JP2000090746A - Wiring assembly - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wiring assembly eliminating wiring errors due to wiring hooks without decreasing the degree of freedom of wiring and facilitating manufacture. SOLUTION: A constitution is related to a wiring assembly including a foam body sheet 11 where a series of wires 14 are fixed along the foam body sheet 11. The wires 14 have electrical connectors 18 fixed on both ends for electrical connection. Foam body belts 20 are fixed on the wires 14, and fix and protect the wires 14 along the foam body sheet 11. Another constitution is also related to the wiring assembly including the foam body sheet 11 where the series of the wires 14 are fixed along the foam body sheet 11. The wires 14 have electrical connectors 18 fixed on both ends for electrical connection. The foam body sheet 11 has at least multiple holes arranged near the electrical connectors 18 to pass the electrical connectors 18 from one side of the foam body sheet 11 to the other side of the foam body sheet 11.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a wiring assembly.

[0002]

2. Description of the Related Art A wiring harness is typically fixed to an automobile using individual wiring hooks for the harness. The wiring hook secures the wire at the proper place in the car. In this step, it is necessary for the operator to fix the correct electric wire at a correct position in the automobile, and the operator is liable to be mistaken in that the electric wire is arranged in a wrong place. Also, this step is very time consuming. Since these wiring harnesses are typically flexible and easily entangled,
Difficult to handle.

JP-A-63-46945 (Japanese Patent Application No. 61-46945)
Japanese Patent No. 189632) discloses an automotive wiring device having an electrical wiring conductor that is directly and quickly disposed on a main body part of an automobile. The body part is made of an electrically insulating material. The electrical conductor terminates in a vehicle body part, such as a vehicle frame, more specifically, a contact element that protrudes into the edge of an access opening formed in the insulating material of the door frame.

[0004]

However, in this wiring apparatus for automobiles, since the wiring work of the wiring harness on the assembly line becomes unnecessary, there is no problem of erroneous wiring.
Although the automation and weight reduction of the wiring can be realized, there is a problem that since the wiring is fixed, there is no flexibility in wiring, and it is difficult to respond to wiring change.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a wiring assembly which is easy to manufacture without erroneous wiring caused by wiring hooks without reducing the degree of freedom of wiring.

[0006]

SUMMARY OF THE INVENTION The present invention relates to a wiring assembly comprising a flexible sheet having a series of conductors fixed along the flexible sheet. The conductor has electrical connectors secured at its ends to provide electrical connection. A second flexible sheet is secured over the conductor and secures and protects the conductor along the flexible sheet.

[0007] The invention further relates to a wiring assembly comprising a foam sheet having a series of conductors secured along the foam sheet. The conductor has electrical connectors secured at its ends to provide electrical connection. The foam sheet has holes located near at least some of the electrical connectors so that the connector can be inserted from one side of the foam sheet to the opposite side.

[0008] The present invention also relates to a wiring assembly including the foam sheet in which a series of conductors are fixed along the foam sheet. The conductor is used to provide an electrical connection
It has electrical connectors fixed at both ends. A band of foam is secured over the conductor to secure and protect the conductor along the foam sheet. The foam sheet has holes located near at least some of the electrical connectors so that the connector can be inserted from one side of the foam sheet to the opposite side.

Further, the present invention relates to a wiring assembly having a rigid panel having a series of grooves extending along the rigid panel. A series of conductors are arranged in the groove. The conductor is terminated to the electrical connector at a specific location along the rigid panel. The foam cover is secured over the rigid panel and the groove and secures the conductor in the groove.

[0010]

Preferred embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG.
1 is a plan view showing a wiring assembly of the present invention. FIG.
It is a perspective view which shows the wiring assembly except the band of the foam. FIG. 3 is a perspective view of another embodiment of the present invention. FIG.
It is an exploded perspective view of another embodiment of the present invention.

FIG. 1 shows a wiring assembly for use in an automobile door, ie, a pre-assembled wiring harness. It will be appreciated that the invention may be used to form other specific devices used in other applications. The assembly may also be used for a rear gate with, for example, a headliner, seat, center console, trunk liner, rear dash deck, or many other applications.

FIG. 1 shows a wiring assembly 10 previously arranged on a foam sheet 11. FIG. 2 shows a similar wiring assembly 10 without the foam band 20. Wiring assembly 10
Comprises a multiplexing module 12 which is the main input into this assembly 10. The multiplexing module 12 can be an intelligent box that processes signals in addition to distributing signals. The multiplexing module 12 may also be another connector or a series of connectors that provide connection points from automotive wiring to door wiring.

Extending from the multiplex module 12 is a series of wires 14. These wires 14 extend in different directions to provide signals and power to other areas of the door. Although these wires 14 are shown as conventional distribution wires, the wiring may be performed by ribbon cables or other types of electrical distribution systems.

The electrical wires 14 are distributed in a path from the multiplex module to the individual areas 16 requiring electrical connection. These areas 16 cover the entire door frame
It is located anywhere needed for signal or power use, for example, near a switch near a door or near a motor for a power window.

Both ends of each wire 14 are terminated to an electrical connector 18. The electrical connector 18 can be any type of connector suitable for components in a particular area 16. Some of these connectors may be blind mating connectors to facilitate mating with a mating connector.

The foam sheet 11 has a hole 15 in an area 16 of the assembly 10. The hole 15 allows the electrical connector 18 to be connected to the mating connector on the opposite side of the foam sheet 11. Thereby, the assembly 10 can electrically connect the components located on both side surfaces of the foam sheet 11. Only those connectors 18 that need to be connected to a mating connector on the opposite side of the foam sheet 11 require holes 15 formed through the foam sheet. However, holes can be formed at all electrical connector 18 locations to increase the flexibility of the assembly 10.

The electric wires 14 may be terminated to a self-aligned connector. The self-aligning connector has a flange large enough to cover the hole. This connector may be fixed to the foam sheet 11 by having a flange fixed around the opening. For this reason,
The flange provides a barrier to moisture passing through the hole 15. Additionally, additional foam may be secured over the connector and aperture 15 to form a better barrier.

The wires 14 are laid out on the surface of the foam sheet 11 to hold all of the wires 14, the multiplex module 12 and the connector 18 in place in the assembly 10. The electric wire 14 is first fixed to the foam sheet 11 by an adhesive (not shown). The adhesive may be a type that is directly applied to the surface of the foam sheet 11, or may be another type such as a double-sided adhesive tape.

The wires 14 are first secured to the surface of the foam sheet 11 and then covered with a second foam layer 20. The second foam layer 20 is used to cover most of the electric wires 14 along the surface of the foam sheet 11. Second foam layer 2
0 may have a sticky back surface that adheres the foam layer 20 to the front surface of the foam sheet 11 and to the electrical wires 14, or the adhesive may be applied to the second foam layer 20 Body layer 20
May be fixed to the electric wire 14 and the foam sheet 11. Further, the second foam layer 20 may be fixed to the foam sheet by heat caulking or welding the foam and the foam layer.

Foam sheet 11 and second foam layer 20
May be a closed cell polyethylene or other type of foam. The foam is so flexible that it does not rub against the part and cause rattling or fricative noise in the door or end use. Further, it is desirable that the foam has water resistance and can be formed into an appropriate shape required for a final use state. The foam must also comply with environmental requirements, especially in motor vehicle doors, and must be able to be used within the intended temperature range of use in the door. The second foam layer 20 is preferably made of the same material as the foam sheet 11,
It may be manufactured from a second material that is compatible with the composition of the foam sheet 11 and has equivalent or similar properties.

Although the foam sheet 11 is shown as a flat sheet, the foam sheet may have a foam sheet formed into a particular shape to suit a particular use. For example, foam sheet 11 may be shaped to conform to the contour of a door or seat. Further, the second foam layer 20 may also be formed in a specific specific shape. Further, the foam sheet 11 may be formed with a groove for receiving the electric wire. The second foam layer 20 may have a complementary groove received on the wire.

Once the wiring 14 is arranged at an appropriate position on the surface of the foam sheet 11, the second foam layer 20 is
Once secured on the assembly 4, the assembly 10 is ready for assembly into the door panel of the vehicle. Once the assembly 10 is assembled and once the assembly 10 is secured to the door panel, all electrical connectors 18 are in place and connected to provide signals and power to components within the door panel. 18 are secured in their appropriate locations.

Alternatively, the foam sheet 11 and the wiring 14
May be mounted directly to the structure of the vehicle, for example a door structure. The foam sheet may be secured using an adhesive bead.

The individual holes 1 serve as a barrier to water.
Additional flaps of foam may be placed on 5. Alternatively, the foam sheet 11 may be used as a barrier to water.
May be fitted with one large flap. These flaps are dropped into place after assembly of the foam sheet and wiring. As a result, once the foam sheet 11 is placed in the end-use product, the flap becomes a barrier to water.

An advantage of embodiments of the present invention is that the wiring assembly 1
It is very easy to install the 0 in a door panel or end use product, and it is very easy to connect the correct electrical connector 18 to the mating connector in the door frame. Further, the foam sheet 11 and the second foam layer 20 maintain the position of the wiring during use of the automobile. This prevents the wires 14 and the electrical connector 18 from rattling in the door during use of the vehicle. The foam sheet 11 and the second foam layer 20 do not generate noise when rubbing with other components in the door frame. Additionally, an alignment mechanism may be incorporated into the foam sheet to minimize lateral movement within the door frame. The alignment mechanism can also assist in incorporating the foam sheet 11 into an automobile. Another advantage is that there is no need to use separate wiring hooks to secure the assembly in the door frame. All the wires are fixed simultaneously on the foam sheet 11 in the door.

FIG. 3 shows another embodiment of the present invention. FIG. 3 shows a panel 100 comprising a rigid plastic panel 102 as a component. The plastic panel 102
It has a flexible foam cover 104 disposed thereon. FIG. 3 shows the opposite side of the plastic panel 102. The rigid plastic panel 102 has grooves 110 extending along it and opening only on one side.
Having the following sequence: The side opposite the one faces the drawing. Also, the solid plastic panel 102
It has a private chamber 112 molded therein. Also, the rigid plastic panel 102 may be designed with multiple compartments depending on which components need to be attached to the panel. The compartment is designed to hold the multiplex module 114 and other components such as switches, motors and other devices that may be used in the door. The compartment 112 may be a recess in which the module is received, or an opening 116 having a series of straps 118 shaped to accommodate the module 114. The particular arrangement of the private room 112 depends on the end use of the private room 112.

The panel 100 has an assembly of electric wires 120 assembled along the groove 110. Wires 120 are terminated to electrical connectors 122 at predetermined locations to provide signals or power to different components within the door. Some wires 120 are connected to openings 1 in rigid plastic panel 102.
It extends through 24. As a result, the electrical connector 122
Are accessible on both sides of panel 100.

FIG. 4 shows the electric wire 120 and the electric connector 12.
FIG. 2 is an exploded perspective view of a wiring assembly 130, a rigid plastic panel 102, and a foam cover 104 made of two.
Since the wires 120 are incorporated into the multiplex module 114, all assemblies are mounted on the rigid plastic panel 102 with the electrical connectors in place.

Next, the foam cover 104 is fixed on the wiring assembly 130 with some kind of adhesive or adhesive tape. Alternatively, the foam cover 104 is fixed on the wires by heat swaging or welding the foam cover to the rigid plastic panel 102. The foam cover 104 has an opening 132 through which any electrical connector 122 passes and an opening 134 through which other modules, such as the multiplex module 114, pass. The foam cover 104 also has a shaped area 136 designed to be received around a portion of the door. The entire rigid plastic panel 102 may be shaped. The rigid plastic panel 102 may have openings for components or wiring. The foam cover 104 may be formed by encapsulating components in addition to the wiring assembly 130.

One embodiment of the present invention is an integral unit formed around a rigid or semi-rigid resin-based panel or substrate. The panel is formed to have a suitable shape to conform to the structural components of the vehicle and to allow all components mounted on the panel to conform. For example, the panels can be formed in any suitable shape that is received within the door structure.

Alternatively, the integral unit may be formed around a rigid or semi-rigid resin-based panel or substrate. The panel should have the appropriate shape to conform to components such as door interior panels, headliners, set liners or other automotive components, and all components attached to the panel should be conformable. It is formed. Each of these arrangements has the appropriate wiring for the component to which the wiring is to be attached. For example, a panel received in a seat may have wiring for a seat motor, heater or speaker.

The panel also has the required mounting mechanisms to mount it to the structural members of the vehicle and to enable the mounting of all components mounted to the panel. In some cases, a separate container for components for the electronic circuit is not required. The parts are designed to receive items such as multiple electronics, electrical connectors such as blind-fit connectors and crimp connectors, motors, door lock mechanisms, snap-in switches, lighting fixtures or other suitable items. Including, but not limited to, mounting hardware.

The panels may be reinforced with metal structures, fiber reinforced plastics or other material components that support the structural load. The panels enhance mounting and provide a level of impact protection when incorporated into certain areas of the vehicle. These structures can be incorporated during the manufacture of the panel, or they can be attached to the panel as separate components.

In some circumstances, it may be necessary to waterproof. In such an environment, the sealing bea
A peripheral groove or gasket for d) may be provided. If a seal is incorporated, the panel can act as a barrier to water. The panel is provided with grooves for routing all necessary conductors.

The conductor attached to the panel comprises a standard circular wire, ribbon cable, flat flexible conductor, flat cable, or etched flat cable. Also, other types of conductors can be used. Further, the panel may be shaped to accommodate an optical fiber.

Incorporating multiple electronics integrated into a single location facilitates point-to-point cabling. Point-to-point wiring assemblies can be designed for automated assembly and handling. The foam layer is attached to the panel to capture the conductor. This foam also reduces external sound noise and prevents rattling of the wiring and attached parts.

One of the advantages of the illustrated embodiment is that the panel provides one of the wiring management methods since the wiring is part of the panel. The present invention facilitates the handling of wiring,
The purpose of the present invention is to provide wiring flexibility for each structural element or structural component and to provide a medium on which the described information is carried. The panels can be equipped with conventional circular wires or different types of wiring for flat flexible or ribbon cables.

A further advantage is that the panel is easy to assemble into doors or other structural elements or components. The panels also provide a barrier to dry humidity and sound reduction. Even if it is an individual small part or even if it replaces the whole panel, it can be easily repaired. The foam cover may be cut into small parts so that repairs can be made to certain areas. In this case, a small portion of the foam cover may be located above the repair area.

The wiring assembly and many of the attendant advantages of the present invention will be understood from the foregoing description. Obviously, various modifications in shape, structure, and arrangement of parts are possible without departing from the spirit or scope of the invention or sacrificing all material advantages.

[0040]

According to the wiring assembly according to the first aspect, the flexible sheet having a series of conductors fixed along the flexible sheet, and electrical connectors at both ends to provide an electrical connection. And the second flexible sheet fixed on the conductor and fixing and protecting the conductor along the flexible sheet. Therefore, there is an advantage that a wiring assembly which does not require wiring hooks and is easy to manufacture without lowering the degree of freedom of the conductor wiring can be obtained. In addition, since the conductor is fixed and protected by the second flexible sheet, there is also an advantage that the position of the conductor is reliably maintained and the rattle of the conductor does not occur.

According to the wiring assembly according to the second aspect, the foam sheet having a series of conductors fixed along the foam sheet, and electrical connectors at both ends to provide an electrical connection. Wherein the foam sheet has at least some holes arranged near the electrical connector, and is opposed from one side of the foam sheet through the holes. Characterized in that the electrical connector can be inserted into the side surface on the side. Therefore, there is an advantage that a wiring assembly which does not require wiring hooks and is easy to manufacture without lowering the degree of freedom of the conductor wiring can be obtained.
Further, the foam sheet has a high sound noise suppressing effect.
Furthermore, there is an advantage that the connection of the correct electrical connector between both side surfaces of the foam sheet can be easily made by the holes.

According to the wiring assembly of the third aspect, the foam sheet having a series of conductors fixed along the foam sheet, and electrical connectors at both ends to provide an electrical connection. Is fixed on the conductor, and fixed on the conductor,
A band of foam that secures and protects the conductor along the foam sheet, the foam sheet having holes located near at least some of the electrical connectors; The electrical connector can be inserted through the hole from one side of the foam sheet to the side opposite to the side. Therefore, there is an advantage that a wiring assembly which does not require wiring hooks and is easy to manufacture without lowering the degree of freedom of the conductor wiring can be obtained. Further, the foam sheet has a high sound noise suppressing effect. Furthermore, there is an advantage that the connection of the correct electrical connector between both side surfaces of the foam sheet can be easily made by the holes. Furthermore, since the conductor is fixed and protected by the foam band, there is an advantage that the position of the conductor is securely maintained and the rattling of the conductor does not occur.

According to the wiring assembly of the fourth aspect, the rigid panel having a series of grooves along the rigid panel and the series of conductors arranged in the grooves, A conductor cover terminated to the electrical connector at a particular location along the foam, and a foam cover secured over the rigid panel and the groove for securing the conductor in the groove. Therefore, there is an advantage that not only the high sound noise suppression effect by the foam cover but also the ease of management and handling of the wiring without lowering the degree of freedom of the wiring.

[Brief description of the drawings]

FIG. 1 is a plan view showing a wiring assembly according to the present invention.

FIG. 2 is a perspective view showing a wiring assembly excluding a foam band.

FIG. 3 is a perspective view of another embodiment of the present invention.

FIG. 4 is an exploded perspective view of still another embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Wiring assembly 11 Foam sheet (flexible sheet) 14, 120 Electric wire (conductor) 15 Hole 18, 122 Electrical connector 20 2nd foam layer (flexible sheet) 102 Panel 104 Foam cover 110 Groove

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Christopher W. Sherry United States 17036 Pennsylvania United States 17036 Hammerstown Canker Avenue 363 (72) Inventor Retard EF Granitz United States Pennsylvania 17112 Harrisburg Nantucket Road 4477 (72) Inventor Case Earl Denlinger United States Pennsylvania 17601 Lancaster Voice Avenue 982 (72) Inventor Robert E. Gallagher Senior United States 17109 Pennsylvania 17109 Harrisburg South Madisons Treat 111 (72) Inventor William Herbert Bear United States 17055 Mechanicsburg Brooke, Pennsylvania Tsu-di-drive 3977 F-term (reference) 5G309 AA03 LA24 5G363 AA16 BA02 DC03

Claims (4)

[Claims] 1. A flexible sheet having a series of conductors fixed along the flexible sheet; the conductor having electrical connectors fixed at both ends to provide electrical connection; and A second flexible sheet that is fixed and secures and protects the conductor along the flexible sheet. 2. A foam sheet having a series of conductors secured along the foam sheet, and the conductor having electrical connectors secured at both ends to provide electrical connection. The foam sheet has holes arranged in the vicinity of at least some of the electric connectors, and the electric connector is inserted from one side to the opposite side from one side of the foam sheet through the holes. A wiring assembly characterized by being able to do. 3. A foam sheet having a series of conductors secured along the foam sheet; a conductor having electrical connectors secured at both ends to provide electrical connection; and A foam band that secures and protects the conductors along the foam sheet, wherein the foam sheet has holes located near at least some of the electrical connectors. A wiring assembly, wherein the electrical connector can be inserted from one side to the opposite side from the one side of the foam sheet through the hole. 4. A rigid panel having a series of grooves along a rigid panel, and a series of conductors located in the grooves, terminating in an electrical connector at a particular location along the rigid panel. A wiring assembly comprising: the conductor to be fixed; and a foam cover fixed on the rigid panel and the groove and fixing the conductor in the groove.