US20200180526A1 - Wire harness - Google Patents
Wire harness Download PDFInfo
- Publication number
- US20200180526A1 US20200180526A1 US16/627,898 US201816627898A US2020180526A1 US 20200180526 A1 US20200180526 A1 US 20200180526A1 US 201816627898 A US201816627898 A US 201816627898A US 2020180526 A1 US2020180526 A1 US 2020180526A1
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- United States
- Prior art keywords
- sheath
- wire
- wires
- wire harness
- sheath member
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
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- 238000009954 braiding Methods 0.000 claims description 5
- 238000010008 shearing Methods 0.000 claims description 5
- 229910052751 metal Inorganic materials 0.000 description 22
- 239000002184 metal Substances 0.000 description 22
- 230000017525 heat dissipation Effects 0.000 description 10
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
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- 229920003235 aromatic polyamide Polymers 0.000 description 2
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- 229920001601 polyetherimide Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
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- 229910052782 aluminium Inorganic materials 0.000 description 1
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- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
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- 239000003365 glass fiber Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920001230 polyarylate Polymers 0.000 description 1
- -1 polyethylene terephthalate Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/42—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction
- H01B7/421—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
- B60R16/0207—Wire harnesses
- B60R16/0215—Protecting, fastening and routing means therefor
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0045—Cable-harnesses
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
- H01B7/0208—Cables with several layers of insulating material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
- H01B7/0208—Cables with several layers of insulating material
- H01B7/0216—Two layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/22—Metal wires or tapes, e.g. made of steel
- H01B7/228—Metal braid
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/533—Bases, cases made for use in extreme conditions, e.g. high temperature, radiation, vibration, corrosive environment, pressure
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/20—Coupling parts carrying sockets, clips or analogous contacts and secured only to wire or cable
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/009—Cables with built-in connecting points or with predetermined areas for making deviations
Definitions
- the present invention relates to a wire harness.
- a wire harness used for a vehicle such as a hybrid car or an electric car includes electric wires that electrically connect electric devices such as a high voltage battery or an inverter (for example, refer to Patent Document 1).
- an exterior member such as a corrugated tube or a metal pipe covers the outer sides of wires to protect and electromagnetically shield the wires.
- Patent Document 1 Japanese Laid-Open Patent Publication No. 2004-171952
- the electric devices used for a hybrid car, an electric car, or the like include high voltage inverters, batteries, and the like.
- a current of, for example, several hundred amperes flows through a wire and readily increases the temperature of the wire.
- one object of the present invention is to provide a wire harness that improves heat dissipation of electric wires.
- a wire harness that solves the above problem includes an electric wire and an exterior member.
- the electric wire includes a core wire and an insulation sheath.
- the core wire is formed by a conductor.
- the insulation sheath covers an outer circumference of the core wire.
- the electric wire is inserted through the exterior member.
- the electric wire includes a non-sheathed portion at an intermediate portion in a longitudinal direction of the electric wire where the insulation sheath is removed.
- the non-sheathed portion has an outer circumference covered by an insulative and meshed sheath member.
- the non-sheathed portion is covered by the meshed sheath member so that heat of the core wire is released to the outside through the mesh. This improves heat dissipation of the electric wire.
- the sheath member be formed from a material having a higher wear resistance than the insulation sheath.
- the sheath member is formed from a material having higher wear resistance than the insulation sheath to avoid tearing of the sheath member even when the sheath member contacts the exterior member. This avoids exposure of the core wire.
- the sheath member be formed by braiding reinforced fibers having a higher shearing resistance than the insulation sheath.
- the sheath member is formed by braiding reinforced fibers having higher shearing resistance than the insulation sheath. This reduces tearing in the sheath member.
- non-sheathed portion and the sheath member be arranged at a bent portion of the exterior member.
- the sheath member is meshed and thus more flexible than a non-meshed structure. This allows the sheath member arranged at the bent portion to readily follow the bent portion. Further, the bent portion has a structure in which the sheath member readily contacts the braided member. Thus, as described above, it is preferred that the sheath member be formed from a material having higher wear resistance than the insulation sheath.
- the core wire be squeezed and flattened into a flat portion at a position corresponding to the non-sheathed portion.
- the flat portion is arranged on the core wire so that the surface area of the core wire is increased compared to, for example, when the cross section of the core wire is a substantially true circle. This improves the heat dissipation.
- the electric wire be one of a plurality of the same electric wires inserted through the exterior member.
- the core wires of the plurality of electric wires are collectively covered by one of the sheath member at a position corresponding to the non-sheathed portion.
- a single sheath member can collectively cover multiple core wires of the electric wires in an insulated state. This eliminates the need for a plurality of sheath members and limits increases in the number of parts.
- the wire harness of the present invention improves heat dissipation of the electric wire.
- FIG. 1 is a schematic diagram showing a wire harness according to one embodiment.
- FIG. 2 is a cross-sectional view showing the wire harness of the same embodiment.
- FIG. 3A is a plan view showing an electric wire of a modified example.
- FIG. 3B is a side view showing the electric wire of the same modified example.
- FIG. 4 is a cross-sectional view showing a wire harness of a modified example.
- a wire harness 10 of the present embodiment is laid out to extend under a floor or the like of a vehicle such as a hybrid car or an electric car to connect, for example, a high voltage battery 11 arranged at the rear of the vehicle and an inverter 12 arranged at the front of the vehicle.
- the inverter 12 is connected to a wheel driving motor (not shown) serving as a power source when the vehicle travels and generates alternating current from the direct current of the high voltage battery 11 to supply the alternating current to the motor.
- the high voltage battery 11 is a battery that is configured to supply a voltage of several hundred volts.
- the wire harness 10 includes high voltage wires 13 and 14 and an electromagnetic shield 15 .
- the high voltage wires 13 and 14 are respectively connected to the positive terminal and the negative terminal of the high voltage battery 11 .
- the electromagnetic shield 15 is tubular and surrounds both of the high voltage wires 13 and 14 .
- Each of the high voltage wires 13 and 14 is a non-shielded wire, which does not include a shielding structure, and is applicable to high voltages and large currents.
- the high voltage wires 13 and 14 are inserted through the electromagnetic shield 15 .
- the high voltage wires 13 and 14 each include one end connected to the high voltage battery 11 by a connector C 1 and another end connected to the inverter 12 by a connector C 2 .
- the electromagnetic shield 15 is elongated and tubular.
- the electromagnetic shield 15 includes an intermediate portion in a longitudinal direction of the electromagnetic shield 15 formed by a metal pipe 21 .
- the electromagnetic shield 15 in ranges including the two longitudinal ends of the electromagnetic shield 15 and excluding the portion formed by the metal pipe 21 is formed by braided members 22 .
- the braided member 22 is an exterior member through which the high voltage wires 13 and 14 are inserted.
- the metal pipe 21 is formed from, for example, an aluminum-based metal material.
- the metal pipe 21 is laid out under the floor of the vehicle and bent into a predetermined shape in correspondence with the structure of the floor.
- the metal pipe 21 of the present embodiment includes a straight portion 21 a, bent portions 21 b, and upwardly extending portions 21 c.
- the straight portion 21 a is laid out under the floor in a front-rear direction of the vehicle.
- the bent portions 21 b are arranged at the ends of the straight portion 21 a.
- the upwardly extending portions 21 c extend from the bent portions 21 b toward an upper side of the vehicle.
- the metal pipe 21 electromagnetically shields both of the inserted high voltage wires 13 and 14 and protects the high voltage wires 13 and 14 from flying pebbles or the like.
- the braided members 22 are tubular members formed by braiding a plurality of metal strands.
- the braided members 22 are connected to the longitudinal ends of the metal pipe 21 by a coupling member such as a swaging ring or the like so that each braided member 22 is electrically connected to the metal pipe 21 .
- each braided member 22 is surrounded by an exterior member 24 such as a corrugated tube.
- the exterior member 24 is separate from the braided member 22 through which the high voltage wires 13 and 14 are inserted.
- rubber grommets 25 are attached to portions connecting the metal pipe 21 and the braided members 22 to cover the outer circumference of the connection portions and prevent the entrance of water.
- the braided members 22 entirely surround the outer circumference of portions of the high voltage wires 13 and 14 extending out of the ends of the metal pipe 21 (out-of-pipe portions X). Accordingly, the braided member 22 electromagnetically shields the out-of pipe portions X of the high voltage wires 13 and 14 .
- the exterior members 24 of the present embodiment include a first exterior member 31 located toward the front of the vehicle and a second exterior member 32 located toward the rear of the vehicle.
- the first exterior member 31 includes a first straight portion 31 a, a bent portion 31 b, and a second straight portion 31 c.
- the first straight portion 31 a is connected to the metal pipe 21 extending straight and substantially upward in vertical direction.
- the bent portion 31 b extends from the first straight portion 31 a and is bent toward the front.
- the second straight portion 31 c extends straight from the bent portion 31 b toward the front.
- the second exterior member 32 includes a first straight portion 32 a, a bent portion 32 b, and a second straight portion 32 c, in at least a state arranged in the vehicle, the first straight portion 32 a is connected to the metal pipe 21 extending straight and substantially upward in the vertical direction.
- the bent portion 31 b extends from the first straight portion 31 a and is bent toward the rear.
- the second straight portion 31 c extends straight from the bent portion 31 b toward the rear.
- each of the high voltage wires 13 and 14 is a sheathed electric wire in which a core wire 41 is covered by an insulation sheath 42 .
- the core wire 41 is formed by a conductor, and the insulation sheath 42 is formed from a resin material.
- a single-core wire or a stranded wire can be used as the core wire 41 .
- the insulation sheath 42 is formed on the circumferential surface of the core wire 41 through, for example, extrusion coating, and covers the circumferential surface of the core wire 41 in a state of contact.
- the high voltage wires 13 and 14 each include an intermediate portion in the longitudinal direction defining a non-sheathed portion 43 where the insulation sheath 42 is not sheathed.
- the non-sheathed portion 43 has an outer circumference covered by an insulative meshed sheath member 44 .
- the sheath member 44 is configured to be tubular and covers each non-sheathed portion 43 .
- the sheath member 44 is formed from, for example, a material having higher wear resistance than the insulation sheath 42 .
- the sheath member 44 of the present example has a structure braiding reinforced fibers having superior insulation properties and superior wear resistance properties. That is, the sheath member 44 is meshed. Further, the sheath member 44 has a meshed structure and thereby has higher flexibility and dissipates more heat than the insulation sheath 42 that is not meshed.
- Each sheath member 44 is long enough to entirely cover a single non-sheathed portion 43 . Specifically, the two longitudinal ends of the sheath member 44 are overlapped with the insulation sheath 42 located at the two ends of each non-sheathed portion 43 .
- the reinforced fibers forming the sheath member 44 have, for example, shearing resistance that is more superior to that of the insulation sheath 42 .
- the reinforced fiber include para-aramid fiber, polyarylate fiber, poly para-phenyiene benzobisoxazole (PBO) fiber, polyethylene terephthalate (PET) fiber, ultra-high molecular weight polyethylene fiber, polyetherimide (PEI) fiber, glass fiber, ceramic fiber, or the like.
- PBO poly para-phenyiene benzobisoxazole
- PET polyethylene terephthalate
- PEI polyetherimide
- glass fiber glass fiber
- ceramic fiber or the like.
- one or more types of the above fibers are used in accordance with the physical property required for the sheath member 44 .
- the sheath member 44 is formed from a single type of the para-aramid fiber.
- Each non-sheathed portion 43 and the sheath member 44 which corresponds to the non-sheathed portion 43 , can be arranged at any position in a longitudinally intermediate portion of each of the high of the voltage wires 13 and 14 .
- the non-sheathed portion 43 and the sheath member 44 can be arranged, for example, at a position corresponding to the straight portion 21 a of the metal pipe 21 , the bent portion 21 b of the metal pipe 21 , or the first and second exterior members 31 and 32 .
- the heat produced by the high voltage wires 13 and 14 can readily be released through the meshing of the sheath members 44 , for example, in a structure that includes the non-sheathed portion 43 of the high voltage wires 13 and 14 inside the first and second exterior members 31 and 32 and covers the outer side of the non-sheathed portions 43 with the meshed sheath members 44 . It can be expected that this increases the heat dissipation at such a portion by approximately 5% to 10% compared to when the core wires 41 of the electric wires 13 and 14 remain covered by the insulation sheath 42 .
- the first and second exterior members 31 and 32 are bent to form the bent portions 31 b and 32 b.
- the high voltage wires 13 and 14 are inserted through the exterior members 31 and 32 in advance.
- the high voltage wires 13 and 14 each include the non-sheathed portion 43 at positions corresponding to the bent portions 31 b and 32 b of the exterior members 31 and 32 and the outer sides of the non-sheathed portions 43 are covered by the sheath members 44 .
- the first and second exterior members 31 and 32 can be readily bent to form the bent portions 31 b and 32 b because the sheath member 44 is more flexible than the insulation sheath 42 .
- the outer side of the core wire 41 at the non-sheathed portion 43 , where the insulation sheath 42 is removed, is covered by the meshed sheath member 44 .
- the heat produced by the core wire 41 is dissipated from the sheath member 44 .
- the sheath member 44 is formed from reinforced fibers having higher wear resistance than the insulation sheath 42 . This avoids tearing of the sheath member 44 even when the sheath member 44 contacts (slides on) the exterior member 24 or the braided member 22 .
- the non-sheathed portion 43 is covered by the meshed sheath member 44 so that heat of the core wire 41 is released to the outside through the mesh. This improves heat dissipation of the electric wires 13 and 14 .
- the sheath member 44 is formed from a material having higher wear resistance than the insulation sheath 42 to avoid tearing of the sheath member 44 even when the sheath member 44 contacts the braided member 22 or the exterior member 24 . This avoids exposure of the core wire 41 .
- the sheath member 44 which is formed from braided reinforced fibers having higher shearing resistance than the insulation sheath 42 , avoids tearing in the sheath member 44 . This avoids situations in which the core wires 41 of the high voltage wires 13 and 14 , which are covered by the sheath members 44 , directly contact each other or are short-circuited through other components or the like.
- the sheath member 44 is meshed and is more flexible than a non-meshed structure.
- the sheath members 44 readily follow the bent portions 31 b and 32 b even when the sheath members 44 are located at the bent portions 31 b and 32 b of the exterior member 24 .
- the bent portions 31 b and 32 b have a structure in which the sheath members 44 readily contact the braided members 22 or the exterior members 24 .
- the sheath members 44 be formed from a material having higher wear resistance than the insulation sheath 42 .
- the above embodiment employs the braided members 22 and the exterior member 24 as the exterior members of the electric wires 13 and 14 , which are covered by the sheath members 44 .
- this may be changed.
- the braided members 22 may be omitted if the electromagnetic shielding is not necessary.
- the exterior members 24 may be omitted so that only the braided members 22 are used.
- the metal pipe 21 may be employed as an exterior member that is separate from the braided members 22 and the exterior members 24 .
- the non-sheathed portion 43 may be arranged on the electric wires 13 and 14 inside the metal pipe 21 so that the sheath member 44 covers the core wire 41 at positions corresponding to the non-sheathed portion 43 .
- the sheath member 44 may be in contact with the metal pipe 21 .
- heat can be released through the metal pipe 21 . This improves heat dissipation.
- the core wire 41 at positions corresponding to the non-sheathed portion 43 may be squeezed and flattened to include a flat portion 51 .
- the cross section of the core wire 41 is changed, for example, from a substantially circular shape to a substantially elliptic shape thereby increasing the surface area. This improves the heat dissipation effect of the core wire 41 .
- the core wire 41 can readily be bent in a direction toward which a main surface 51 a of the flat portion 51 faces (direction orthogonal to main surface 51 a ) so that the formation of the bent portions 31 b and 32 b will not be hampered when the bent portions 31 b and 32 b are bent in the same direction.
- the sheath member 44 is tubular but may have another shape.
- a twisted tube including a slit extending in the longitudinal direction (longitudinal direction of electric wires 13 and 14 ) may be employed as the sheath member 44 .
- the twisted tube is braided and thus meshed in the same manner as the sheath member 44 of the embodiment.
- the two ends of the sheath member 44 in the longitudinal direction of the electric wires 13 and 14 may be fixed by wrapping with a tape.
- portions of the core wire 41 corresponding to the non-sheathed portions 43 of the high voltage wires 13 and 14 are each covered by the sheath member 44 .
- the structure may be changed. A structure in which a single sheath member covers multiple core wires may be employed as long as the insulation between the core wires 41 is maintained.
- One example of the above structure will be now described with reference to FIG. 4 .
- a sheet-like sheath member 55 may be wound around the core wires 41 of the electric wires 13 and 14 in in correspondence with the non-sheathed portions 43 (not shown).
- the sheath member 55 is wound to have a substantially S-shaped cross section taken in the radial direction of the core wires 41 .
- the sheath member 55 is located between the core wires 41 of the electric wires 13 and 14 to maintain the insulation between the core wires 41 .
- a single sheath member 55 can collectively cover the core wires 41 of multiple electric wires 13 and 14 in an insulated state. This eliminates the need for a plurality of sheath members and limits increases in the number of parts.
- each portion of the core wire 41 corresponding to the non-sheathed portion 43 of the electric wires 13 and 14 is covered by the sheath member 44 Alternatively, only one of the core wires 41 may be covered by the sheath member 44 .
- any number of non-sheathed portions 43 may be arranged on the electric wires 13 and 14 and any number of the sheath members 44 may be used corresponding to the non-sheathed portions 43 as long as the number is greater than or equal to one.
- the arrangement of a plurality of the non-sheathed portions 43 and the sheath members 44 that correspond to the non-sheathed portions 43 improves the heat dissipation.
- the non-sheathed portion 43 and the sheath member 44 that correspond to the non-sheathed portion 43 be arranged at each bent portion.
- two electric wires namely, the high voltage wires 13 and 14 are inserted through the electromagnetic shield 15 .
- the structure of the electric wires inserted through the electromagnetic shield 15 may be changed in accordance with the vehicle structure.
- a low voltage wire may be added and inserted through the electromagnetic shield 15 to connect a low voltage battery and various types of low voltage devices (e.g., lamp, vehicle audio, or the like).
- the positional relationship of the high voltage battery 11 and the inverter 12 in the vehicle is not limited to the above embodiment and may be changed in accordance with the vehicle structure. Further, in the above embodiment, the high voltage battery 11 is connected to the inverter 12 with the high voltage wires 13 and 14 . Instead, the high. voltage battery 11 may be connected to a high voltage device, which is not the inverter 12 .
- the present invention is applied to the wire harness 10 that connects the high voltage battery 11 and the inverter 12 .
- the present invention may also be applied to a wire harness that connects the inverter 12 and a wheel driving motor.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Insulated Conductors (AREA)
- Coupling Device And Connection With Printed Circuit (AREA)
- Connector Housings Or Holding Contact Members (AREA)
- Details Of Indoor Wiring (AREA)
Abstract
Description
- The present invention relates to a wire harness.
- Conventionally, a wire harness used for a vehicle such as a hybrid car or an electric car includes electric wires that electrically connect electric devices such as a high voltage battery or an inverter (for example, refer to Patent Document 1).
- In the wire harness disclosed in
Patent Document 1, an exterior member such as a corrugated tube or a metal pipe covers the outer sides of wires to protect and electromagnetically shield the wires. - Patent Document 1: Japanese Laid-Open Patent Publication No. 2004-171952
- As described above, the electric devices used for a hybrid car, an electric car, or the like include high voltage inverters, batteries, and the like. A current of, for example, several hundred amperes flows through a wire and readily increases the temperature of the wire. Thus, there is a need to improve heat dissipation.
- Accordingly, one object of the present invention is to provide a wire harness that improves heat dissipation of electric wires.
- A wire harness that solves the above problem includes an electric wire and an exterior member. The electric wire includes a core wire and an insulation sheath. The core wire is formed by a conductor. The insulation sheath covers an outer circumference of the core wire. The electric wire is inserted through the exterior member. The electric wire includes a non-sheathed portion at an intermediate portion in a longitudinal direction of the electric wire where the insulation sheath is removed. The non-sheathed portion has an outer circumference covered by an insulative and meshed sheath member.
- With this structure, the non-sheathed portion is covered by the meshed sheath member so that heat of the core wire is released to the outside through the mesh. This improves heat dissipation of the electric wire.
- In the above wire harness, it is preferred that the sheath member be formed from a material having a higher wear resistance than the insulation sheath.
- With this structure, the sheath member is formed from a material having higher wear resistance than the insulation sheath to avoid tearing of the sheath member even when the sheath member contacts the exterior member. This avoids exposure of the core wire.
- In the above wire harness, it is preferred that the sheath member be formed by braiding reinforced fibers having a higher shearing resistance than the insulation sheath.
- With this structure, the sheath member is formed by braiding reinforced fibers having higher shearing resistance than the insulation sheath. This reduces tearing in the sheath member.
- In the above wire harness, it is preferred the non-sheathed portion and the sheath member be arranged at a bent portion of the exterior member.
- With this structure, the sheath member is meshed and thus more flexible than a non-meshed structure. This allows the sheath member arranged at the bent portion to readily follow the bent portion. Further, the bent portion has a structure in which the sheath member readily contacts the braided member. Thus, as described above, it is preferred that the sheath member be formed from a material having higher wear resistance than the insulation sheath.
- In the above wire harness, it is preferred that the core wire be squeezed and flattened into a flat portion at a position corresponding to the non-sheathed portion.
- With this structure, the flat portion is arranged on the core wire so that the surface area of the core wire is increased compared to, for example, when the cross section of the core wire is a substantially true circle. This improves the heat dissipation.
- In the above wire harness, it is preferred that the electric wire be one of a plurality of the same electric wires inserted through the exterior member. The core wires of the plurality of electric wires are collectively covered by one of the sheath member at a position corresponding to the non-sheathed portion.
- With this structure, a single sheath member can collectively cover multiple core wires of the electric wires in an insulated state. This eliminates the need for a plurality of sheath members and limits increases in the number of parts.
- The wire harness of the present invention improves heat dissipation of the electric wire.
-
FIG. 1 is a schematic diagram showing a wire harness according to one embodiment. -
FIG. 2 is a cross-sectional view showing the wire harness of the same embodiment. -
FIG. 3A is a plan view showing an electric wire of a modified example. -
FIG. 3B is a side view showing the electric wire of the same modified example. -
FIG. 4 is a cross-sectional view showing a wire harness of a modified example. - One embodiment of a wire harness will now be described with reference to the drawings. The drawings may not be to scale, and the relative size, proportions, and. depiction of elements in the drawings may be exaggerated or simplified for clarity, illustration, and convenience.
- As shown in
FIG. 1 , awire harness 10 of the present embodiment is laid out to extend under a floor or the like of a vehicle such as a hybrid car or an electric car to connect, for example, ahigh voltage battery 11 arranged at the rear of the vehicle and aninverter 12 arranged at the front of the vehicle. Theinverter 12 is connected to a wheel driving motor (not shown) serving as a power source when the vehicle travels and generates alternating current from the direct current of thehigh voltage battery 11 to supply the alternating current to the motor. Thehigh voltage battery 11 is a battery that is configured to supply a voltage of several hundred volts. - The
wire harness 10 includeshigh voltage wires electromagnetic shield 15. Thehigh voltage wires high voltage battery 11. Theelectromagnetic shield 15 is tubular and surrounds both of thehigh voltage wires high voltage wires high voltage wires electromagnetic shield 15. Thehigh voltage wires high voltage battery 11 by a connector C1 and another end connected to theinverter 12 by a connector C2. - The
electromagnetic shield 15 is elongated and tubular. Theelectromagnetic shield 15 includes an intermediate portion in a longitudinal direction of theelectromagnetic shield 15 formed by ametal pipe 21. Theelectromagnetic shield 15 in ranges including the two longitudinal ends of theelectromagnetic shield 15 and excluding the portion formed by themetal pipe 21 is formed by braidedmembers 22. Thebraided member 22 is an exterior member through which thehigh voltage wires - The
metal pipe 21 is formed from, for example, an aluminum-based metal material. Themetal pipe 21 is laid out under the floor of the vehicle and bent into a predetermined shape in correspondence with the structure of the floor. Themetal pipe 21 of the present embodiment includes astraight portion 21 a,bent portions 21 b, and upwardly extendingportions 21 c. Thestraight portion 21 a is laid out under the floor in a front-rear direction of the vehicle. Thebent portions 21 b are arranged at the ends of thestraight portion 21 a. The upwardly extendingportions 21 c extend from thebent portions 21 b toward an upper side of the vehicle. Themetal pipe 21 electromagnetically shields both of the insertedhigh voltage wires high voltage wires - The braided
members 22 are tubular members formed by braiding a plurality of metal strands. The braidedmembers 22 are connected to the longitudinal ends of themetal pipe 21 by a coupling member such as a swaging ring or the like so that each braidedmember 22 is electrically connected to themetal pipe 21. - The outer circumference of each
braided member 22 is surrounded by anexterior member 24 such as a corrugated tube. Theexterior member 24 is separate from the braidedmember 22 through which thehigh voltage wires rubber grommets 25 are attached to portions connecting themetal pipe 21 and the braidedmembers 22 to cover the outer circumference of the connection portions and prevent the entrance of water. - The braided
members 22 entirely surround the outer circumference of portions of thehigh voltage wires braided member 22 electromagnetically shields the out-of pipe portions X of thehigh voltage wires - As shown in
FIG. 1 , theexterior members 24 of the present embodiment include afirst exterior member 31 located toward the front of the vehicle and asecond exterior member 32 located toward the rear of the vehicle. - The
first exterior member 31 includes a first straight portion 31 a, abent portion 31 b, and a secondstraight portion 31 c. In at least a state arranged in the vehicle, the first straight portion 31 a is connected to themetal pipe 21 extending straight and substantially upward in vertical direction. Thebent portion 31 b extends from the first straight portion 31 a and is bent toward the front. The secondstraight portion 31 c extends straight from thebent portion 31 b toward the front. - The
second exterior member 32 includes a firststraight portion 32 a, abent portion 32 b, and a secondstraight portion 32 c, in at least a state arranged in the vehicle, the firststraight portion 32 a is connected to themetal pipe 21 extending straight and substantially upward in the vertical direction. Thebent portion 31 b extends from the first straight portion 31 a and is bent toward the rear. The secondstraight portion 31 c extends straight from thebent portion 31 b toward the rear. - The structure of the
high voltage wires - As shown in
FIG. 2 , each of thehigh voltage wires core wire 41 is covered by aninsulation sheath 42. Thecore wire 41 is formed by a conductor, and theinsulation sheath 42 is formed from a resin material. For example, a single-core wire or a stranded wire can be used as thecore wire 41. Theinsulation sheath 42 is formed on the circumferential surface of thecore wire 41 through, for example, extrusion coating, and covers the circumferential surface of thecore wire 41 in a state of contact. - Further, the
high voltage wires non-sheathed portion 43 where theinsulation sheath 42 is not sheathed. Thenon-sheathed portion 43 has an outer circumference covered by an insulative meshedsheath member 44. - The
sheath member 44 is configured to be tubular and covers eachnon-sheathed portion 43. Thesheath member 44 is formed from, for example, a material having higher wear resistance than theinsulation sheath 42. Thesheath member 44 of the present example has a structure braiding reinforced fibers having superior insulation properties and superior wear resistance properties. That is, thesheath member 44 is meshed. Further, thesheath member 44 has a meshed structure and thereby has higher flexibility and dissipates more heat than theinsulation sheath 42 that is not meshed. - Each
sheath member 44 is long enough to entirely cover a singlenon-sheathed portion 43. Specifically, the two longitudinal ends of thesheath member 44 are overlapped with theinsulation sheath 42 located at the two ends of eachnon-sheathed portion 43. - Preferably, the reinforced fibers forming the
sheath member 44 have, for example, shearing resistance that is more superior to that of theinsulation sheath 42. Examples of the reinforced fiber include para-aramid fiber, polyarylate fiber, poly para-phenyiene benzobisoxazole (PBO) fiber, polyethylene terephthalate (PET) fiber, ultra-high molecular weight polyethylene fiber, polyetherimide (PEI) fiber, glass fiber, ceramic fiber, or the like. Preferably, one or more types of the above fibers are used in accordance with the physical property required for thesheath member 44. In the present embodiment, thesheath member 44 is formed from a single type of the para-aramid fiber. - Each
non-sheathed portion 43 and thesheath member 44, which corresponds to thenon-sheathed portion 43, can be arranged at any position in a longitudinally intermediate portion of each of the high of thevoltage wires non-sheathed portion 43 and thesheath member 44 can be arranged, for example, at a position corresponding to thestraight portion 21 a of themetal pipe 21, thebent portion 21 b of themetal pipe 21, or the first and secondexterior members high voltage wires 13 and 14 (core wires 41) can readily be released through the meshing of thesheath members 44, for example, in a structure that includes thenon-sheathed portion 43 of thehigh voltage wires exterior members non-sheathed portions 43 with themeshed sheath members 44. It can be expected that this increases the heat dissipation at such a portion by approximately 5% to 10% compared to when thecore wires 41 of theelectric wires insulation sheath 42. - Further, when laying out the
wire harness 10 in the vehicle, the first and secondexterior members bent portions high voltage wires exterior members high voltage wires non-sheathed portion 43 at positions corresponding to thebent portions exterior members non-sheathed portions 43 are covered by thesheath members 44. The first and secondexterior members bent portions sheath member 44 is more flexible than theinsulation sheath 42. - The operation of the present embodiment will now be described.
- In the
wire harness 10 of the present embodiment, the outer side of thecore wire 41 at thenon-sheathed portion 43, where theinsulation sheath 42 is removed, is covered by themeshed sheath member 44. Thus, the heat produced by thecore wire 41 is dissipated from thesheath member 44. Further, thesheath member 44 is formed from reinforced fibers having higher wear resistance than theinsulation sheath 42. This avoids tearing of thesheath member 44 even when thesheath member 44 contacts (slides on) theexterior member 24 or thebraided member 22. - The advantages of the present embodiment will now be described.
- (1) The
non-sheathed portion 43 is covered by themeshed sheath member 44 so that heat of thecore wire 41 is released to the outside through the mesh. This improves heat dissipation of theelectric wires - (2) The
sheath member 44 is formed from a material having higher wear resistance than theinsulation sheath 42 to avoid tearing of thesheath member 44 even when thesheath member 44 contacts thebraided member 22 or theexterior member 24. This avoids exposure of thecore wire 41. - (3) The
sheath member 44, which is formed from braided reinforced fibers having higher shearing resistance than theinsulation sheath 42, avoids tearing in thesheath member 44. This avoids situations in which thecore wires 41 of thehigh voltage wires sheath members 44, directly contact each other or are short-circuited through other components or the like. - (4) The
sheath member 44 is meshed and is more flexible than a non-meshed structure. Thus, thesheath members 44 readily follow thebent portions sheath members 44 are located at thebent portions exterior member 24. Further, thebent portions sheath members 44 readily contact the braidedmembers 22 or theexterior members 24. Thus, as described above, it is preferred that thesheath members 44 be formed from a material having higher wear resistance than theinsulation sheath 42. - The above-described embodiment may be modified as follows.
- The above embodiment employs the braided
members 22 and theexterior member 24 as the exterior members of theelectric wires sheath members 44. However, this may be changed. For example, the braidedmembers 22 may be omitted if the electromagnetic shielding is not necessary. Further, theexterior members 24 may be omitted so that only the braidedmembers 22 are used. - Alternatively the
metal pipe 21 may be employed as an exterior member that is separate from the braidedmembers 22 and theexterior members 24. Further, thenon-sheathed portion 43 may be arranged on theelectric wires metal pipe 21 so that thesheath member 44 covers thecore wire 41 at positions corresponding to thenon-sheathed portion 43. In such a structure, thesheath member 44 may be in contact with themetal pipe 21. When thesheath member 44 is in contact with themetal pipe 21, heat can be released through themetal pipe 21. This improves heat dissipation. - As shown in
FIGS. 3A and 3B , thecore wire 41 at positions corresponding to thenon-sheathed portion 43 may be squeezed and flattened to include aflat portion 51. With this structure, the cross section of thecore wire 41 is changed, for example, from a substantially circular shape to a substantially elliptic shape thereby increasing the surface area. This improves the heat dissipation effect of thecore wire 41. Further, thecore wire 41 can readily be bent in a direction toward which amain surface 51 a of theflat portion 51 faces (direction orthogonal tomain surface 51 a) so that the formation of thebent portions bent portions - In the above embodiment, the
sheath member 44 is tubular but may have another shape. For example, a twisted tube including a slit extending in the longitudinal direction (longitudinal direction ofelectric wires 13 and 14) may be employed as thesheath member 44. The twisted tube is braided and thus meshed in the same manner as thesheath member 44 of the embodiment. When using such asheath member 44 including a slit, for example, the two ends of thesheath member 44 in the longitudinal direction of theelectric wires - In the above embodiment, portions of the
core wire 41 corresponding to thenon-sheathed portions 43 of thehigh voltage wires sheath member 44. However, the structure may be changed. A structure in which a single sheath member covers multiple core wires may be employed as long as the insulation between thecore wires 41 is maintained. One example of the above structure will be now described with reference toFIG. 4 . - As shown in
FIG. 4 , a sheet-like sheath member 55 may be wound around thecore wires 41 of theelectric wires FIG. 4 , thesheath member 55 is wound to have a substantially S-shaped cross section taken in the radial direction of thecore wires 41. Thesheath member 55 is located between thecore wires 41 of theelectric wires core wires 41. In this manner, asingle sheath member 55 can collectively cover thecore wires 41 of multipleelectric wires - In the above embodiment, each portion of the
core wire 41 corresponding to thenon-sheathed portion 43 of theelectric wires sheath member 44 Alternatively, only one of thecore wires 41 may be covered by thesheath member 44. - Although not particularly indicated in the above embodiment, any number of
non-sheathed portions 43 may be arranged on theelectric wires sheath members 44 may be used corresponding to thenon-sheathed portions 43 as long as the number is greater than or equal to one. For example, the arrangement of a plurality of thenon-sheathed portions 43 and thesheath members 44 that correspond to thenon-sheathed portions 43 improves the heat dissipation. Particularly, in a structure in which the exterior member is bent at multiple locations to form multiple bent portions, it is preferred that thenon-sheathed portion 43 and thesheath member 44 that correspond to thenon-sheathed portion 43 be arranged at each bent portion. - In the
wire harness 10 of the above embodiment, two electric wires, namely, thehigh voltage wires electromagnetic shield 15. However, the structure of the electric wires inserted through theelectromagnetic shield 15 may be changed in accordance with the vehicle structure. For example, a low voltage wire may be added and inserted through theelectromagnetic shield 15 to connect a low voltage battery and various types of low voltage devices (e.g., lamp, vehicle audio, or the like). - The positional relationship of the
high voltage battery 11 and theinverter 12 in the vehicle is not limited to the above embodiment and may be changed in accordance with the vehicle structure. Further, in the above embodiment, thehigh voltage battery 11 is connected to theinverter 12 with thehigh voltage wires voltage battery 11 may be connected to a high voltage device, which is not theinverter 12. - In the above embodiment, the present invention is applied to the
wire harness 10 that connects thehigh voltage battery 11 and theinverter 12. However, the present invention may also be applied to a wire harness that connects theinverter 12 and a wheel driving motor. - The above embodiment and the modifications may be combined.
- It should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the technical concepts of the invention. For example, components described in the embodiment (or one or more of its modifications) may be partially omitted or combined. The scope of the invention is intended to embrace all such alternatives, modifications, and variations, along with all equivalents thereof, within the scope of the claims.
- 10) wire harness; 13, 14) high voltage electric wire (electric wire); 21) metal pipe (exterior member); 21 b) bent portion; 22) braided member (exterior member); 24) exterior member; 31, 32) first and second exterior members (exterior member); 31 b, 32 b) bent portion, 41) core wire; 42) insulation sheath; 43) non-sheathed portion; 44) sheath member; 51) flat portion, 55) sheath member
Claims (6)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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JP2017-179024 | 2017-09-19 | ||
JP2017179024A JP6760234B2 (en) | 2017-09-19 | 2017-09-19 | Wire harness |
PCT/JP2018/032191 WO2019058921A1 (en) | 2017-09-19 | 2018-08-30 | Wire harness |
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US20200180526A1 true US20200180526A1 (en) | 2020-06-11 |
US10696247B1 US10696247B1 (en) | 2020-06-30 |
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US16/627,898 Active US10696247B1 (en) | 2017-09-19 | 2018-08-30 | Wire harness |
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US (1) | US10696247B1 (en) |
JP (1) | JP6760234B2 (en) |
CN (1) | CN110832605B (en) |
WO (1) | WO2019058921A1 (en) |
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JP3909763B2 (en) | 2002-11-20 | 2007-04-25 | 株式会社オートネットワーク技術研究所 | Vehicle conductive path with shield function |
WO2006118273A1 (en) * | 2005-04-28 | 2006-11-09 | Autonetworks Technologies, Ltd. | Electricity distribution body |
JP5089330B2 (en) * | 2007-10-18 | 2012-12-05 | 株式会社ビスキャス | Power cable connecting apparatus and method for configuring the same |
JP5320775B2 (en) * | 2007-10-23 | 2013-10-23 | 住友電気工業株式会社 | Thin coaxial cable harness |
CN101527189B (en) * | 2008-03-06 | 2013-11-06 | 住友电气工业株式会社 | Small diameter coaxial cable bunch and method for producing the same |
JP5458707B2 (en) * | 2009-07-08 | 2014-04-02 | 日立金属株式会社 | cable |
JP5434748B2 (en) * | 2009-12-24 | 2014-03-05 | 日立金属株式会社 | Conductive path for vehicles |
JP5884134B2 (en) * | 2011-11-25 | 2016-03-15 | 矢崎総業株式会社 | Manufacturing method of wire harness |
JP6002985B2 (en) * | 2011-12-27 | 2016-10-05 | 矢崎総業株式会社 | Intermediate member for wire harness and wire harness |
JP5920181B2 (en) * | 2012-11-15 | 2016-05-18 | 住友電装株式会社 | Wire harness and method for manufacturing wire harness |
JP2015076900A (en) * | 2013-10-04 | 2015-04-20 | 住友電装株式会社 | Shield pipe |
JP6295063B2 (en) * | 2013-11-08 | 2018-03-14 | 矢崎総業株式会社 | Coated wire and method of manufacturing covered wire |
JP2017099205A (en) * | 2015-11-27 | 2017-06-01 | 住友電装株式会社 | Wire sheathing material and wiring harness |
CN205376139U (en) * | 2015-12-25 | 2016-07-06 | 东莞市联思电子有限公司 | Carbon fiber woven mesh tube |
JP6555135B2 (en) * | 2016-01-12 | 2019-08-07 | 株式会社オートネットワーク技術研究所 | Wiring structure for vehicle and manufacturing method thereof |
CN206097959U (en) * | 2016-09-26 | 2017-04-12 | 南昌友星电子电器有限公司 | Easy radiating automobile high pressure pencil |
CN206460794U (en) * | 2017-03-06 | 2017-09-01 | 东莞市固尚电子科技有限公司 | A kind of fireproof wear-resisting weaves webmaster |
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JP6760234B2 (en) | 2020-09-23 |
US10696247B1 (en) | 2020-06-30 |
WO2019058921A1 (en) | 2019-03-28 |
JP2019053958A (en) | 2019-04-04 |
CN110832605B (en) | 2021-05-11 |
CN110832605A (en) | 2020-02-21 |
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