GB2191348A - Cable harness attaching unit - Google Patents

Abstract

An attaching unit (A) for installing a flat wire harness (W), composed of a plurality of wires united by synthetic resin insulation (2), has a clip section (4) and an attachment part (3). The attachment part (3) is made at least partly of a material capable of being fused to the insulation (2). The clip section (4) may be integral with or separate from the attachment part (3). Many embodiments of the invention are shown in the 64 figures of the clip section (4) and the attachment part (3). The attachment part may be in two pieces which fit around or through the harness. <IMAGE>

Description

SPECIFICATION Flat Wire Harness Attaching Unit The present invention relates to a flat wire harness attaching unit for fixedly attaching a flat wire harness formed by bundling a plurality of wires in a flat shape to the body of an automobile.

Referring to Figs. 1 and 2, a conventional flat wire harness attaching unit X having a plate memberb and a clip member c projecting from the plate member b is bound firmly by means of tapes dto one side of a flat wire harness W' formed by bundling a plurality of parallel wires a in a flat shape and adhesively joining the parallel wires a together.

Such a conventional wire harness attaching unit requires a troublesome taping process for binding the wire harness attaching unit to the flat wire harness and the binding effect of the tapes deteriorates due to the aging of the tapes.

Consequently, the flat wire harness attaching unit is unable to hold the flat wire harness in place and the flat wire harness is liable to be moved relative to the body of the automobile by vibrations.

It is therefore an object of the present invention to provide a flat harness attaching unit capable of being easily and firmly connected to a flat wire harness and securely and durably holding the flat wire harness in place.

In order to achieve the above object, there is provided in one aspect a flat wire harness attaching unit for installing a flat wire harness formed of a plurality of conductors covered with synthetic resin insulation, said plurality of wires being bundled and united into a flat integral structure having a first surface and a second surface by said synthetic resin insulation, said flat wire harness attaching unit comprising a clip section provided in association with a vehicle body side; and an attaching section made of a material capable of being made integral with said synthetic resin insulation through fusion on at least one of said first and second surfaces.

In another aspect, there is essentially provided a flat wire harness attaching unit for installing a flat wire harness formed of a plurality of conductors covered with synthetic resin insulation, said plurality of wires being bundled and united into a flat integral structure having a first surface and a second surface by said synthetic resin insulation, said flat wire harness attaching unit comprising a clip section provided in association with a vehicle body side; an attaching section formed integral with said clip section; and attaching section securing means made of a material capable of being made integral with said synthetic resin insulation of the flat wire harness through fusion and extending beyond the attaching section over at least one of said first and second surfaces of the flat wire harness and to be made integral with synthetic resin insulation through fusion.

In a further aspect, there is essentially provided a flat wire harness attaching unit for installing a flat wire harness formed of a plurality of conductors covered with synthetic resin insulation, said plurality of wires being bundled and united into a flat integral structure having a first surface and a second surface by said synthetic resin insulation, said flat wire harness attaching unit comprising a clip section provided in association with a vehicle body side; an attaching section formed separate from said clip section and having means for engaging said clip section; and attaching section securing means made of a material capable of being made integral with said synthetic resin insulation of the flat wire harness through fusion and extending beyond the attaching section over at least one of said first and second surfaces of the flat wire harness and to be made integral with synthetic resin insulation through fusion.

In the drawings:~ Fig. 1 is a perspective view of a conventional flat wire harness attaching unit which is united with a flat wire harness by means of tapes; Fig. 2 is a cross section of Fig. 1; Fig. 3 is a perspective view of one embodiment of the present invention; Fig. 4 is a cross section of Fig. 3; Fig. 5 is another embodiment of the present invention; Fig. 6 is a cross section of Fig. 5; Fig. 7 is a further embodiment of the present invention; Fig. 8 is a cross section of Fig. 7; Fig. 9 is a still further embodiment of the present invention; Fig. is a cross section of Fig. 9; Fig. 11 is a still further embodiment of the present invention; Fig. 12 is a cross section of Fig. 11;; Fig. 13 is a still further embodiment of the present invention; Fig. 14 is a cross section of Fig. 13; Fig. 15 is a still further embodiment of the present invention; Figs. 16 and 17 are cross sections of Fig. 15; Fig. 18 is a perspective view of another form of flat wire harness; Figs. 1 9A and 19B are perspective view of a still further embodiment of the present invention; Fig. 20 is a cross section of a still further embodiment of the present invention; Fig. 21 is a perspective view of a still further embodiment of the present invention; Fig. 22 is a cross section of Fig. 21; Fig. 23 is a cross section of a still further embodiment; Fig. 24 is a perspective view of a still further embodiment of the present invention;; Fig. 25 is a cross section of Fig. 24; Fig. 26 is an enlarged cross section of a laminated sheet used in the embodiment of Fig. 26; Fig. 27 is a cross section of a still further embodiment of the present invention; Fig. 28 is an enlarged cross section of a laminated sheet used in the embodiment of Fig. 27; Fig. 29 is a perspective view of a still further embodiment of the present invention; Fig. 30 is a cross section of Fig. 29; Fig. 31 is an enlarged cross section of a laminated sheet used in the embodiment of Fig. 30; Fig. 32 is a perspective view of a still further embodiment of the present invention; Fig. 33 is an enlarged cross section of Fig. 32;; Fig. 34 is a perspective view of a laminated sheet used in the embodiment of Fig. 33; Fig. 35 is a perspective view of a still further embodiment of the present invention; Fig. 36 is a cross section of Fig. 35; Fig. 37 is a cross section of a laminated sheet used in the embodiment of Fig. 35; Fig. 38 is a cross section of a still further embodiment of the present invention; Fig. 39 is a perspective view of a still further embodiment of the present invention; Fig. 40 is a cross section of the embodiment of Fig.

39; Fig. 41 is a cross section of a laminated sheet used in the embodiment of Fig. 39; Fig. 42 is a still further embodiment of the present invention; Fig. 43 is a cross section of Fig. 42; Fig. 44 is a perspective view of a still further embodiment of the present invention; Fig. 45 is a cross section of Fig. 44; Fig. 46 is an enlarged cross section of a laminated sheet used in the embodiment of Fig. 45; Figs. 47A and 47B are perspective views of laminated sheets which can be used in the embodiment of Fig. 45; Fig. 48 is a perspective view of a still further embodiment of the present invention; Fig. 49 is a cross section of the embodiment shown in Fig. 48;; Fig. 50 is an exploded views of the laminated sheet and the wire harness attaching unit; Fig. 51 is a perspective view of the laminated sheet and the wire harness attaching unit in the assembled state; Fig. 52 is a perspective view of a still further embodiment of the present invention; Fig. 53 is a cross section of the embodiment of Fig.

52; Fig. 54 is a perspective view of a laminated sheet used in the embodiment of Fig. 52; Fig. 55 is a perspective view of a still further embodiment of the present invention; Fig. 56 is a cross section of Fig. 55; Fig. 57 is a perspective view of a still further embodiment of the present invention; Figs. 58 and 59 are cross sections of the embodiment shown in Fig. 57; Figs. 60A and 60B are exploded views of the embodiment shown in Fig. 57; Fig. 61 is a perspective view of a still further embodiment of the present invention; Fig. 62 is a cross section of the embodiment shown in Fig. 61; Figs. 63A and 63B are exploded views of the above embodiment shown in Fig. 61; and Fig. 64 is a still further type of flat wire harness.

Referring to Figs. 3 and 4 showing a first embodiment of the present invention, a flat wire harness W is formed by arranging a plurality of parallel wires 1 in a flat state in synthetic resin layers 2. The insulating covering 1 b covering the conductor 1 a of each wire 1 is formed of polyvinyl chloride. The synthetic resin layers 2 also are formed of polyvinyl chloride. The wires 1 and the synthetic resin layers 2 are joined integrally through fusion.

The flat wire harness attaching unit A comprises a base plate 3 and a clip 4 projecting from the base plate 3, which are formed of polyvinyl chloride in an integral member. The attaching unit A is connected to the surface of the flat wire harness W by heat fusing a portion of the base plate 3 whereby the clip 4 is provided to be attached the vehicle body.

Referring to Figs. 5 and 6 showing a flat wire harness attaching unit, in another embodiment, according to this invention, a flat wire harness W is formed by binding a plurality of parallel wires in a flat arrangement between synthetic resin films 2.

The insulating covering 1 b of each wire 1 covering the conductor 1 a is formed of polyvinyl chloride and the synthetic resin films 2 are polyvinyl chloride films. The wires 1 and the synthetic resin films 2 are united together through fusion.

The attaching unit A of the flat wire harness attaching unit comprises a base member 3 provided with a clip member 4 projecting therefrom, holding members 6 extending below and along the opposite sides of the base member 3, and a connecting member 5 interconnecting the base member 3 and the holding member 6, which are formed in an integral member of polyvinyl chloride.

As illustrated in Figs. and 6, the attaching unit A receives the flat wire harness W so as to clamp the flat wire harness W between the base member 3 and the holding members 6. The base member 3 and the holding members 6, which are formed of polyvinyl chloride, are heated to unite the base member 3, the holding member 6 and the synthetic resin films 2 through fusion.

Referring to Figs. 7 and 8 showing a flat wire harness attaching unit, in a further embodiment, according to this invention, an attaching unit A comprises a base member 3 formed of polyvinyl chloride, a holding member 6 having a hinge section 7 joined to the base member 3, and a fastening member 8. In clamping a flat wire harness W, the flat wire harness W is held between the base member 3 and the holding member 6, then flanges 3b and 6b formed along the side edges of the base member 3 and the holding member 6 are inserted in the dovetail groove of the fastening member 8 to clamp the flat wire harness W between the base member 3 and the holding member 6, and then the attaching unit A is heated to unite the flat wire harness W and the attaching unit A by fusion.

Referring to Figs. 9 and 10 showing a still further embodiment of the present invention, a flat wire harness attaching unit A comprises a base plate 3 formed of polyvinyl chloride and a clip 4 formed of nylon. A dovetail groove 3a is formed in the upper surface of the base plate 3 and a detaining projection 3b is formed on the bottom surface of the dovetail groove 3a. The bottom surface of the pedestal 3' of the clip 4 is recessed partly to form a shoulder 3c. The base plate 3 is connected to the flat wire harness W by heating and fusing a portion thereof. The base plate 3 and the clip 4 are combined by inserting the pedestal 3' of the clip 6 into the dovetail groove 3a of the base plate 3 so that the shoulder 3c of the pedestal 3' engages with the detaining projection 3b of the base plate 3.In this embodiment, the clip 4 can be formed of a material having a high strength and the clip 4 is combined with the base plate 3 in mounting the flat wire harness Won the body of a vehicle. Therefore, only the base plate 3 needs to be attached to the flat wire harness W, which reduces the bulkiness of the flat wire harness and facilitates transportation and storage of the flat wire harness W.

Referring to Figs. 11 and 12 showing a still further embodiment of the present invention, a flat wire harness attaching gadget comprises an attaching unit C including a base plate 3 formed of polyvinyl chloride and an elastic gripping member 31 formed of polyvinyl chloride, which are formed in an integral member. The attaching unit A is connected to the flat wire harness W by heating and fusing a portion of the base plate 32 Referring to Figs. 13 and 14 showing a flat wire harness attaching unit, in a still further embodiment, according to this invention, the attaching unit A comprises a base member 3 provided with a clip member 4 projecting therefrom and formed of a synthetic resin having a comparatively high strength such as, for example, polyacetal or 6-nylon, and a separate holding member 6 formed of polyvinyl chloride.In clamping the flat wire harness W between the base member 3 and the holding member 6, the holding member 6 is placed on the backside of the flat wire harness W, and then the base member 3 is joined to the holding member 6 by combining channel sections 3a formed along the opposite side edges of the base member 3 and channel sections 6a formed along the opposite side edges of the holding member 6. Then, the holding member 6 is heated to unite the holding member 6 and the flat wire harness W through fusion.

Referring to Figs. 15 through 17, a flat wire harness attaching device of the invention includes an attaching section 3 and a clip section 4; said attaching section 3 is generally formed of an insulating synthetic resin and has therein a retaining member 31 and a base plate 33 on which said retaining member 31 is erected whereas said clip section 4 is again generally formed of an insulating synthetic resin and has therein a clip member 41, a base plate 42, a downward hook 41 and a shoulder 41d Said clip section 4 is used for engagement with a hole formed in a panel or the like of the vehicle body whereas the retaining member 31 of the attaching section 3 is designed to engage with the cylindrical body 41a- In attaching the flat wire clamping device to a flat wire harness W, the retaining member 31 is passed through a slit S formed in the flat wire harness W and is engaged with the clamping member 1 to hold the flat wire harness W between the attaching section 3 and clip section 4.

The clip member41 shown in Fig. 15 is formed so as to act as a catch for catching the retaining member 31 as well as a clip. That is, two holes 41b for receiving two hooks 32 formed by splitting the upper end of the retaining member 31 are formed diametrically at the upper end of the cylindrical body 41a of the clip member 41 which receives the retaining member 31 therein, and downward hooks 41 < each having a shoulder 41d are formed at the opposite ends of a diameter, which is perpendicular to the diameter on which the holes 41b are formed, on the outer surface of the cylindrical body 41aye The flat wire harness W shown in Fig. 15 is formed by connecting together a plurality of insulated wires arranged in parallel in the form of a flat member by dissolving the insulating coverings not shown by a solvent, by adhesively connecting the insulating coverings with an adhesive or by partly fusing the insulating coverings. The flat wire harness W may be formed by molding the flat arrangement of a plurality of parallel wires 1 such as, for example, conductive strips or conductive wires, in a resin 2 such as, for example as shown in Fig. 18, polyvinyl chloride or polyethylene. The slit S may be formed beforehand in a process of manufacturing the flat wire harness W or may be formed at a desired position in the flat wire harness W with a knife in attaching the clamping device to the flat wire harness W.

As illustrated in Fig. 15, in securing the flat wire harness attaching device of the present invention to a flat wire harness W, the hooks 32 provided on the retaining member 31 is passed through the slit S formed in the flat wire harness W and is inserted into the cylindrical body 41a of the clip member 41 while the retaining member 31 formed of synthetic resin insulation is made integral with the wires 1 covered with the synthetic resin insulation through fusion. Then, the two hooks 32 firmly engage with the holes 41b (Figs. 16 and 17).Thus, the attaching device can be attached very easily to the flat wire harness W and without curving the flat wire harness W and without requiring troublesome taping work.

The flat wire harness W thus attached with the attaching unit can readily be attached to the body of a vehicle by inserting the clip member 41 into a hole formed in the body.

Referring again to Figs. to 17, a clip member 4 provided on the base plate 43 acts as a member to engage with a retaining member 31 provided on the base plate 33 as well as a clip.

Figs. 19A and 19B illustrate flat wire harness clamping devices in a still further embodiments according to the present invention. Referring to Fig.

19A, a pair of retaining members 31 projects from a base plate 33. Another base plate 42 is provided with a clip member 41 and a pair of slots 42a for receiving the retaining members 31 therethrough. Referring to Fig. 19B, a base plate 43 is provided with a clip member 4 on one side thereof and a pair of retaining members 42b on the other side thereof. Another attaching member 31 is provided with a pair of slots 34for receiving the retaining members 42b therethrough. Both the flat wire harness clamping devices can easily clamp a flat wire harness between the attaching section 3 and clip section 4 by simply passing the retaining members 31 through slits formed in the flat wire harness and making the base plate 3 integral with the insulation coverings of the wires 1.

Referring to Fig. 20, a base plate 33 of the attaching section is formed of the same synthetic resin such as, for example, polyvinyl chloride or polyethylene, as that forming the insulating covering not shown of the insulated wires 1 of a flat wire harness W. The base plate 3 and the flat wire harness W are joined together by partly fusing or dissolving the base plate 3 and the insulating coverings or by an adhesive. To join the base plate 3 and the flate wire harness W together by partly fusing or dissolving the base plate 3 and the insulating coverings, the base plate 3 and the insulating coverings 1 are partly fused by heating or partly dissolved by spraying a solvent.It is preferable to provide an insulating sheet 2 formed of the same synthetic resin as that forming the base plate 3 and the insulating coverings between the base plate 3 and the flat wire harness W so that the thickness of the insulating coverings may not be reduced below an effective thickness. When the attaching member 31 is thus secured to the flat wire harness W, the junction of the attaching member and the flat wire harness W is reinforced, so that neither the flat wire harness is torn at the slit S by an external force exerted to the flat wire harness nor the flat wire harness W is dislocated.

Referring to Figs. 21 and 22 showing a still further embodiment of the present invention, a flat wire harness W is formed by binding a plurality of parallel wires 1 together in a flat shape with a synthetic resin layer 2. The insulating covering 1 b of each wire 1 is formed of polyvinyl chloride and the synthetic resin layer 2 is also formed of polyvinyl chloride. The synthetic resin layer 2 and the wires 1 are united together by fusing part of the synthetic resin layer 2 and part of the insulating coverings 1 b of the wires 1.

The flat wire harness attaching unit A including a base plate 3 and a clip member 4 projecting from the base plate 3, The base plate 3 is formed of polyvinyl chloride, while the clip member 4 is formed of a synthetic resin having a comparatively high strength such as, for example, polyacetal or 6-nylon.

The base plate 3 and the flip member 41 are united together by fitting the foot 43 of the clip member 4 in a recess 3d formed in the bottom surface of the base plate 3, and then fusing the foot 43 and the base plate 3 together by high frequency welding.

The attaching unit A is united with the synthetic resin layer 2, namely, polyvinyl chloride layer, by fusing part of the base plate 3.

Referring to Fig. 23 showing a still further embodiment of the present invention, the flat wire harness attaching unit A including a base plate 3 formed of polyvinyl chloride, and a clip member 4 formed of 6-nylon and having a foot 43 buried in the base plate 3. The attaching unit A is secured to the flat wire harness by fusing part of the base plate 3 in a manner similar to that implemented in the foregoing embodiments.

Referring to Figs. 24 and 25 showing a still further embodiment, a flat wire harness W is formed by binding a plurality of parallel wires 1 together in a flat shape with a synthetic resin layer 2. The insulating covering 1 b of each wire 1 is formed of polyvinyl chloride and the synthetic resin layer 2 is also formed of polyvinyl chloride. The synthetic resin layer 2 and the wires 1 are united together by fusing part of the synthetic resin layer 2 and part of the insulating coverings 1 b of the wires 1.

The flat wire harness attaching unit A including a base plate 3 and a clip member 4 projecting from the base plate 3, which are formed of a synthetic resin having a comparatively high strength such as, for example, polyacetal or 6-nylon, in an integral member.

A laminated sheet B is placed over the base plate 3 of the attaching unit A placed on one side of the flat wire harness W and is joined to the synthetic resin layer 2 by fusing part of the synthetic resin layer 2 and part thereof to secure the base plate 3 to the flat wire harness W. That is, the laminated sheet B is formed by laminating a synthetic resin film Q such as, for example, a polyacetal film or 6-nylon film having a comparatively high strength, and a polyvinyl chloride film P. An opening B1 through which the clip member 4 of the attaching unit A protrudes is formed in the central portion of the laminated sheet B.The laminated sheet B is placed over the synthetic resin layer 2, namely, the polyvinyl chloride layer 2, with the polyvinyl chloride film P in contact with the synthetic resin layer 2 so as to cover the base plate 3 of the attaching unit A, and then part of the synthetic resin film P and part of the synthetic resin layer 2 are fused to bind the laminated sheet B to the flat wire harness W, so that the attaching unit A is secured to the flat wire harness W (Fig. 26).

Referring to Fig. 27 showing a flat wire harness attaching gadget in a still further embodiment, the attaching unit A is the same as that of the previous embodiment. In this embodiment, a laminated sheet B has an upper layer formed of a polyvinyl chloride film P and a lower layer formed of a synthetic resin film Q. A further polyvinyl chloride film 2' extends from over the upper synthetic resin film P of the laminated sheet B to therearound. The laminated sheet B is placed on the flat wire harness W so as to cover the base plate 3 of the attaching unit A, and then the portion 2' of the polyvinyl chloride film P extending from over the synthetic resin film Q is fused to the synthetic resin layer 2 of the flat wire harness W, thus securing the attaching unit A to the wire harness.

Referring to Figs. 29 to 31 showing a flat wire harness attaching gadget, in a still further embodiment, an attaching unit A is the same as those of the foregoing embodiments. In this embodiment, the base plate 3 of the attaching unit A is sealed in beforehand between a polyvinyl chloride film C and a laminated sheet B. The assembly of the attaching unit A, the polyvinyl chloride film C and the laminated sheet B is placed on the flat wire harness W, and then the polyvinyl chloride film C and the polyvinyl chloride layer of the flat wire harness W are fused together to secure the attaching unit A to the flat wire harness W.

Referring to Figs. 32 and 33 showing a still further embodiment, an attaching unit of this embodiment is substantially the same as that of the foregoing embodiment shown in Figs. 24 and 25 except that through holes 3f are formed in the base plate 3 of the attaching unit. Part of the polyvinyl chloride layer 2 of the flat wire harness W corresponding to the through holes 3f are fused to the polyvinyl chloride film P of the laminated sheet B to reinforce the attachment of the attaching unit to the flat wire harness. Fig. 34 is a perspective view of the laminated sheet having the opening Br in the center thereof.

Referring to Figs. 35 and 36 showing a still further embodiment, a flat wire harness W is formed by binding a plurality of parallel wires 1 in a flat shape with a synthetic resin film 2. The insulating coverings ib covering the conductors 1 a of the wires 1 are formed of polyvinyl chloride and the synthetic resin film 2 is a polyvinyl chloride film. The wires 1 and the synthetic resin film 2 are united together by fusion.

An attaching unit A includes a plate-shaped base member 3 having a circular protrusion 35 and a clip member 4 projecting from the protrusion 35. The base member 3 is formed of a synthetic resin having a comparatively high strength such as polyacetal or 6-nylon.

The attaching unit A is secured to one side of the flat wire harness W by placing a laminated sheet B over the base member 3, and then joining the laminated sheet B to the synthetic resin film 2 forming the surface of the flat wire harness W by fusion.

As shown in Fig. 37, the laminated sheet B is formed by laminating a polyvinyl chloride film P and a synthetic resin film Q having a comparatively high strength such as a polyacetal film or a 6-nylon film.

The laminated sheet B is provided in the central portion thereof with a circular hole B' for receiving the circular protrusion 35 and the clip member 4 therethrough. The polyvinyl chloride film P is heated so that the laminated sheet B is joined to the flat wire harness W by fusion to secure the attaching unitAto the flat wire harness W.

Referring to Fig. 38 showing a manner of attaching the flat wire harness to the body of a vehicle with the flat wire harness attaching unit, when the clip member 4 is inserted in a hole C' formed in a steel plate C, the circular protrusion is brought into abutment with burrs C" projecting from the edge of the hole C', and hence the laminated sheet B is protected from being torn by the burrs C", which prevents the durability of the flat wire harness attaching unit from being deteriorated.

Referring to Figs. 39 and 40, a still further embodiment is shown, in which the flat wire harness is formed by binding a plurality of conductors 1 with synthetic resin insulation thereon and united into a flat structure by a layer 2 of the synthetic resin insulation. The insulation 1 b covering the conductors 1 a is formed of polyvinyl chloride as well as said layer 2 of the synthetic resin insulation such that they are fused into an integral continuum.

The attaching unit is composed of a planar base member 3 and a clip 4 erected thereon, both members being integrally formed of an identical synthetic resin material of comparative strength including polyacetal, 6-nylon etc. The attaching unit further includes a laminated sheet B extending over and beyond said base member 3 such that said laminated sheet B is fusion united with the polyvinyl chloride material on the flat wire harness.

More specifically, the laminated sheet B is composed of, as shown in Fig. 41, a polyvinyl chloride layer Panda layer Q of comparatively strong synthetic resin material including polyethylene, nylon, etc. Further as shown in Figs.

47A and 47B, said laminated sheet B is formed with a central opening B' for allowing extension of the clip 4 therethrough while slits or slots B" are formed therein on opposite sides of the central opening B' such that a pair of catch members 3g formed at opposite ends of the base member 3 are projected through said slits or slots B". In this way, the base member 3 with the clip 3 thereon is assembled the laminated sheet B in advance and then the polyvinyl chloride layer P of the laminated sheet B is fusion united to the polyvinyl chloride layer 2 of the flat wire harness W through heat application.

In the modification shown in Figs. 42 and 43, the base member 3 is formed with apertures therein, through which the polyvinyl chloride layer 2 of the wire harness and the polyvinyl chloride layer P of the laminated sheet are united as a result of fusion thereof, thus enhancing the attaching strength.

Figs. through 46 show a still further embodiment of the invention, in which a further polyvinyl chloride sheet C is provided immediately beneath the polyvinyl chloride layer P of the laminated sheet B. The base member 3 of the attaching unit is held between the elevated central portion of the laminated sheet B and the lower peripheral portion thereof, which is then fusion united with said polyvinyl chloride sheet C. The thus assembled members are placed to be fusion united with the polyvinyl chloride layer 2 of the flat wire harness.

Referring to Figs. 48 and 49 showing a flat wire harness attaching unit in a still further embodiment, a flat wire harness W is formed by binding a plurality of parallel wires 1 arranged in a flat shape with a synthetic resin film 2. The coverings 1 b covering the conductors 1 a of the wires 1 are formed of polyvinyl chloride and the synthetic resin film 2 is formed also of polyvinyl chloride. The wires 1 and the synthetic resin film 2 are united together by fusion.

An attaching unit A comprises a plate-shaped base member 3 and a clip member 4 projecting therefrom are formed of a synthetic resin having a comparatively high strength such as, for example, polyacetal or 6-nylon in a single member. Foldable cap members 3g are hinged to the opposite side edges of the base member 3 with hinge members 3h formed integrally with the base member 3, respectively. Projections 3i and recesses 3j, which mate with each other, are formed in the respective free ends of the cap members 39, respectively, to lock the cap members 39 in a closed position.

Recesses 3kforforming an opening for allowing the clip member 4 to protrude therethrough when the cap members 39 are closed are formed in the free ends of the cap members 3g, respectively.

The attaching unit is combined beforehand with a laminated sheet B. The laminated sheet B is formed by laminating a polyvinyl chloride film P and a synthetic resin film Q of a synthetic resin having a comparatively high strength such as, for example, polyethylene or nylon. The laminated sheet B is provided with an opening B' in the central portion thereof and slots B" near the opposite ends thereof.

As illustrated in Figs. 50 and 51, in combining the attaching unit and the laminated sheet B, the clip member 4 is passed through the opening B', the cap members 39 are passed through the slots B", and then the cap members 39 are folded over the laminated sheet B.

Then, the laminated sheet B is heated to fuse the polyvinyl chloride film P so that the laminated sheet B and the flat wire harness W are united together to secure the attaching unit A to the flat wire harness W.

Referring to Figs. 52 and 53 showing a flat wire harness attaching unit in a still further embodiment, the attaching unit A has a plate-shaped base member 3, which is similar to the base member of the embodiment shown in Figs. 48 and 49, provided with through holes 3f to allow portions of the polyvinyl chloride film 2 of the flat wire harness W corresponding to the through holes 3f and portions of the polyvinyl chloride film P of the laminated sheet B to be joined by fusion to enhance the strength of attachment of the attaching unit A to the flat wire harness W.

Referring to Figs. 55 and 56, a flat wire harness attaching gadget, in a still further embodiment, an attaching unit A includes a plate-shaped base member 3 integrally provided with foldable cap members 39 provided at the respective free ends with split clip members 3m which form a flip when joined together. A projection 3m and a recess 3n, which mate with each other, are formed in the opposite surfaces of the split clip members 31 to lock the split clip members 31 when the cap members 3g are closed.

A laminated sheet B is placed over the base members so as to extend across a direction in which the cap members 39 are turned for folding to secure the attaching unit A to the flat wire harness W by portions thereof extending from the side edges of the base member.

Referring to Figs. 57 through 60B, there is shown a still further embodiment of the present invention. A laminated sheet B which has a layer P of the same synthetic resin material as the insulation layer 2 of the flat wire harness is held between the base plate 43 having a clip 4' erected thereon and the attaching base plate 3 having a catch section 31. Due to adhesion of the laminated sheet B and the insulation layer 2, the attaching unit A is secured on one surface of the flat wire harness W.

As shown in Figs. 58 and 59, the wire harness W is composed of a plurality of conductor wires 1 arranged side by side and bound into a flat and integral structure by a synthetic resin insulation layer. The wires 1 are each composed of a conductor la and insulation covering 1 b of polyvinyl chloride.

Said insulation layer 2 is of the same material, that is, polyvinyl chloride or may be of a bonding agent, an adhesive sheet or the like.

The laminated sheet B is composed of a polyvinyl chloride layer and a synthetic resin of relatively high strength including polyester, polyamide resin (for example nylon) laminated thereon and is formed with a central opening B' therein. The base plate 3 has an area smaller than the laminated sheet B and is made of a synthetic resin of a relatively high strength such as polyacetal of 6-nylon to be integrally formed with a catch section 31. Said catch section has bifurcated claw 33.

The attaching plate 43 is made of a material which is the same as the base plate 3 and their size is substantially equal thereto. The clip 4' erected on the base plate 43 has a cylindrical body 41 and catch hole 43 at the upper end portions of side walls of said cylindrical body 41. Said catch section 31 is admitted into said cylindrical body 4, such that said bifurcated claw 32 is locked in said catch holes 43. On the other hand, the clip section 4 has a catch claw 4' having a shoulder section 44 at side walls provided perpendicular to said catch holes. Said catch claws 4' is designed to engage with a hole (not shown) formed in the vehicle body.

As shown in Figs. 60A and 60B, the central hole B' in the laminated sheet B receives the catch section 3, therethrough from the polyvinyl chloride layer side such that said catch section 3, is inserted into the cylindrical body 41a of the clip 4 with the result that the bifurcated claw 32 is locked into the catch holes 41b This completes the assembly of the base plate 3 and the attaching section 4 with the laminated sheet held therebetween to produce the attaching unit.

This attaching unit A is placed at a predetermined position on the insulation layer 2 of the flat wire harness W and when the laminated sheet B is heated, the polyvinyl chloride layer P thereof and the insulation layer 2 of the wire harness is fusion united with each other into an integral body. Said laminated sheet B is not susceptible to deformation or degradation due to heat fusion treatment because the polyvinyl chloride layer P thereof is reinforced by a heat resistive different kind of synthetic resin material layer Q.

Referring to Figs. 61 through 63B, there is shown a still further embodiment of the invention. In the figures, the base plate 3 is formed with catch section 39 of elongated hook shaped structure at opposite ends thereof while it is provided with a positioning pin 31 at a central portion thereof. The laminated sheet B is formed with slots B" for admitting catch section 39 therethrough besides said central opening B'. On the other hand, the base plate 43 is erected with a clip 41 having a rectangular hollow body having an engaging recess 41e at its lower end.

As in the foregoing embodiment, the bifurcated claw 4' has shoulder sections 41d In the present embodiment, the catch section 39 of the base plate 3 is admitted through the slots B" from below the laminated sheet B and when the attaching base plate 42 is pressed against with the positioning pin 31 and the engaging recess 41e in contact, the opposite ends of the base plate 42 come into engagement with the hook shaped catch section 39, thus assembling the attaching unit A.

Said attaching unit A is also fusion secured to the flat wire harness Was in the foregoing embodiment.

Referring to Fig. 64, there is shown another modification of the flat wire harness W, in which ribbon shaped conductors 1 are arranged side by side and integrally molded in insulation layer 2 of polyvinyl chloride into a flat structure. Said wire harness W is, unlike an ordinary insulated wire 1 as shown in Fig.1, arranged with a plurality of conductors 1 and secured side by side in a flat structure beforehand with the result that the aforementioned attaching unit is directly fusion secured thereto.

Needless to say, if the aforementioned insulation 1 b, the insulation layer 2 and the insulation layer 2' are of polyethylene or cross linked polyethylene, the polyvinyl chloride layer 3a of the laminated sheet B must be replaced with the polyethylene or cross linked polyethylene layer.

It is to be understood that the attaching unit of the present invention assures a firm attachment thereof to the flat wire harness and ensures that the flat wire harness is installed in the vehicle body providing vibration over the long period of service. Further, the securing work of the attaching unit to the flat wire harness can be changed from manual work to the automatic operation, thus improving the productivity.

Claims (25)

1.An attaching unitfora flat wire harness formed of a plurality of conductors bundled and united into a flat integral structure by means of a synthetic resin insulation providing a first surface and a second surface, the attaching unit comprising: a clip section for association with a vehicle body to attach the wire harness; and an attachment part having at least a portion made of a material capable of being integrated by fusion with the synthetic resin insulation on at least one of the first and second surfaces.

2. A unit according to claim 1, wherein the clip section and attachment part are formed integrally.

3. A unit according to claim 1 or claim 2, further including a holding section extending from the attachment part by way of a connecting member, so as to contact the second surface of the harness when the first surface is contacted by the attachment part.

4. A unit according to claim 1, wherein the clip section and attachment part are separate members having means for engagement with each other.

5. A unit according to claim 4, wherein the attachment part and the clip section are adapted to engage the flat wire harness from the first surface side and the second surface side respectively.

6. A unit according to claim 4 or claim 5, wherein the engagement means extends on both lateral sides of the clip section and the attachment part.

7. A unit according to claim 1, wherein the attachment part includes: an attaching section formed integrally with the clip section; and an attaching section securing means made of a material capable of being integrated with the synthetic resin insulation of the flat wire harness through fusion and extending in use beyond the attaching section over at least one of the first and second surfaces of the flat wire harness.

8. A unit according to claim 7, wherein the attaching section securing means includes a base plate to hold the attaching section in cooperation with the first surface of the flat wire harness.

9. A unit according to claim 7, wherein the attaching section securing means includes a base plate in which the attaching section is buried.

10. A unit according to claim 7, wherein the attaching section securing means includes a laminated sheet of a material capable of being integrated with the synthetic resin insulation of the flat wire harness through fusion and having an area largerthan the attaching section and being formed with a central opening through which the clip section extends.

11. A unit according to claim 10, wherein the attaching section is formed with vertical through holes.

12. A unit according to claim 10 or claim 11, wherein the attaching section is formed with a protrusion therein having a size small than the central opening of the laminated sheet and extending therethrough.

13. A unit according to any of claims 10 to 12, wherein the laminated sheet is formed with a pair of slit means one on each side of the opening, the attaching section having opposite ends thereof extend through the slit means.

14. A unit according to claim 13, wherein the attaching section has hinge sections at portions corresponding to the slit means such that the attaching section can bent and folded over the laminated sheet.

15. A unit according to claim 1, wherein the attachment part includes: an attaching section formed separately from the slip section and having means for engaging the clip section; and attaching section securing means made of a material capable of being integrated with the synthetic resin insulation of the flat wire harness through fusion and extending in use beyond the attaching section over at least one of the first and second surfaces of the flat wire harness.

16. A unit according to claim 15, wherein the attaching section securing means includes a laminated sheet having a synthetic resin layer thereon of a material capable of being fusion united to the insulation of the wires, the laminated sheet having an area larger than the attaching section and being formed with a central opening through which the clip section engaging means extends.

17. A according to claim 16, wherein the laminated sheet is formed with a pair of slit means one on each side of the central opening, the attaching section having opposite ends thereof extending through the slit means.

18. A unit according to claim 17, wherein the clip section has engaging means provided with a positioning pin extending through the central opening and a pair of catch sections at opposite ends thereof to extend through the slit means to be engaged with the clip section.

19. An attaching unit for a flat wire harness, substantially as described with reference to any of the examples described herein with reference to the accompanying drawings.

20. A flat wire harness provided with one or more attaching units according to any of claims 1 to 19, the or each unit being integrated by fusion into the synthetic resin of the harness.

21. A harness according to claim 20 when dependent on claim 10, wherein the synthetic resin insulation of the flat wire harness includes a first synthetic resin, the first synthetic resin insulation forming a first layer on the first surface of the harness, the laminated sheet being composed of layers of the first synthetic resin and a second synthetic resin laminated together, the layer of the first synthetic resin of the laminated sheet being opposed to the first layer of the first synthetic resin on the flat wire harness and united thereto through fusion.

22. A harness according to claim 20 when dependent on claim 10, wherein the synthetic resin insulation of the flat wire harness includes a first synthetic resin insulation forming a first layer on the first surface of the flat wire harness, the laminated sheet being composed of layers of the first synthetic resin and a second synthetic resin laminated together, the second synthetic resin layer of the laminated sheet being opposed to the first layer of the first synthetic resin on the first surface of the flat wire harness, the first surface of the flat wire harness having a second layer of the first synthetic resin over the first of the first synthetic resin, and the second layer of the first synthetic resin being opposed to the first synthetic resin layer of the laminated sheet and united thereto through fusion.

23. A harness according to claim 20 when dependent on claim 10, further including a further layer of the synthetic resin interposed between the laminated sheet and the flat wire harness such that the attaching section is fusion sealed between the laminated sheet and the further layer of the first synthetic resin.

24. A harness according to claim 20, when dependant on claim 5, wherein the wire harness is formed centrally with a slit, the chip of the attachment unit being passed through the slit and located on one side and the attachment part being located on the other side.

25. A method of attaching a flat wire harness to a vehicle using an attaching unit according to any of claims 1 to 19.