WO2024114311A1 - 一种分层布置的硬质化线束及车辆 - Google Patents

一种分层布置的硬质化线束及车辆 Download PDF

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Publication number
WO2024114311A1
WO2024114311A1 PCT/CN2023/130067 CN2023130067W WO2024114311A1 WO 2024114311 A1 WO2024114311 A1 WO 2024114311A1 CN 2023130067 W CN2023130067 W CN 2023130067W WO 2024114311 A1 WO2024114311 A1 WO 2024114311A1
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WO
WIPO (PCT)
Prior art keywords
flat
wiring harness
cable
fixing
cables
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.)
Ceased
Application number
PCT/CN2023/130067
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English (en)
French (fr)
Inventor
王超
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Changzhou Jetty Automotive Parts Corp
Original Assignee
Changzhou Jetty Automotive Parts Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Changzhou Jetty Automotive Parts Corp filed Critical Changzhou Jetty Automotive Parts Corp
Priority to EP23896463.9A priority Critical patent/EP4629265A4/en
Publication of WO2024114311A1 publication Critical patent/WO2024114311A1/zh
Priority to MX2025006167A priority patent/MX2025006167A/es
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • H01B7/08—Flat or ribbon cables
    • 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
    • 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
    • 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
    • H01B7/08—Flat or ribbon cables
    • H01B7/0861—Flat or ribbon cables comprising one or more screens
    • 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
    • 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
    • H01B7/40—Insulated conductors or cables characterised by their form with arrangements for facilitating mounting or securing

Definitions

  • the present application relates to the field of automobile design and manufacturing, and in particular to a layered hardened wiring harness and a vehicle.
  • the automotive wiring harness is the main network of the automotive circuit and is the blood vessels and nerves connecting the automotive electrical system. It must ensure both good transmission of electrical signals and the reliability of the connected circuits.
  • the purpose of the present application is to provide a layered hardened wiring harness and vehicle to solve the technical problems mentioned in the background technology.
  • a layered hardened wiring harness including a protective groove for accommodating the wiring harness, the wiring harness is at least partially arranged in the protective groove, and the wiring harness includes:
  • At least one flat wire and at least one flat cable containing a plurality of core wires, the flat cable and the flat wire are stacked and arranged in the protection groove.
  • the wiring harness further includes at least one functional cable, and the functional cable is distributed on top of the flat cable and the flat wire.
  • a protective cover is disposed on the top of the flat cable and the flat wire, and the functional cables are distributed on the top of the protective cover.
  • At least one cable fixing member for fixing a functional cable is fixedly disposed on the top of the protective cover.
  • the protective cover is an elastic hat-shaped structure, at both ends of the hat-shaped structure are correspondingly provided with at least one group of buckles, a slideway matching with at least one group of buckles is opened on the inner wall of the protective groove, and a slot matching with the buckle is provided at the end of the slideway, and the buckle on the protective cover slides into the protective groove along the slideway and is finally locked in the slot.
  • the width of the flat cable is smaller than the width of the flat wire, and the flat cable is located above the flat wire.
  • a protective cover is conformally disposed on top of the flat cables and flat wires.
  • the protection groove is composed of a plurality of shell units arranged in sequence, and each shell unit is provided with at least one connecting ear plate for fixing the shell unit.
  • both ends of each shell unit are respectively provided with mutually matching positioning notches and positioning convex edges, and adjacent shell units are spliced through the positioning notches and positioning convex edges.
  • the cross section of the housing unit is a U-shaped groove structure.
  • a plurality of housing units are arranged along the direction of the wiring harness, and a top cover is detachably fastened to the top of the housing unit.
  • a plurality of fixing holes are correspondingly provided on the flat cable and the flat wire, and a plurality of fixing parts for passing the fixing holes provided on the flat cable and the flat wire and for fixing the flat cable and the flat wire are provided on the inner side of the bottom of the protective groove, and the flat cable and the flat wire are fixed to the fixing parts through the fixing holes.
  • the fixing member includes a fixing portion connected to the inner wall of the housing unit and a connecting portion connected to the fixing portion;
  • the connecting part is a guide head which is integrally arranged with the fixing part, and a plurality of notches which penetrate through the side wall of the guide head are arranged in the circumferential direction.
  • the fixing portion is a columnar structure matching the shape of the fixing hole.
  • the fixing member further includes a crimping member having a crimping hole matched with the guide head.
  • a crimping member having a crimping hole matched with the guide head.
  • a buffer layer is provided between at least one of adjacent flat cables and flat wires, between flat wires and flat wires, between flat cables and flat cables, and between flat cables and crimping parts, and the buffer layer is provided with a through hole matching the fixing part.
  • the outer wall of the flat wire is covered with an insulating layer, and a shielding sleeve is provided on the outer side of the insulating layer.
  • the flat wire is a flat aluminum wire; and the flat cable is a FPC/FFC cable.
  • a vehicle of the present application includes the above-mentioned hardened wiring harness.
  • the present application stacks a flat wire for transmitting power signals and a flat cable for transmitting data signals in a protective groove.
  • the present application provides a protective cover on the top of the flat cable and the flat wire to prevent the functional cable from causing damage to the flat cable and the flat wire during assembly and use; and a buffer layer is provided between the adjacent flat cables and flat wires, between the flat wires and the flat wires, between the flat cables and the flat cables, and between the flat cables and the crimping parts, to further prevent the flat cables and the flat wires from being damaged when the crimping parts are installed, thereby ensuring the stability of signal transmission;
  • a plurality of fixing holes are correspondingly opened on the flat cable and the flat wire, and a fixing piece is provided on the inner side of the bottom of the protection groove for passing the fixing holes opened on the flat cable and the flat wire and for fixing the flat cable and the flat wire, and then the flat cable and the flat wire are fixed to the fixing piece through the fixing holes, and the functional cables are distributed on the top of the flat cable, so as to adapt to the automatic assembly of the wiring harness, and the production efficiency is greatly improved compared with the existing manual assembly;
  • the protective groove in the present application is used to protect and solidify the internal cables to achieve hardening of the wiring harness; moreover, the protective groove is composed of a plurality of shell units arranged in sequence, which can be spliced and arranged according to the direction and needs of the wiring harness, and has strong applicability and can be applied to most positions of the vehicle.
  • FIG1 is a schematic diagram of the structure of a layered hardened wiring harness provided by the present application.
  • FIG2 is a schematic diagram of the structure of the protective cover in the hardened wiring harness shown in FIG1 ;
  • FIG3 is a schematic diagram showing the distribution of slideways and slots on the guard groove
  • FIG4 is a schematic structural diagram of a single housing unit
  • FIG5 is a top view of a single housing unit
  • FIG6 is a schematic diagram of the splicing of adjacent housing units
  • FIG7 is a schematic diagram of the structure of a fixing member in the hardened wiring harness shown in FIG1 ;
  • FIG. 8 is a schematic diagram showing the distribution of fixing holes on a flat cable/flat conductor.
  • a layered hardened wiring harness includes a protective groove 10 for accommodating the wiring harness, the protective groove 10 is used to protect and solidify the internal cables to achieve hardening of the wiring harness; the wiring harness is at least partially arranged in the protective groove 10, and the wiring harness includes: at least one flat wire 70 for transmitting power signals and at least one flat cable 60 containing multiple core wires and used to transmit data signals, the flat cable 60 and the flat wire 70 are stacked in the protective groove 10, and the wiring harness also includes at least one functional cable 12 for transmitting special signals, and the functional cable 12 is distributed on the top of the flat cable 60 and the flat wire 70.
  • the present application adopts the flat wire 70 and the flat cable 60 to replace the existing power line and part of the data line, which can significantly reduce the diameter of the existing automotive wiring harness at the automotive trunk wiring harness, and can effectively reduce the volume and weight of the entire vehicle wiring harness.
  • the flat wire 70 is a flat aluminum wire
  • the flat cable 60 is an FPC/FFC cable, which can be an FPC cable.
  • an insulating layer (not shown in the figure) can be extruded and wrapped on the outer wall of the flat wire 70, and a shielding sleeve 701 is provided on the outer side of the insulating layer; it should be noted here that the flat aluminum wire itself is an existing technical solution in the field, which is to make the traditional wire into a flat sheet.
  • the present application can save energy compared with the round wire by fitting and fixing the flat aluminum wire used to transmit the power signal to the bottom of the protective groove 10.
  • the harness space of the protection groove 10 is increased, thereby reducing the volume of the entire harness.
  • the single-layer thickness of the FPC cable is only 0.2mm.
  • a 50mm wide FPC cable can pass through about 35 loops.
  • the FPC cable can be stacked in multiple layers. If used in a large range, it can further save the wiring harness layout space. According to statistics, compared with ordinary cables with the same loop, it can save 80% of the space and reduce 70% of the weight.
  • Functional cables 12 mainly include ordinary cables and HSD/FAKRA/Ethernet cables: ordinary cables mainly refer to twisted pair cables, shielded cables, some power cables and other loops that cannot be used with FPC cables; HSD/FAKRA/Ethernet cables mainly transmit differential signals, radio frequency signals, etc., and such signal loops cannot be replaced by FPC cables.
  • a protective cover 30 is provided on the top of the flat cable 60 and the flat conductor 70, and the functional cable 12 is distributed on the top of the protective cover 30.
  • the provision of the protective cover 30 can prevent the functional cable from causing damage to the flat cable 60 and the flat conductor 70 during assembly and use, thereby protecting both.
  • the protective cover 30 is an elastic cap-shaped structure, and at least one group of buckles 302 are correspondingly arranged at both ends of the cap-shaped structure.
  • a slideway 101 matching with at least one group of buckles 302 is opened on the inner wall of the protective groove 10, and a slot 102 matching with the buckle 302 is arranged at the end of the slideway 101. After the buckle 302 on the protective cover 30 slides into the protective groove 10 along the slideway 101, it is finally locked in the slot 102, thereby realizing the installation of the protective cover 30.
  • the width of the flat cable 60 is smaller than the width of the flat wire 70, and the flat cable 60 is located above the flat wire 70.
  • the protective cover 30 is arranged on the top of the flat cable 60 and the flat wire 70.
  • the shape of the protective cover 30 changes with the shape of the flat wire 70 and the flat cable 60, and is attached to the outside of the flat wire 70 and the flat cable 60. Firstly, the space inside the protective groove 10 is saved, so that more functional cables 12 can be accommodated; secondly, the stability is strong to prevent the protective cover 30 from shaking during the operation of the vehicle, thereby affecting the flat cable 60 and the flat wire 70 arranged inside it.
  • At least one cable fixing part 301 for fixing the functional cable 12 is provided on the top of the protective cover 30.
  • the cable fixing part 301 is generally a U-shaped buckle for facilitating the fixing and disassembly of the cable, and a plurality of the cable fixing parts 301 may be provided.
  • the functional cables 12 may be directly fixed by a plurality of buckles to prevent the functional cables 12 from swinging left and right in the protective groove 10.
  • the inner diameters of different buckles may also be different, thereby achieving the fixation of cables of different diameters.
  • a plurality of fixing holes 13 are correspondingly provided on the flat cable 60 and the flat wire 70, and a distribution diagram of the fixing holes 13 on the flat cable 60/flat wire 70 is shown in FIG8 , and different fixing holes 13 can be arranged at intervals and distributed on the same straight line; correspondingly, as shown in FIG1 and FIG8 , a plurality of fixing holes 13 provided on the bottom inner side of the protection groove 10 are provided, through which the fixing holes 13 provided on the flat cable 60 and the flat wire 70 pass, and the fixing member 40 for fixing the flat cable 60 and the flat wire 70 is provided, and the flat cable 60 and the flat wire 70 are fixed on the fixing member 40 through the fixing holes 13; at the same time,
  • the protective cover 30 and the protective groove 10 are installed by means of the mutually cooperating buckles 302 and the slideway 101, so that the hardened wiring harness of the present application can adapt to the automatic assembly of the wiring harness, and the production efficiency is greatly improved compared with the existing manual assembly.
  • the fixing member provided in this embodiment is shown in FIG. 7 , and specifically includes a fixing portion 401 connected to the inner wall of the housing unit 20 and a connecting portion 402 connected to the fixing portion 401 ;
  • the fixing portion 401 is a columnar structure matching the shape of the fixing hole 13, and the connecting portion 402 includes a guide head 4021 integrally provided with the fixing portion 401, and the two are mushroom-shaped as a whole, and a plurality of notches 4022 penetrating the side wall of the guide head 4021 are provided along the circumferential direction.
  • the fixing member 40 also includes a crimping member 403, and a crimping hole 4031 matching the guide head 4021 is provided on the crimping member 403. When the crimping hole 4031 of the crimping member 403 passes through the guide head 4021, the guide head 4021 is squeezed and the guide crimping member 403 is clamped inside the crimping hole 4031.
  • the inner diameter of the crimping hole 4031 should be set to be smaller than the maximum outer diameter of the guide head 4021 in the natural state, and larger than the maximum outer diameter of the guide head 4021 under the external force state.
  • the crimping part 403 is a disc-type structure with elasticity.
  • the crimping part 403 passes through the guide head 4021, it is necessary to continuously press the crimping part 403, and the crimping part 403 is slightly deformed along the axial direction, and finally stuck on the inner side of the guide head 4021.
  • the crimping part 403 abuts against the flat wire 70 and the flat cable 60 installed on the outside of the fixing part 401, thereby increasing the contact area between the crimping part 403 and the flat wire 70 and the flat cable 60, and improving the fixing effect.
  • the height of the fixing part 401 i.e., the columnar structure, should match the overall thickness of the flat aluminum wire and the FPC cable, so that the crimping part 403 abuts against the flat wire 70 and the flat cable 60 installed on the outside of the fixing part 401 after being installed.
  • At least one of the four adjacent flat cables 60 and flat wires 70, between flat wires 70 and flat wires 70, between flat cables 60 and flat cables 60, and between flat cables 60 and crimping parts 403 is provided with a buffer layer 80, and a through hole matching the fixing part 40 is provided on the buffer layer 80 (not shown in the figure).
  • the buffer layer 80 can be selected as a rubber pad, sponge, or other soft material that can be deformed when subjected to external force, and can be provided in all four. The provision of the buffer layer 80 can further prevent damage to the flat cable 60 and the flat wire 70 when the crimping part 403 is installed, thereby ensuring the stability of signal transmission.
  • the protection groove 10 is composed of a plurality of shell units 20 arranged in sequence, and a top cover 50 is detachably fastened to the top of the shell unit 20 to facilitate assembly and subsequent maintenance.
  • each housing unit 20 is provided with at least one connecting ear plate 11 for fixing the housing unit 20.
  • the connecting ear plate 11 is provided with a threaded hole and a screw is provided thereon. It is connected to the vehicle body through connectors. It should be noted that in order to achieve the best protection effect for the wiring harness, multiple housing units 20 can be continuously spliced. If the convenience and cost of maintenance are taken into consideration, they can also be discontinuously arranged to expose part of the wiring harness.
  • the shell unit 20 can be set as a deformable structure that can be bent along the shape of the vehicle shell and installed in matching the corresponding position of the vehicle shell. It has strong applicability and can be applied to most positions of the entire vehicle.
  • the cross-section of the shell unit 20 is a U-shaped groove structure, and each shell unit 20 is respectively provided with a positioning notch 201 and a positioning ridge 202 that cooperate with each other at both ends. Adjacent shell units 20 are spliced through the positioning notch 201 and the positioning ridge 202.
  • Figure 6 is a schematic diagram of the splicing of adjacent shell units; it should be noted here that the positioning notch 201 and the positioning ridge 202 are only used to achieve the purpose of splicing between adjacent shell units 20, and the specific fixation is still achieved by connecting the ear plate 11.
  • the housing units 20 are pre-assembled to form the protection groove 10, and then the fixing holes 13 are correspondingly opened on the flat wire 70 and the flat cable 60;
  • An automated device such as a robot is used to successively grab the flat wire 70, the flat cable 60 and the buffer layer 80 after the opening, and drive the flat wire 70 and the flat cable 60 to be pressed down and arranged outside the fixing part 401; then the crimping part 403 is grabbed to fix the flat wire 70 and the flat cable 60 together;
  • An automated device such as a robot is used to grab the protective cover 30, and the buckle 302 on the protective cover 30 is made to slide into the protective groove 10 along the slideway 101, and finally is locked in the locking groove 102;
  • An automated device such as a robot is used to grab the functional cable 12 and then put it into the protective groove 10.
  • the functional cable 12 is randomly distributed on the top of the protective cover 30 under the action of its own gravity;
  • the upper cover 50 is grasped by automated equipment such as a robot and fastened to the top of the housing unit 20 to complete the automated assembly of the hardened wiring harness.
  • the present application also provides a vehicle, which includes the above-mentioned hardened wiring harness.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Installation Of Indoor Wiring (AREA)
  • Insulated Conductors (AREA)

Abstract

本申请公开了一种分层布置的硬质化线束及车辆，本申请将用于传输电源信号的扁平导线以及用于传输数据信号的扁平线缆堆叠设置在护槽内，通过采用扁平导线和扁平线缆来代替现有的电源线及部分数据线，可明显降低现有汽车线束在汽车主干线束处的直径，并可有效的降低汽车线束的体积和重量；同时，本申请在扁平线缆和扁平导线的顶部设置有保护罩，并在相邻的扁平线缆与扁平导线之间、扁平导线与扁平导线之间、扁平线缆与扁平线缆之间以及扁平线缆与压接件之间四者中，至少一者设置有缓冲层，可防止功能线缆在装配及使用的过程中，对扁平线缆与扁平导线造成损坏，从而可确保信号的传输稳定性。

Description

一种分层布置的硬质化线束及车辆
相关申请
本申请要求于2022年11月28日递交的申请号为202211497186.7的中国专利申请的可以权，并引用上述专利申请公开的内容作为本申请的一部分。
技术领域
本申请涉及汽车设计和制造领域，尤其涉及一种分层布置的硬质化线束及车辆。
背景技术
汽车线束是汽车电路的网络主体，是连接汽车电气系统的血管和神经，它既要确保传送电信号良好，也要保证连接电路的可靠性。
目前，传统的汽车线束大多由一根一根的导线包扎到一起的，加上汽车导线的回路多，分支多，因此会存在线束杂乱、产品复杂的问题，而且重量大、成本高，随着汽车功能的日益复杂，汽车线束长度和重量进一步增加，尤其是在汽车主干线束处的直径会进一步加大，占用了大量的车内空间，同时，现有线束还有难以适应自动化装配的情况，在生产上大多通过人工来完成，因此还存在生产效率低下的问题。
发明内容
有鉴于此，本申请的目的是提供一种分层布置的硬质化线束及车辆，以解决背景技术中提到的技术问题。
为了达到上述目的，本申请所采用的技术方案是：一种分层布置的硬质化线束，包括用于容置线束的护槽，线束至少部分设置在护槽内，线束包括：
至少一个扁平导线以及至少一个包含多根芯线的扁平线缆，扁平线缆与扁平导线在护槽内堆叠设置。
在一些实施方式中，线束还包括至少一根功能线缆，且功能线缆分布在扁平线缆和扁平导线的顶部。
在一些实施方式中，扁平线缆和扁平导线的顶部设置有保护罩，功能线缆分布在保护罩的顶部。
在一些实施方式中，保护罩的顶部固定设置有至少一个用于固定功能线缆的线缆固定件。
在一些实施方式中，保护罩为具有弹性的帽型结构，帽型结构的两端对应设置有至少一组卡扣，护槽的内壁上开设有与的至少一组卡扣相配合的滑道，并在滑道的末端设置有与卡扣相匹配的卡槽，保护罩上的卡扣沿滑道滑入护槽后，最终卡设在卡槽内。
在一些实施方式中，扁平线缆的宽度小于扁平导线的宽度，且扁平线缆位于扁平导线的上方。
在一些实施方式中，保护罩随形设置在扁平线缆和扁平导线的顶部。
在一些实施方式中，护槽由多个依次设置的壳体单元组成，每一壳体单元上均设置有至少一个用于对其进行固定的连接耳板。
在一些实施方式中，每一壳体单元的两端分别设置有相互配合的定位缺口和定位凸沿，相邻壳体单元之间通过定位缺口和定位凸沿进行拼接。
在一些实施方式中，壳体单元的横截面为U型槽状结构。
在一些实施方式中，多个壳体单元沿线束的走向进行布置，且壳体单元的顶部可拆卸的扣合有上盖。
在一些实施方式中，扁平线缆和扁平导线上对应开设有多个固定孔，护槽的底部内侧设置有多个用于扁平线缆和扁平导线上开设的固定孔通过，并用于对扁平线缆和扁平导线进行固定的固定件，扁平线缆和扁平导线通过固定孔固定在固定件上。
在一些实施方式中，固定件包括与壳体单元内壁相连的固定部以及与固定部相连的连接部；
连接部为与固定部一体设置的引导头，引导头上沿周向开设有多个贯穿其侧壁的缺口。
在一些实施方式中，固定部为与固定孔的形状相匹配的柱形结构。
在一些实施方式中，固定件还包括压接件，压接件上开设有与引导头相匹配的压接孔，压接件的压接孔在通过引导头的过程中，引导头受挤压后引导压接件卡设在其内侧。
在一些实施方式中，相邻的扁平线缆与扁平导线之间、扁平导线与扁平导线之间、扁平线缆与扁平线缆之间，以及扁平线缆与压接件之间四者中至少一者设置有缓冲层，缓冲层上开设有与固定件相匹配的通孔。
在一些实施方式中，扁平导线的外壁上包覆有绝缘层，并在绝缘层的外侧套设有屏蔽套。
在一些实施方式中，扁平导线为扁平铝导线；扁平线缆为FPC/FFC线缆。
本申请的一种车辆，包括上述的硬质化线束。
与现有技术相比，本申请的有益效果是：
1、本申请将用于传输电源信号的扁平导线以及用于传输数据信号的扁平线缆堆叠设置在护槽内，通过采用扁平导线和扁平线缆来代替现有的电源线及部分数据线，可明显降低现有汽车线束在汽车主干线束处的直径，并可有效的降低汽车线束的体积和重量；
2、本申请在扁平线缆和扁平导线的顶部设置有保护罩，防止功能线缆在装配及使用的过程中，对扁平线缆与扁平导线造成损坏；并在相邻的扁平线缆与扁平导线之间、扁平导线与扁平导线之间、扁平线缆与扁平线缆之间以及扁平线缆与压接件之间四者中，至少一者设置有缓冲层，可进一步防止在压接件装入时，对扁平线缆与扁平导线造成损坏，从而可确保信号的传输稳定性；
3、本申请在扁平线缆和扁平导线上对应开设有多个固定孔，在护槽的底部内侧设置用于扁平线缆和扁平导线上开设的的固定孔通过并用于对扁平线缆和扁平导线进行固定的固定件，然后将扁平线缆和扁平导线通过固定孔固定在固定件上，功能线缆分布在扁平线缆的顶部，从而能够适应线束的自动化装配，相对于现有的人工装配，生产效率大大提高；
4、本申请中的护槽用来保护和固化内部线缆，以实现线束的硬质化；而且，护槽由多个依次设置的壳体单元组成，可根据线束的走向及需要进行拼接设置，适用性强，能够应用于整车的大部分位置。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本申请的实施例，并且连同其说明一起用于解释本申请的原理。
图1为本申请提供的分层布置的硬质化线束的结构示意图；
图2为图1所示硬质化线束中保护罩的结构示意图；
图3为滑道和卡槽在护槽上的分布示意图；
图4为单个壳体单元的结构示意图；
图5为单个壳体单元的俯视图；
图6为相邻壳体单元的拼接示意图；
图7为图1所示硬质化线束中固定件的结构示意图；
图8为固定孔在扁平线缆/扁平导线上的分布示意图。
图中标示如下：
10、护槽；11、连接耳板；12、功能线缆；13、固定孔；
101、滑道；102、卡槽；
20、壳体单元；201、定位缺口；202、定位凸沿；
30、保护罩；301、线缆固定件；302、卡扣；
40、固定件；401、固定部；402、连接部；4021、引导头；4022、缺口；403、压接件；
4031、压接孔；
50、上盖；
60、扁平线缆；
70、扁平导线；701、屏蔽套。
80、缓冲层。
具体实施方式
现在将参照附图来详细描述本申请的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本申请的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本申请及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
一种分层布置的硬质化线束，如图1所示，包括用于容置线束的护槽10，护槽10用来保护和固化内部线缆，以实现线束的硬质化；线束至少部分设置在护槽10内，线束包括：至少一个用于传输电源信号的扁平导线70以及至少一个包含多根芯线并用于传输数据信号的扁平线缆60，扁平线缆60与扁平导线70在护槽10内堆叠设置，线束还包括至少一根用于传输特殊信号的功能线缆12，且功能线缆12分布在扁平线缆60和扁平导线70的顶部。本申请通过采用扁平导线70和扁平线缆60来代替现有的电源线及部分数据线，可明显降低现有汽车线束在汽车主干线束处的直径，并可有效的降低整车线束的体积和重量。
在一实施方式中，扁平导线70为扁平铝导线，扁平线缆60为FPC/FFC线缆，可以为FPC线缆，为了防止扁平导线70的电磁信号对扁平线缆60内的信号产生干扰，可以在扁平导线70的外壁上挤塑包裹绝缘层(未在图中示出)，并在绝缘层的外侧套设有屏蔽套701；此处需要说明的是，扁平铝导线本身为本领域现有的技术方案，其为将传统导线做成扁平片状，本申请通过将用于传输电源信号的扁平铝导线贴合固定在护槽10的底部，与圆线相比可以节约 护槽10的线束空间，进而减少整个线束体积。
FPC线缆的单层厚度仅为0.2mm，同时，50mm宽度的FPC线缆约可以通过35根回路，与功能线缆12相比，可以大范围节约线束体积和重量，同时FPC线缆可以叠加多层，如大范围使用，可以进一步节约线束布置空间，据统计，与同等回路普通线缆相比，可以节约80％的空间，降低70％的重量。
功能线缆12主要包括普通线缆和HSD/FAKRA/以太网线缆：普通线缆主要是指双绞线、屏蔽线、部分电源线等FPC线缆无法使用的回路；HSD/FAKRA/以太网线主要是传输差分信号、射频信号等，此类信号回路同样无法使用FPC线缆替代。
在一实施方式中，如图1所示，扁平线缆60和扁平导线70的顶部设置有保护罩30，功能线缆12分布在保护罩30的顶部，保护罩30的设置，可防止功能线缆在装配及使用的过程中，对扁平线缆60与扁平导线70造成损坏，起到保护两者的作用。
进一步的，如图2和图3所示，保护罩30为具有弹性的帽型结构，帽型结构的两端对应设置有至少一组卡扣302，护槽10的内壁上开设有与至少一组卡扣302相配合的滑道101，并在滑道101的末端设置有与卡扣302相匹配的卡槽102，保护罩30上的卡扣302沿滑道101滑入护槽10后，最终卡设在卡槽102内，实现保护罩30的装入。
本实施例中，扁平线缆60的宽度小于扁平导线70的宽度，且扁平线缆60位于扁平导线70的上方，相对应的，保护罩30随形设置在扁平线缆60和扁平导线70的顶部，如图1所示，保护罩30的形状随扁平导线70和扁平线缆60的形状进行变化，并贴合在扁平导线70和扁平线缆60的外侧，其一，节省护槽10内部的空间，从而能够容纳更多的功能线缆12；其二，稳定性强，防止在车辆运行的过程中，保护罩30晃动，对设置在其内侧的扁平线缆60和扁平导线70造成影响。
在一实施方式中，如图2所示，保护罩30的顶部设置有至少一个用于固定功能线缆12的线缆固定件301，线缆固定件301一般为便于对线缆进行固定及拆卸的U型卡扣，并可以设置多个，当护槽10内所需固定的功能线缆较少时，可以直接通过多个卡扣进行固定即可，防止功能线缆12在护槽10内左右晃动，为了达到最佳的使用效果，不同卡扣的内径也可以不同，从而实现对不同直径线缆的固定。
在一实施方式中，扁平线缆60和扁平导线70上对应开设有多个固定孔13，固定孔13在扁平线缆60/扁平导线70上的分布示意图如图8所示，不同固定孔13之间可以间隔设置，并分布在同一条直线上；相对应的，如图1和图8所示，护槽10的底部内侧设置有多个从扁平线缆60和扁平导线70上开设的固定孔13通过，并用于对扁平线缆60和扁平导线70进行固定的固定件40，扁平线缆60和扁平导线70通过固定孔13固定在固定件40上；同时， 如前文所述，保护罩30与护槽10之间通过相互配合的卡扣302和滑道101来实现装入，从而本申请的硬质化线束能够适应线束的自动化装配，相对于现有的人工装配，生产效率大大提高。
本实施例中提供的固定件如图7所示，具体包括与壳体单元20内壁相连的固定部401以及与固定部401相连的连接部402；
固定部401为与固定孔13的形状相匹配的柱形结构，连接部402包括与固定部401一体设置的引导头4021，两者整体呈蘑菇状，引导头4021上沿周向开设有多个贯穿其侧壁的缺口4022。固定件40还包括压接件403，压接件403上开设有与引导头4021相匹配的压接孔4031，压接件403的压接孔4031在通过引导头4021的过程中，引导头4021受挤压后引导压接件403卡设在其内侧。
为了减小压接件403通过引导头4021过程中的阻力，将缺口4022设置有多个，但是为了保证引导头4021具有较好的强度，并具有很好的恢复能力，可以将缺口4022设置有两个，且两个缺口4022对称设置在引导头4021上。本领域技术人员应当知道，为了实现上述目的，压接孔4031的内径应当设置为：小于引导头4021在自然状态下的最大外径，并大于引导头4021在受外力状态下的最大外径。
此外，压接件403为具有弹性的盘式结构，压接件403在通过引导头4021的过程中，需要持续按压压接件403，压接件403沿轴向发生轻微的形变，并最终卡设在引导头4021的内侧，此时，压接件403与安装在固定部401外侧的扁平导线70和扁平线缆60抵接，从而可增大压接件403与扁平导线70和扁平线缆60的接触面积，提升固定效果。此处需要说明的是，固定部401即柱形结构的高度应与扁平铝导线以及FPC线缆的整体厚度相匹配，使得压接件403在装入后，与安装在固定部401外侧的扁平导线70和扁平线缆60抵接。
进一步的，相邻的扁平线缆60与扁平导线70之间、扁平导线70与扁平导线70之间、扁平线缆60与扁平线缆60之间，以及扁平线缆60与压接件403之间四者中至少一者设置有缓冲层80，缓冲层80上开设有与固定件40相匹配的通孔(为在图中示出)。缓冲层80可以选择为胶垫、海绵等在受外力时可发生形变并且柔软的材质，并可以在四者中全部设置，缓冲层80的设置，可进一步防止在压接件403装入时，对扁平线缆60与扁平导线70造成损坏，从而可确保信号的传输稳定性。
在一实施方式中，护槽10由多个依次设置的壳体单元20组成，壳体单元20的顶部可拆卸的扣合有上盖50，便于装配及后续检修。
图4和图5为单个壳体单元的结构示意图，如图4和图5所示，每一壳体单元20上均设置有至少一个用于对其进行固定的连接耳板11，连接耳板11上开设有螺纹孔，并通过螺丝 等连接件与车身相连，此处需要说明的是，为了达到对线束最佳的防护效果，多个壳体单元20之间可以连续为拼接设置，若考虑到检修的便捷性及成本问题，也可断续设置，使部分线束露出。
进一步的，多个壳体单元20沿线束的走向进行布置，本领域技术人员可根据线束的走向及需要进行拼接设置，为了达到最佳的使用效果，壳体单元20可以设置为能够随车壳形状弯曲，并与车壳相应位置匹配安装的可形变结构，适用性强，能够应用于整车的大部分位置。
如图1、图4所示，壳体单元20的横截面为U型槽状结构，每一壳体单元20的两端分别设置有相互配合的定位缺口201和定位凸沿202，相邻壳体单元20之间通过定位缺口201和定位凸沿202进行拼接，图6为相邻壳体单元的拼接示意图；此处需要说明的是，定位缺口201和定位凸沿202仅仅是用来实现相邻壳体单元20之间拼接的目的，具体固定，则还是通过连接耳板11来实现。
本申请的自动化装配过程如下：
根据线束的走向及需要，预先将壳体单元20拼接形成护槽10，然后在扁平导线70和扁平线缆60上对应开设固定孔13；
采用自动化设备如机械手先后抓取开孔后的扁平导线70、扁平线缆60及缓冲层80，并带动扁平导线70和扁平线缆60下压后设置在固定部401的外侧；然后抓取压接件403对扁平导线70和扁平线缆60共同进行固定；
采用自动化设备如机械手抓取保护罩30，并使得保护罩30上的卡扣302沿滑道101滑入护槽10后，最终卡设在卡槽102内；
采用自动化设备如机械手抓取功能线缆12，然后放入护槽10内，功能线缆12在自身重力的作用下随机分布在保护罩30的顶部；
采用自动化设备如机械手抓取上盖50，扣合在壳体单元20的顶部，即可完成硬质化线束的自动化装配。
本申请还提供一种车辆，其包括上述的硬质化线束。
虽然已经通过例子对本申请的一些特定实施例进行了详细说明，但是本领域的技术人员应该理解，以上例子仅是为了进行说明，而不是为了限制本申请的范围。本领域的技术人员应该理解，可在不脱离本申请的范围和精神的情况下，对以上实施例进行修改。本申请的范围由所附权利要求来限定。

Claims (19)

  1. 一种分层布置的硬质化线束，包括用于容置线束的护槽，所述线束至少部分设置在所述护槽内，其特征在于，所述线束包括：
    至少一个扁平导线以及至少一个包含多根芯线的扁平线缆，扁平线缆与扁平导线在护槽内堆叠设置。
  2. 根据权利要求1所述的一种分层布置的硬质化线束，其特征在于：所述线束还包括至少一根功能线缆，且功能线缆分布在扁平线缆和扁平导线的顶部。
  3. 根据权利要求2所述的一种分层布置的硬质化线束，其特征在于：所述扁平线缆和扁平导线的顶部设置有保护罩，功能线缆分布在所述保护罩的顶部。
  4. 根据权利要求3所述的一种分层布置的硬质化线束，其特征在于：所述保护罩的顶部固定设置有至少一个用于固定功能线缆的线缆固定件。
  5. 根据权利要求3所述的一种分层布置的硬质化线束，其特征在于：所述保护罩为具有弹性的帽型结构，帽型结构的两端对应设置有至少一组卡扣，所述护槽的内壁上开设有与所述的至少一组卡扣相配合的滑道，并在滑道的末端设置有与所述卡扣相匹配的卡槽，所述保护罩上的卡扣沿滑道滑入护槽后，最终卡设在卡槽内。
  6. 根据权利要求5所述的一种分层布置的硬质化线束，其特征在于：所述扁平线缆的宽度小于扁平导线的宽度，且扁平线缆位于扁平导线的上方。
  7. 根据权利要求6所述的一种分层布置的硬质化线束，其特征在于：所述保护罩随形设置在所述扁平线缆和扁平导线的顶部。
  8. 根据权利要求1所述的一种分层布置的硬质化线束，其特征在于：所述护槽由多个依次设置的壳体单元组成，每一壳体单元上均设置有至少一个用于对其进行固定的连接耳板。
  9. 根据权利要求8所述的一种分层布置的硬质化线束，其特征在于：每一壳体单元的两端分别设置有相互配合的定位缺口和定位凸沿，相邻壳体单元之间通过定位缺口和定位凸沿进行拼接。
  10. 根据权利要求8所述的一种分层布置的硬质化线束，其特征在于：所述壳体单元的横截面为U型槽状结构。
  11. 根据权利要求8所述的一种分层布置的硬质化线束，其特征在于：多个所述壳体单元沿所述线束的走向进行布置，且壳体单元的顶部可拆卸的扣合有上盖。
  12. 根据权利要求1所述的一种分层布置的硬质化线束，其特征在于：所述扁平线缆和扁平导线上对应开设有多个固定孔，所述护槽的底部内侧设置有多个用于所述扁平线缆和扁平导线上开设的固定孔通过，并用于对扁平线缆和扁平导线进行固定的固定件，所述扁平线 缆和扁平导线通过固定孔固定在固定件上。
  13. 根据权利要求12所述的一种分层布置的硬质化线束，其特征在于：所述固定件包括与壳体单元内壁相连的固定部以及与固定部相连的连接部；
    所述连接部为与所述固定部一体设置的引导头，所述引导头上沿周向开设有多个贯穿其侧壁的缺口。
  14. 根据权利要求13所述的一种分层布置的硬质化线束，其特征在于：所述固定部为与所述固定孔的形状相匹配的柱形结构。
  15. 根据权利要求13所述的一种分层布置的硬质化线束，其特征在于：所述固定件还包括压接件，所述压接件上开设有与所述引导头相匹配的压接孔，所述压接件的压接孔在通过引导头的过程中，引导头受挤压后引导压接件卡设在其内侧。
  16. 根据权利要求15所述的一种分层布置的硬质化线束，其特征在于：相邻的扁平线缆与扁平导线之间、扁平导线与扁平导线之间、扁平线缆与扁平线缆之间，以及扁平线缆与压接件之间四者中至少一者设置有缓冲层，所述缓冲层上开设有与所述固定件相匹配的通孔。
  17. 根据权利要求1所述的一种分层布置的硬质化线束，其特征在于：所述扁平导线的外壁上包覆有绝缘层，并在绝缘层的外侧套设有屏蔽套。
  18. 根据权利要求1所述的一种分层布置的硬质化线束，其特征在于：所述扁平导线为扁平铝导线；所述扁平线缆为FPC/FFC线缆。
  19. 一种车辆，其特征在于：包括权利要求1-18任一项所述的硬质化线束。
PCT/CN2023/130067 2022-11-28 2023-11-07 一种分层布置的硬质化线束及车辆 Ceased WO2024114311A1 (zh)

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