inferior by about 10 to 20 dB in the high frequency band (about 10 MHz to 1 GHz).

  From these results, the magnetic field canceling conductor is disposed along the longitudinal direction of the insulated sheathed electric wire, both ends thereof are grounded to the metal casing, and the outer periphery of the magnetic field canceling conductive wire and the insulated sheathed electric wire are made of metal. It can be seen that shielding with a layer exhibits a high shielding effect in a wide frequency band with a simple structure.

1, 1 ', 100, 100': Wire harness shield structure 2, 2 ', 200, 200': Wire harness 3: Insulated coated electric wire 4: Magnetic field canceling conductor 5: Resin pipe 6, 600: Metal layer 7: Resin layer 8: Metal housing 11 and 11 'of electric / electronic equipment: Magnetic layer

Claims (6)

One or more insulated insulated wires; and
One or more magnetic field canceling conductors arranged along the longitudinal direction of the insulation-coated electric wire to cancel a magnetic field generated by energization of the insulation-coated electric wire by being grounded;
And a metal layer covering the periphery of the insulated wire and the magnetic field canceling wires,
Wherein the insulated wire and a resin tube for accommodating the magnetic field canceling wires have a <br/>,
The metal layer is formed on the outer periphery of the resin tube,
A wire harness , wherein a magnetic layer is provided on at least a part of a circumferential surface between the resin tube and the metal layer in the longitudinal direction . The wire harness according to claim 1, wherein the magnetic field canceling conductive wire is disposed in parallel with the insulating coated electric wire. The wire harness according to claim 1 , wherein the magnetic field canceling conductor is twisted with the insulation-coated electric wire. The wire harness according to any one of claims 1 to 3, wherein the metal layer is covered with a resin layer . The wire harness according to any one of claims 1 to 4, wherein the magnetic field canceling lead is made of any one of copper, aluminum, a copper alloy, and an aluminum alloy . It is the shield structure of the wire harness using the wire harness as described in any one of Claims 1-5,
A shield structure for a wire harness, wherein both end portions of the metal layer and the magnetic field canceling conductor are grounded.

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