JP2002095139A - Molding module and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To integrally form a molding such as roof liner and a wire without any troublesome work to reduce the number of components and improve a structure and a manufacturing method for the periphery of the molding module, so that the wires and electric devices within the molding such as roof liner can be easily and quickly connected electrically. SOLUTION: A molding module Y comprises a molding 1 and a wire 2a inserted to the molding 1 and can be connected with pressure with pressure- contact terminals 4a, 6h, 6i provided in an electric device 3. Moreover, a molding module Z is manufactured with the processes that a wire 2a is set within a cavity of metal die to form the predetermined molding 1, and the cavity is filled with a raw material of the base material 1a of at least the molding 1 for inserting mold of the molding 1 and wire 2a. Thereafter, the electric device 3 and wire 2a are connected with the pressure-contact method using the pressure-contact terminals 4a, 6h, 6i for enabling application of electrical power.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flexible flat circuit (abbreviated as FFC), a flexible printed circuit (abbreviated as FPC), a circuit composed of a round conductor ribbon wire, and a circuit composed of a flat conductor. And a molded body module for electrically connecting an electric component and an electric wire provided in a molded body such as a roof liner to a car roof liner in which a circuit body such as a flat wire harness is integrally formed with the roof liner. The present invention relates to a method for manufacturing a module.

[0002]

2. Description of the Related Art FIG. 18 is an exploded perspective view showing an example of a conventional automobile roof liner 1 and an electric wire 2 such as a wire harness 2 attached thereto. A connector 10a for connecting to a wire harness provided from an electric junction box such as a junction box (J / B) or a relay box (R / B), a dome lamp (DOME LP) 10b for connecting to a driver's seat side, a connector 10c for connecting to a vanity mirror room lamp (abbreviated as VTY LP RH) provided for illuminating the driver's seat side, and provided for illuminating the passenger seat side. A connector 10d for connecting to a vanity mirror room lamp (abbreviated as VTY LP LH), and a connector 10e for connecting to a rear room lamp (abbreviated as RR RM LP RH) provided for illuminating the right rear seat. , Rear room lamp (RR RM) provided to illuminate the left rear seat
LPLH).
f is provided, and the connector 10a and the connectors 10b to 10f for connecting to the various electrical components are connected by dedicated wires for various purposes.

As shown in FIG. 18, these electric wires are partially wound and bundled by using a tape 12 for converging various electric wires. It has become. At the stage of manufacturing by bundling the wire harness 2 and the like, the tape 12 for converging the roughly wound various electric wires is dispersed and wound around many places so that the electric wires for various applications are not loosened. It plays the role of bundling. Electric wires for various applications are collected in a connector 10a for connecting to a wire harness provided from an electric connection box such as a junction box or a relay box.

[0004] In the conventional configuration in which the roof liner 1 and the wire harness 2 used for the roof liner 1 are separate from each other, when the module is so-called integrated and the assembling work of the automobile in the later process is simplified, the fixing work is performed. The wire harness 2 was attached to the roof liner 1 using a tape 13 or the like. For this reason, the wire harness 2 has an extra length in consideration of the displacement of the attaching position.

However, when the wire harness 2 is provided with an extra length, the roof liner 1 and the wire harness 2
When the vehicle is driven after being assembled to the ceiling of the vehicle, the extra length of the wire harness 2 may come into contact with other neighboring members of the wire harness 2 due to the vibration of the vehicle or the like, causing abnormal noise. Was causing it.

[0006] As a solution to prevent such a problem, for example, a method of insert-molding a circuit body, such as a wire harness 2 or various kinds of electric equipment around the wire harness 2, into the roof liner 1, and a method for the roof liner 1. Attachment and integral molding are being considered. An example of such a conventional technique will be described in detail below with reference to FIGS.

FIG. 19 is a perspective view of a conventional roof liner 1 in which a flat wire harness 2a is insert-molded into the roof liner 1. The roof module Y is formed by insert-molding the flat wire harness 2a on the roof liner 1. A part of the flat wire harness 2a is partially cut away from the electrical component mounting portion 1c of the roof liner 1, that is, from the end face of the opening 1c. And a connector 10 for connecting to a predetermined electrical component is attached to the end of the flat wire harness 2a shown in FIG.

The flat wire harness 2a is bent at a bent portion 2e at a substantially right angle in the roof liner 1, and is insert-molded and integrated with the roof liner 1. Then, the roof liner 1 is fixed to a predetermined frame portion provided on the ceiling of the automobile by using screws such as bolts, screws, pins, rivets, clips, clamps or other metal or resin stoppers in the respective mounting holes 1e. It is attached.

FIG. 20 is a sectional view taken along line AA of FIG.
The roof liner 1 is mainly composed of a layer composed of the base material 1a and a layer composed of the skin 1b. In the roof liner 1 shown in FIG. 20, a flat wire harness 2a is insert-molded at a substantially intermediate portion of the layer composed of the substrate 1a. Then, the roof module Y is formed integrally. The flat wire harness 2a is manufactured so as to protrude outside the roof liner 1 from an end face 1d of an opening provided in the roof liner 1 and extend therefrom. Flat wire harness 2 from opening 1c of roof liner 1 to connector 10
The length of “a” is a length having a predetermined extra length.

A connector 10 is attached to the end of the flat wire harness 2a shown in FIG. The connector 10 is mainly a connector housing 10g.
And a release rod 10h for releasing connection with a predetermined connector on the electrical component side.
Within 0 g, a metal terminal 11 having electrical conductivity is provided.

In order to release the connector 10 from a predetermined connector on the electrical component side, the release rod 10h can be pushed down in the rotation direction F as shown by the arrow F. Further, the conductor connection portion 11a of the metal terminal 11 having electrical conductivity and the conductor 2b of the flat wire harness 2a are crimped and connected to each other to enable electrical connection, and the covering crimping piece 11b is connected to the flat wire harness 2a. The connector 10 and the flat wire harness 2a are firmly connected by pressure to the insulating cover 2c.

On the other hand, if we look at patent publications and the like,
An example of the prior art is, for example, JP-A-1-306340. This patent publication mainly introduces the technical contents relating to a molded ceiling assembly and a method of manufacturing the same.

[0013]

Based on the above-mentioned prior art, first, referring to the automobile roof liner 1 and the wire harness 2 attached thereto in FIG.
In the prior art shown in (1), the roof liner 1, connectors 10a to 10f for various purposes, connectors for various electrical components electrically connected to these, and the like are required, and the number of components is still large.

Further, a roof liner 1, an electric wire 2 such as a wire harness 2, and electric components are separately attached to the ceiling of an automobile, and various connectors 10a to 10f connected to the electric wire 2 such as the wire harness 2 are provided. Work time is required to electrically connect various electrical components via the connector, and it has been desired to further improve such workability.

As a measure for improving such an attachment property, an electric wire 2a such as a flat wire harness 2a as shown in FIGS.
It has also been proposed to integrate the component (a) and manufacture a roof module Y mainly formed of the two members.

However, as shown in FIGS. 19 and 20, when the flat wire harness 2a is insert-molded into the roof liner 1, for example, the flat wire harness 2 to which the various connectors described above are attached is attached.
When the roof liner 1 is to be insert-molded by using a, when the trimming process is performed on the roof liner 1 in the conventional form, the trimming process is established because the connector 10 bites into peripheral members such as a mold, a tool, and a jig. There was a problem not to do.

Here, trimming, trimming processing or trimming processing will be described. Here, a deburring operation of a molded body manufactured using a molding die such as a roof liner 1 or the like, and a molding having a predetermined shape are performed. To remove unnecessary parts from the molded body to perform the trimming, and this may be simply referred to as trimming or trimming.

Further, in order to provide the exposed portion of the flat wire harness 2a in the opening 1c of the roof liner 1, in order to establish such a molding step and a trimming step, the shape of the molding die must be extremely complicated. Requires a great deal of labor, time, and cost in many respects, such as design, processing, prototyping, and the overall cost of changing such molds significantly. And it was.

More specifically, referring to FIG. 20, when the worker performs the above-described trimming process on the roof module Y having such a structure, the connector 10 and the flat wire harness 2a are trimmed so as not to be damaged. This requires a great deal of attention, labor, and other complicated work, resulting in poor workability and a lot of time required for this. I had to.

An object of the present invention is to modularize a molded body such as a roof liner, electric wires, and electric components. Modularization, as used herein, generally refers to the integration of parts and other components to save labor and reduce the price associated with them.For example, to simplify the process of assembling automobiles. The purpose of the present invention is to integrate a molded body such as a roof liner, electric wires such as a wire harness, and electric components attached thereto.

As specific examples thereof, a flexible flat circuit, a flexible printed circuit,
When constructing a roof module as an integrally molded product by inserting and molding electric wires used for flat wire harnesses such as circuit bodies consisting of round conductor ribbon electric wires and flat wire electric circuits together with molded objects such as roof liners An object of the present invention is to make it possible to easily and surely make an electrical connection between this and an electrical component.

Further, according to the present invention, as in the prior art, the assembly work of finishing the ceiling portion of the vehicle by separately attaching the roof liner, electric wires, and electrical components to the ceiling portion of the vehicle can be made easier and faster. In this way, the molded body is modularized, and as a specific example, the integrated structure of the roof liner is aimed at. One of the results is, for example, a molded article obtained by integrating a roof liner, various electric wires, and other various electric components. As an assembly product or an assembly product,
An object of the present invention is to provide a molded module such as a roof module.

Further, the present invention relates to a method of manufacturing the above-mentioned molded body module, and simplifies a step of assembling an automobile, for example, when modularizing a molded body such as a roof liner and an electric wire as described above. With regard to a manufacturing method for integrating a molded body such as a roof liner and various electric wires such as a wire harness with a primary focus on the molded body such as a roof liner and electric wires which are insert-molded and integrated with the molded body, An object of the present invention is to manufacture a molded body module such as a roof module quickly and easily by assembling electric components integrally with each other, and to facilitate and speed up a manufacturing process and to save labor associated therewith.

[0024]

Means for Solving the Problems In order to solve the above problems, the invention according to claim 1 is a molded body module comprising a molded body and an electric wire insert-molded in the molded body, wherein a predetermined electric component is provided. Thus, the molded body module was configured to be capable of being press-connected to the press-contact terminal provided in the module.

By adopting such means, it is possible to reduce the number of parts in forming a molded body module compared to the conventional molded body module, and to reduce the weight and cost of the molded body module. That is, the price can be reduced.

When the molded body module and the electrical component are attached to each other and assembled, simultaneously, at the same time, the conductor of the electric wire provided on the molded body module and the press contact terminal provided on the electrical component can be easily connected. The workability at the time of assembly can be improved, and the overall price can be reduced.

Here, the method of press-connecting by the press-connecting terminal will be described in detail. The press-connecting terminal press-fits the coated electric wire to simultaneously peel off the insulating coating and connect the conductor. A terminal having a U contact can be exemplified.

To briefly explain the shape of the press contact terminal, the press contact terminal is formed with a pair of inclined portions at a portion where the electric wire starts to be inserted, and the inclined portions are inclined with a sharp shape like a blade shape. In addition, a press-contact slit having a dimension substantially equal to the diameter of the conductor for guiding the conductor is provided in the center of the press-contact terminal.

First, when the press-connecting terminal starts to be pressed into the electric wire by a press-welding tool or the like, the insulating covering of the electric wire starts to be cut off by the sharp tip. As the press-fitting is further performed, the slit provided at the center of the press-contact terminal comes into contact with the conductor inside the electric wire while tearing the insulating coating. That is, the peeling of the insulating cover and the connection of the conductor can be performed simultaneously.

In this way, when the slit of the press contact terminal comes into contact with the conductor inside the electric wire, it becomes possible to conduct electricity. Also,
The electric connection between the electric wire and the electric wire provided in the molded body module can be made only by press-fitting the press contact terminal into a predetermined portion of the electric wire. Therefore, if the press-connecting is performed using the press-connecting terminals in this way, the molded body module and the electrical component can be easily connected.

According to a second aspect of the present invention, there is provided the molded article module according to the first aspect, wherein an electric component is further attached to the molded module, and the electric component is provided on the electric wire conductor and the electric component. The molded body module was press-connected to the press-connecting terminal to enable current to flow.

By adopting such means, it is possible to integrally assemble the molded body, the electric wire, and the electric component, and separately attach the molded object, the electric wire, and the electric component as in the related art. An assembly operation such as finishing a predetermined portion can be performed easily and quickly.
In addition, it is possible to provide a molded body module that can be easily attached to a predetermined portion and has excellent assemblability.

According to a third aspect of the present invention, there is provided the molded article module according to the first or second aspect, wherein the electric wire has a predetermined length from the end face of the electrical component mounting portion from inside the molded article. Extends out of the molded body,
A portion of the electric wire extending toward the inside of the electrical component mounting portion and extending a predetermined length amount outside the molded body,
The molded module was configured to be capable of pressure connection using pressure terminals.

By adopting such means, when press-connecting the press-connecting terminal provided on the electrical component and the electric wire provided on the molded body, the electric wire is formed by a predetermined length. Since they protrude to the outside and extend, they can be easily pressed and connected. The wire here is
The term includes a conductor protected by an insulating coating or a conductor alone.

Further, when connecting the electric wire and the press contact terminal provided on the electrical component, the connection is performed using the press contact terminal, so that the connector on the electric wire side is omitted, and the weight of the molded module can be reduced. The price can be reduced as well as the price can be reduced. Further, with the omission of the connector on the electric wire side, the degree of freedom in designing the peripheral portion of the molded body mounting portion is increased.

According to a fourth aspect of the present invention, there is provided the molded article module according to the first or second aspect, wherein the electric wires are arranged on the end surface of the electrical component mounting portion of the molded article, and are provided inside the molded article. The molded article module was provided so as to fit.

By adopting such means, it has been conventionally considered difficult to perform a trimming process on a molded body in which an electric wire is insert-molded, that is, to perform a deburring operation. The trimming process can be easily performed because the trimmed surface is arranged on the end face of the electrical component mounting portion so that the trimming process can be easily performed. As a result, an inexpensive molded body module having excellent productivity can be provided. It becomes possible. At the same time, when performing the pressure connection, it is possible to easily connect the pressure terminal provided on the electrical component and the electric wire insert-molded inside the molded body.

The invention of claim 5 is based on claims 1 and 2
Or the invention relating to the molded body module according to any one of the above items 4, wherein the molded body module is pierced with a press contact terminal to be connected by pressure contact.

By adopting such means, when assembling the electric component and the molded body module, the electric component is mounted on a predetermined portion of the molded body module including the molded body and the electric wire insert-molded in the molded body. When the pressure contact terminal is pierced, the pressure contact terminal breaks through the molded body module and enters the inside, and is pressure-connected to a conductor of an electric wire provided inside the molded body module to be able to conduct electricity.

In this way, there is no need to attach a connector to the electric wire of the molded module, and it is also unnecessary to provide a connector on the electrical component side. Therefore, a connector is not required as compared with the conventional molded body module, and the number of components can be significantly reduced.

The invention according to claim 6 is based on claims 1 to 5
3. The invention according to any one of claims 1 to 3, wherein the electrical component is provided with a male lock and a cover having a lock hole for engaging the male lock, and the male lock is inserted into the molded body. The electrical component and the molded body are assembled and integrated by the male lock, the cover having the lock hole, and the pilot hole for the male lock.

By adopting such means, it is possible to mechanically securely fix the molded body module and the electrical component. In this way, the molded body module and the electrical component can be more securely mechanically attached, and the more reliable positioning of the molded body module and the electrical component can be easily performed.

More specifically, since a pilot hole is provided in the molded body module, a male lock provided in the electric component is inserted into the pilot hole, and a lock hole of a cover provided in the electric component is formed. Since the male lock is fitted, the molded body module and the electrical component can be easily and reliably assembled. Further, in this way, the molded body module and the electrical component are more stably fixed as compared with the mechanical connection and the electrical connection relying on the pressure connection.

If such a fixing means is adopted,
Due to the vibration, the electrical contact portion between the conductor of the electric wire provided inside the molded body module and the slit portion of the press contact terminal provided on the electrical component always moves due to resonance, etc. It is possible to prevent the occurrence of such a problem that a poor contact occurs. Further, it is also possible to prevent a problem that the molded module is accidentally detached from the electrical component due to, for example, vibration and the power cannot be supplied.

A seventh aspect of the present invention relates to the molded body module according to the sixth aspect, wherein the molded body module is sandwiched between the inner surface of the cover and the frame at the root of the male lock. As a result, a restoring force is generated at the same time, and the restoring force is used to form a molded module in which the lock hole provided in the cover and the locking portion of the male lock are fixed.

By adopting such means, the molded module that has been appropriately crushed has a restoring force to return to the original thickness of the entire molded module, so that the upper surface of the molded module is covered with the cover. Try to push up the inner surface of. As a result, the locking portion provided in the head of the male lock and the lock hole provided in the cover are securely fixed, and the cover is not shaken finely due to vibration or the like, thereby causing no noise or the like.

Further, for example, due to vibration or the like, poor electrical contact may occur between the electric wire of the molded module and the press-contact terminal of the electrical component, or the portion to be press-connected may be provided integrally with the molded module. It is also possible to prevent the occurrence of such a problem that the inadvertently disconnected electric wire is unintentionally disconnected and cannot be energized.

The invention according to claim 8 is based on claims 1 to 7
The invention according to any one of the above, wherein the molded body module is a molded body module in which a roof module is configured using a roof liner attached to a ceiling of an automobile.

As described above, by applying the molded body module of the present invention to a roof module used for a ceiling of an automobile, a roof liner used by being attached to the ceiling of an automobile, an electric wire integrated therewith, and electrical components It is possible to achieve a so-called roof module, which makes it possible to attach the roof liner, electric wires, and electrical components separately to the ceiling of the car, as in the past. Can be easily performed.

Further, the electric wire, that is, the roof module, which is insert-molded in the roof liner, and the electric component are directly connected to each other.
Since the connection is made, it is possible to reduce the number of components around the electrical connection portion, such as the conventional connectors attached to the electric wires of the roof module. In this way, by reducing the number of parts around the vehicle ceiling, the overall price around the vehicle ceiling can be reduced.

Further, in a limited space such as the interior of a car, if the number of parts can be reduced in order to improve the livability in the space as much as possible, the reduced parts are replaced with the interior of the car. Can be reflected in the space. It is possible to increase the ceiling height in the interior of the car by reducing unnecessary space in the ceiling part of the car, that is, wasted space, and design, manufacture and provide a car with a larger interior space than conventional cars. It is possible to do.

In addition to this, the degree of freedom in designing the peripheral part of the ceiling can be increased, and the peripheral part of the electric components on the automobile ceiling can be compactly arranged so that the appearance of the automobile gives a clear impression. It is thought that it can be given to the people in the room.

According to the ninth aspect of the present invention, a predetermined electric wire is set in a cavity of a mold capable of forming a predetermined molded body, and then at least a raw material serving as a base material of the molded body is filled in the cavity. Then, the molded body and the electric wire are insert-molded, and thereafter, a predetermined electric component and the electric wire are press-connected to each other by using a press-connecting terminal, thereby providing a method of manufacturing a molded body module capable of conducting electricity.

If such a manufacturing method is performed, a wire module is manufactured by insert-molding an electric wire inside a molded body as in the related art, and then the connector attached to the electric wire is attached to the connector on the electrical component side. Work can be simplified, and the compact module and the electrical components can be connected by a simple connection method of performing pressure connection using pressure terminals, thereby speeding up the manufacturing process. be able to.

Further, if the molded body module is manufactured by such a manufacturing method, the molded body, the electric wire, and the electric component can be integrally assembled to quickly and easily form the molded body module. Become. Accordingly, it is possible to speed up the assembling work of separately attaching a molded body, electric wires, and electrical components to finish a predetermined portion as in the related art, and to save labor associated therewith, thereby manufacturing a molded body module. Workability is improved.

According to a tenth aspect of the present invention, there is provided the method for manufacturing a molded body module according to the ninth aspect, wherein the electric wire is inserted from the inside of the molded body to the end face of the electrical component mounting portion during insert molding. A predetermined amount of length is projected out of the molded body and extended, and the electric wire is arranged in a mold so as to extend toward the inside of the electrical component mounting portion, and insert molding is performed. This is a method of manufacturing a molded body module in which the protruding portions are press-connected.

By performing such a manufacturing method, a desired molded body module can be easily manufactured. More specifically, setting an electric wire with a connector in a mold cavity as in the prior art is time-consuming, cumbersome, and inefficient, and it is not possible to actually perform such work. It was not a target.

Even if such an operation is actually to be imposed on an operator, the operator may set an electric wire with a connector in the mold cavity accurately, and may insert the connector into the mold at that time. It was anticipated that skilled work procedures and great care would be required to set up without any slack. In addition, in order to implement such a manufacturing method, it is necessary to manufacture and prepare a dedicated mold having a complicated shape, and such a mold becomes an expensive mold, and from the viewpoint of cost. It was not realistic.

However, as in the present invention, during the insert molding, a predetermined length of the wire protrudes from the end surface of the electrical component mounting portion to the outside of the molded body from inside the molded body without attaching a connector to the wire. Along with extending the wire, arrange the wire in the mold so as to extend toward the inside of the electrical component mounting part, insert mold, and then project the protruding part of the wire and the insulation displacement terminal provided on the electrical component. If the manufacturing method of assembling the molded body module by press-connecting is performed, the molded body module can be easily manufactured without performing the complicated and difficult work as described above.

In order for the wire to extend a predetermined length from the end of the electrical component mounting portion from the inside of the molded body to the outside of the molded body, a predetermined length of the wire is housed in a mold. A space may be provided in advance, and when performing the insert molding of the electric wire and the molded body, the electric wire having a predetermined length may be formed so as to be accommodated in a predetermined space provided in the mold. With this configuration, it is considered that the above-described manufacturing method can be performed by a relatively simple modification of the mold without making the mold a complicated mechanism.

An eleventh aspect of the present invention is directed to a method of manufacturing a molded body module according to the ninth or tenth aspect, wherein after the insert molding, the molded body is subjected to a trimming process. At the time of manufacture of a molded body module, a burr left around the end face of the electrical component mounting portion of the molded body and an electric wire protruding outside the molded body from the end surface of the electrical component mounting portion of the molded body are simultaneously trimmed. It was a method.

If such a manufacturing method is performed, connectors and the like may bite into peripheral members such as molds, tools, and jigs at the time of trimming and so-called deburring work of the molded body as in the prior art. It is possible to solve the problem that the trimming process does not hold, and after insert-molding the wires into the molded body, the workability related to the trimming processing of the molded body has been greatly improved. Can be measured.

Further, there is no need for the operator to perform a trimming process, that is, a deburring operation while taking care not to damage the wires such as the connectors and the flat wire harness as in the related art, which is imposed on the operator. Complicated work contents such as a great deal of attention and labor can be greatly reduced. Accordingly, the workability of the deburring process is improved, and labor and speed in the manufacturing process can be reduced.

The twelfth aspect of the present invention relates to the ninth to nineteenth aspects.
12. The invention according to the method for manufacturing a molded body module according to any one of items 11, wherein a press-fit connection is performed by piercing a press-fit terminal into a molded body module including a molded body and an electric wire during press-fit connection. It was a method of manufacturing a module.

By performing such a manufacturing method, when assembling the electrical component and the molded body module, the electric component is pressed into contact with a predetermined portion of the molded body module including the molded body and the electric wire insert-molded in the molded body. If you pierce the terminal, the insulation displacement terminal breaks through the molded body module and enters inside,
It is press-connected to the conductor of the electric wire provided inside the molded body module, and can be energized. Accordingly, electrical connection can be easily performed, and workability during assembly can be improved.

The invention of claim 13 is the invention of claims 9 to
13. The invention according to the method for manufacturing a molded article module according to any one of the above items 12, wherein the molded article is a method for producing a molded article module that constitutes a roof module using a roof liner attached to an automobile ceiling. is there.

By adopting the method of manufacturing a molded module as a method of manufacturing a roof module used for a ceiling of an automobile, the following advantages can be produced.
In other words, when assembling a vehicle, it is relatively troublesome and time-consuming to attach electric wires and various electric components such as a roof liner and a wire harness to a ceiling portion of the vehicle, respectively. By making the roof module as described above, the assembling work is facilitated and the manufacturing process can be sped up.

In addition, the simplification of the assembling process can be achieved at the same time, whereby the assembling site in the factory can be arranged, and thus the price can be reduced comprehensively. It becomes possible.

[0069]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, electric wires 2, 2a according to the present invention will be described.
As an example, the present invention relates to an automobile ceiling in which a flat wire harness 2a, which is a kind of a flexible flat circuit body, is insert-molded into a roof liner 1. FIGS. 1 to 17 show an embodiment of a roof module Y composed of at least two members and an integrated structure combining such a roof module Y and the electric component 3, that is, a roof module Z composed of at least two parts or more. It will be described based on the following.

Here, the roof liner 1 is a molded body 1 manufactured for use on the ceiling of an automobile, and may be referred to as a molded ceiling. Here, the skin 1b side of the roof module Y in which the electric wire 2a such as the flat wire harness 2a and the roof liner 1 are integrated is referred to as the lower surface side of the roof module Y, and the surface of the roof module Y opposite thereto is referred to as the upper surface side. I do.

In the present invention, the electric wire 2a is a conductor 2b protected by an insulating cover 2c or an enamel material 2c '.
And those not covered with only the conductor 2b. And the electric wire of the present invention may be a cable or a core wire. The parts having the same names as those of the conventional articles are denoted by the same reference numerals, and the detailed description of the structure is omitted.

FIGS. 1 to 3 show a roof liner 1, ie, a roof module Y, after a flat electric wire, that is, a flat wire harness 2 a is insert-molded into the roof liner 1.
FIG. 1 to 3 are enlarged perspective views showing the electric component mounting portion 1c of the roof module Y, that is, the periphery of the opening 1c here. FIGS. 2 and 3 show another embodiment of FIG. It is a thing. In each of FIGS. 1 to 3, a predetermined electrical component 3 is accommodated in an opening 1 c provided in the roof module Y.

Here, the electrical component mounting portion 1c is shown in FIGS.
May be a substantially rectangular opening 1c surrounded by the roof liner 1, or a concave opening with a part of the surrounding roof liner 1 partially removed. It may be an opening having a round shape, an elliptical shape, or a modified shape thereof, and an electrical component mounting portion having a groove shape that does not penetrate the roof liner 1 with the above shape. The electrical component mounting portion of the present invention may take any form.

1 to 3, the flat wire harness 2 a is bent at a bent portion 2 e at a substantially right angle in the roof liner 1, and is insert-molded and integrated with the roof liner 1 to form a roof module Y. Is configured. Then, mounting holes 1e for mounting such roof modules Y and Z at predetermined positions on the ceiling of the automobile are provided at several to several tens of locations at the end of the roof module Y. The roof module Y shown in FIG. 3 is provided with approximately two pilot holes 9 for fitting male locks, and a pair of pilot holes 9 are provided.
Are formed.

FIG. 1 shows a roof module Y including a roof liner 1 and a flat wire harness 2a insert-molded into the roof liner 1. The roof module Y has an end face 1d of the opening 1c.
A flat wire harness 2a having a predetermined length extends from the interior of the roof module Y to protrude outside the roof module Y, and a portion of the flat wire harness 2a protruding and extending to the outside forms a predetermined electrical component. 3 and can be press-connected to the press-connecting terminal 4a.

FIG. 2 shows a molded body module Y similar to that shown in FIG. 1. The roof module Y shown in FIG. 2 has a predetermined shape from the inside of the roof module Y through the end face 1d of the opening 1c. The length of the conductor 2b protrudes out of the roof module Y by about three, and the portion of the conductor 2b protruding out of the outside extends to the press-contact terminal 4a provided on the predetermined electrical component 3. The connection is possible.

On the other hand, FIG. 3 also shows a molded body module Y including a roof liner 1 and a flat wire harness 2a insert-molded into the roof liner 1. The roof module Y is configured to be press-connectable to a bus bar 6b provided with a press-contact terminal 6i provided on a predetermined electrical component 3. Here, the bus bar will be briefly described. The bus bar is formed by an electric circuit network in which an electric circuit is multi-branched by a conductive metal plate and formed with a large number of electric contact pieces, and is also called a bus bar.

The roof module Y having the configuration shown in FIGS. 1 to 3 makes it possible to make the roof module Y smaller in number of parts than the conventional roof module Y, Module Y
It is possible to reduce the weight and cost of the device, that is, to reduce the price.

When the roof module Y and the electric component 3 are attached to each other and assembled, at the same time, the conductor 2b of the flat wire harness 2a provided inside the roof module Y, the press-contact terminal 4a of the electric component 3, Since the bus bar 6b having the press contact terminal 6i can be easily connected, the workability at the time of assembling can be improved, and thereby the overall cost can be reduced.

More specifically, by applying the molded body modules Y and Z to the roof modules Y and Z used for the ceiling of the vehicle, the roof liner 1 used to be mounted on the ceiling of the vehicle and the roof liner 1 integrated therewith. The electric wire 2a, such as the flat wire harness 2a, and the electrical components can be integrally assembled, so that a so-called roof module can be achieved. , The electric wires 2a and the electrical components can be attached separately to finish the ceiling portion of the automobile, and the assembling work can be easily performed.

Further, since the flat wire harness 2a insert-molded in the roof liner 1, that is, the roof module Y, and the electrical components are directly connected,
It is possible to reduce the number of components around the electrical connection portion attached to the roof liner 1 as in the related art. In this way, by reducing the number of parts around the vehicle ceiling, the overall price around the vehicle ceiling can be reduced.

As shown in FIGS. 1 and 2, the flat wire harness 2a or the conductor 2b thereof extends from the inside of the roof module Y to a predetermined length from the end face 1d of the opening 1c which is the electrical component mounting portion 1c. A small amount of the flat wire harness 2a or the conductor 2b protrudes outside the roof module Y and extends. In addition, the flat wire harness 2a or the conductor 2b is also attached to the electrical component mounting portion 1c.
Extending toward the inside of the opening 1c.

However, the connector 10 as shown in the prior art is not attached to the end of the flat wire harness 2a or the conductor 2b shown in FIGS. 1 and 2, and is omitted. The flat wire harness 2a or the conductor 2b protruding and extending outward from the end face 1d of the opening 1c provided in the roof module Y.
In this part, a press-connecting connection with a press-connecting terminal provided on the electrical component is made possible.

In this way, when the pressure contact terminal provided on the electrical component and the flat wire harness 2a or the conductor 2b provided on the roof module Y are connected by pressure contact,
Since the flat wire harness 2a or the conductor 2b extends outwardly from the end face 1d of the opening 1c by a predetermined length, the conductor 2 of the flat wire harness 2a inserted into the roof module Y is formed.
b can be easily press-connected to the press-connecting terminal of the electrical component using a jig such as a blade.

When the flat wire harness 2a or the conductor 2b is connected to the press contact terminal provided on the electrical component, the connector on the flat wire harness 2a or the conductor 2b side is not required and is omitted. The weight of the module Y can be reduced, and the cost of the module Y can be reduced. Furthermore, since the connector 10 on the side of the flat wire harness 2a is omitted because it is not mounted, the degree of freedom in designing the peripheral portion of the mounting portion of the roof module Y is increased.

On the other hand, FIG. 3 differs from FIG. 1 or FIG. 2 in that the flat wire harness 2a does not protrude outside the opening 1c, which is the electrical component mounting portion 1c of the roof module Y. As shown in FIG. 3, the conductor 2b of the flat wire harness 2a insert-molded into the roof liner 1 is connected to the opening 1c of the roof liner 1.
The flat wire harness 2a projects outward from the end face 1d of the opening 1c and does not extend from the end face 1d. That is, the flat wire harness 2a is arranged on the end face 1d of the opening 1c of the roof module Y and provided so as to fit inside the roof module Y.

As described above, by adopting the shape of the opening 1c shown in FIG. 3, even when the conventional roof module Y in which the flat wire harness 2a is insert-molded is subjected to a trimming process, a so-called deburring operation, the trimming process is performed. However, since the flat wire harness 2a is arranged on the end face 1d of the opening 1c of the roof module Y so as to fit inside the roof module Y, the trimming process can be easily performed. , Resulting in a compact module Y with excellent productivity
Can be provided.

As described in detail above, FIG. 19 or FIG.
0, the roof module Y of the prior art shown in FIG.
There was a problem that the above-mentioned trimming work of the roof module Y was hindered. However, if the shape of the opening 1c shown in FIG. 3 is used, such a problem can be solved and a roof module which is inexpensive and has excellent productivity can be obtained. Will be able to

More specifically, in a trimming operation, that is, a so-called deburring operation, a flat wire harness 2a is attached to the conventional roof liner 1 shown in FIGS.
When the connector 10 is an integrated product obtained by insert molding, there is a problem that the above-described trimming process is not established because the connector 10 bites into peripheral members such as a mold, a tool, and a jig.

However, by adopting the configuration as shown in FIG. 3, deburring of the roof liner 1 was facilitated. After the electric wire 2a such as the flat wire harness 2a is insert-molded into the roof liner 1, the roof liner 1
The above-mentioned trimming operation can be greatly improved, and labor saving and speeding up in the manufacturing process are promoted.

In addition, when the roof module Y and the electric component 3 are assembled together, the electric component 3
And the flat wire harness 2a insert-molded inside the roof module Y can be pressure-connected to each other, and a molded module excellent in productivity and inexpensive can be provided.

In this manner, the roof modules Y and Z composed of the roof liner 1 and the electric wires 2a such as the flat wire harness 2a having predetermined shapes are provided with screws such as bolts, screws, pins and rivets in the respective mounting holes 1e. It can be easily attached to a predetermined frame portion provided on the ceiling of the automobile by a metal or resin stopper such as a clip or a clamp.

FIG. 4 is a sectional view of a press contact terminal 4 provided on the electrical component 3.
FIG. 5 is an enlarged perspective view showing a state in which the electrical component 3 and the roof module Y are assembled while the conductor 2a is connected to the conductor 2b of the flat wire harness 2a provided in the roof module Y, and FIG. It is a longitudinal cross-sectional view shown in FIG. Here, the roof module Y shown in FIG. 5 is a longitudinal sectional view of the roof module Y shown in FIG. 2, and represents the QQ sectional view of FIG. More specifically, FIG. 5 is a cross-sectional view of the roof module Z shown in FIG.

As shown also in FIGS. 4 and 5, a conductor 2b of a predetermined length is directed to the outside of the roof module Y from an end face 1d of an opening which is an electrical component mounting portion provided in the roof module Y. Protruding and extending. The roof liner 1 includes a base material 1a and a skin 1b,
A flat wire harness 2 is provided on the substantially intermediate layer portion of the base material 1a.
a is insert-molded to form a roof module Y. As shown in FIG. 5, the conductor 2b is coated with an enamel material 2c 'which is a kind of the insulating cover 2c.

On the other hand, the electrical component 3 is provided with a connector 4, and the connector 4 is provided with a press contact terminal 4 a as an electrical connection portion and a connector housing 5. The press contact terminal 4a mainly includes a press contact piece 4b,
c, elastic contact pieces 4d, locking projections 4e, windows 4f, and engagement holes 4g. The engagement hole 6j of the bus bar 6a is connected to the locking projection 4e of the elastic contact piece 4d of the press contact terminal 4a, so that the connector 4 and the bus bar 6a are integrated.

Here, the press contact terminal 4a will be described in detail. The conductor 2b protected by an insulating cover 2c such as a resin material, a rubber material, a composite material thereof, or an enamel material 2c '.
This is a terminal used for electrical connection with the terminal. The press-fit terminal 4a is press-fitted into the electric wire 2a composed of the conductor 2b protected by the insulating coverings 2c and 2c ', thereby simultaneously separating the insulating coverings 2c and 2c' and connecting the conductor 2b. For example, a terminal having a U-contact can be cited as a typical example.

The shape of the press contact terminal 4a will be briefly described. The press contact terminal 4a has a pair of inclined portions 6f at a portion where the electric wire 2a starts to be inserted.
f has a sharp shape and is inclined like a blade shape, and at the same time, a slit 6e having a dimension substantially equal to the diameter 2d of the conductor 2b for guiding the conductor 2b is provided at the center of the press contact terminal 4a. Is provided.

The operation at the time of press-connecting the conductor 2b to the press-connecting terminal 4a will be described. First, press-fitting of the press-connecting terminal 4a into the flat wire harness 2a or the conductor 2b coated with the enamel material 2c 'using a pressing tool or the like starts. An insulating cover 2c made of a resin or rubber material of the flat wire harness 2a by the sharp inclined portion 6f;
The insulating coverings 2c and 2c 'such as the enamel material 2c' thinly covered around the conductor 2b start to be torn.

When the press-fitting is further performed, the slit 6e provided at the center of the press-connecting terminal 4a is inserted into the insulating coating 2a.
c, 2c 'while cutting flat wire harness 2
a contacts the conductor 2b inside the a. That is, the insulating cover 2
The peeling of c and 2c 'and the connection of the conductor 2b can be performed simultaneously.

Thus, the substantially Y-shaped slit 6e of the press contact terminal 4a is formed by the conductor 2b inside the flat wire harness 2a or the conductor 2b covered with the enamel material 2c '.
When the contact is made, current can be supplied. In addition, the insulation displacement terminal 4
a is simply pressed into a predetermined portion of the flat wire harness 2a or the conductor 2b covered with the enamel material 2c ', so that the flat wire harness 2a provided inside the roof module Y and the electrical component 3 can be energized. be able to. Therefore, the roof module Y and the electrical component 3 can be easily connected.

The connector housing 5 will be described in detail. The connector housing 5 is provided integrally with the frame 3a of the electrical component 3. It is preferable to form the connector housing 5 integrally with the frame 3a of the electrical component 3 because the resin electrical component 3 having the connector housing 5 can be formed without increasing the number of components. The connector housing 5 may be provided separately from the frame 3 a of the electric component 3 depending on the use and shape of the electric component 3.

Here, the connector housing 5 is the electrical component 3
The one that is integrally formed will be described with reference to FIG. FIG. 6 is an explanatory diagram when the press contact terminal 4 a is attached to the connector housing 5. When assembling the press contact terminal 4a to the connector housing 5, for example, as shown in FIG. 6, the press contact terminal 4a electrical equipment is attached to a predetermined position of the connector housing 5 along the insertion direction G2 indicated by the arrow G2.

At this time, a locking projection 5b provided on a flexible locking arm 5a provided on the connector housing 5.
Then, the press contact terminal 4a and the connector housing 5 are fixed by the engagement hole 4g provided in the press contact terminal 4a to form the connector 4. At the same time, the engaging projection 4e provided on the elastic contact piece 4d of the press contact terminal 4a and the engaging hole 6j of the bus bar 6a are fitted to fix the press contact terminal 4a and the bus bar 6a. At the end of the bus bar 6a, a contact tab 6k is provided to easily insert the bus bar 6a into the press contact terminal 4a so that the bus bar 6a can make good contact with the elastic contact piece 4d.

Thus, the connector 4 shown in FIG.
Is assembled. When the electrical component 3 provided with the connector 4 and the roof module Y are connected and integrated, the roof module Y is connected to the conductor 2b of the flat wire harness 2a along the mounting direction E indicated by the arrow E. Using a jig such as a blade B, the terminal is press-fitted into the press-connecting terminal 4a and press-connected.

Alternatively, while applying the conductor 2b with a jig such as a blade B, the electric component 3 is moved in the direction opposite to the direction indicated by the arrow E, and the press-contact terminal 4a provided on the electric component 3 is connected to the conductor 2b. And press-connect. By doing so, the flat wire harness 2a or the conductor 2b protruding from the inside of the roof module Y toward the outside of the roof module Y from the end face 1d of the opening 1c and the connector housing 5 of the electrical component 3 It is possible to connect the housed press contact terminal 4a to enable the power to be supplied.

In this manner, the roof module Z is
Assembled as shown in FIG. FIG. 7 is a top view showing a state when the electrical component 3 and the roof module Y are assembled. The roof module Y shown in FIG.
To the conductor 2b of the flat wire harness 2a and the press contact terminals 4 provided on the electric component 3.
3A shows a roof module Z that is press-connected to a and that can be energized.

Here, as an example of a method of positioning and fixing the roof module Y and the electrical component 3, as shown in FIGS. 4, 5 and 7, for example,
And the electrical component 3
The connector housing 5 may be fixed in such a manner that it comes into contact with the mating surface of the mounting portion 5c of the connector housing 5. In this case, since the positioning can be easily performed, the roof module Y and the electrical component 3 can be quickly mounted.

Then, each crimping piece 4c of the press contact terminal 4a is
The conductor 2b is crimped and fixed as shown in FIG. 7 by being bent in the crimping direction G1 as indicated by an arrow G1 shown in FIG. By assembling in this manner, the roof liner 1 and the flat wire harness 2a insert-molded into the roof liner 1 and integrated therewith.
, And a roof module Y including the electrical component 3, and the flat wire harness 2a and the electrical component 3 are press-connected to each other to manufacture a roof module Z that can be energized.

In this way, the roof liner 1, the flat wire harness 2a, and the electrical component 3 that are used by being attached to the ceiling of an automobile can be integrally assembled, and a so-called roof module can be formed. The roof liner 1 and the flat wire harness 2
a) It is possible to easily perform an assembling operation such as finishing the ceiling part of the automobile by separately attaching the electrical components 3. Then, the roof module Z that can be easily attached to a predetermined portion such as the ceiling of an automobile and has excellent assemblability can be provided.

In addition, since components such as various connectors for connecting the flat wire harness 2a insert-molded to the roof liner 1 and the electrical component 3 are not required, peripheral portions of the electrical connection portion attached to the roof module Y are unnecessary. This makes it possible to reduce the number of parts, and accordingly, it is possible to reduce the overall price around the ceiling of an automobile.

In a limited space such as the interior of a car, if the number of parts can be reduced in order to improve the livability in the space as much as possible, the reduced parts are replaced with the interior of the car. Can be reflected in the space. It is possible to increase the ceiling height in the interior of the car by reducing unnecessary space in the ceiling part of the car, that is, wasted space, and design, manufacture and provide a car with a larger interior space than conventional cars. It is possible to do.

In addition to this, the degree of freedom in designing the peripheral part of the ceiling can be increased, and the peripheral part of the electrical component 3 on the automobile ceiling is compactly arranged, giving a clear impression from its appearance. It is thought that it will be able to give to people in the interior of the car.

The surplus length of the conductor 2b and the surplus length of the flat wire harness 2a are previously stored in the electrical component 3 as shown in FIGS.
An accommodation room 3e for accommodating the extra length of the flat wire harness 2a is provided, and even if the conductor 2b, the flat wire harness 2a, or the like is folded in such an accommodation room, the extra length is absorbed. Good. In this way, the extra length of the flat wire harness 2a is
It is expected that the noise caused by the vibration can be reduced as much as possible because it is housed in the accommodation room 3e and surrounded by the frame 3a of the electrical component 3.

If the extra length of the flat wire harness 2a and its conductor 2b is stored inside the electrical component 3, it is necessary to set a space in which the various connectors can be accommodated in the ceiling portion of the vehicle as in the prior art. Therefore, there is no need to secure an unnecessary space, that is, an unnecessary space. Therefore, the degree of freedom in designing the peripheral portion of the roof module Y or Z can be increased. In addition, with this, the roof module Z having good appearance can be obtained, and the periphery of the electrical component 3 can be made compact.

As an example of another press contact terminal, a bus bar 6b provided with a press contact terminal 6h shown in FIG. 8 is used in the present invention instead of the press contact terminal 4a and the bus bar 6a shown in FIGS. Is also good. FIG. 8 shows the bus bar 6b.
FIG. 5 is an enlarged perspective view of a press contact terminal 6h provided in FIG. The press contact terminal 6h shown in FIG. 8 has a substantially U-shaped slit portion with a substantially Y-shaped edge so that the conductor 2b covered with the enamel material 2c 'can be easily introduced into the slit 6e. It is. The substantially Y-shaped portion has a sharp shape like a blade shape.

The conductor 2b is connected to the center of the pressure contact terminal 6h.
Is provided with a slit 6e having approximately the same size as the diameter 2d of the conductor 2b for introducing the pressure contact.
Such a shape is such that the insulating coatings 2c and 2c 'such as the enamel material 2c' are peeled off so that the conductor 2b can be electrically connected to the press contact terminal 6h.

That is, as shown in FIG. 8, a pressure contact terminal 6h whose tip portion is shaped like a petal and which is sharp may be employed. A bus bar may be used.

However, in order to properly connect the bus bar 6b to the conductor 2b of the roof module Y shown in FIGS. 2 and 3, the conductor 2b must be connected to the conductor 2b like the press contact terminal 6h provided on the bus bar 6b in FIG. It is preferable to use the bus bar 6b having the shape of the press contact terminal 6h in which the insertion portion is substantially Y-shaped and has a sharp shape, because the press contact can be easily performed and the number of parts can be further reduced. The operation of press-connecting the conductor 2b to the press-contact terminal 6h is substantially the same as the operation of press-connecting the conductor 2b to the upper press-contact terminal 4a, and thus a detailed description of the press-connect is omitted here. .

FIG. 9 is a longitudinal sectional view of another example showing a state where the electrical component 3 and the roof module Y on which the flat wire harness 2a is insert-molded are assembled and electrically connected to each other. Opening 1c, which is the electrical component mounting portion 1c of the roof module Y shown in FIG.
, Electrical components 3 are set on the flat wire harness 2
The roof module Y in which a is insert-molded is prepared so as to be able to be energized by piercing into the press contact terminal 6i of the bus bar 6b provided in the electric component 3.

The roof module Y shown in FIG.
FIG. 4 is a longitudinal sectional view of the roof module Y shown in FIG. 3, and shows an RR sectional view shown in FIG. 3. The roof liner 1 includes a base 1a and a skin 1b, and a flat wire harness 2a is insert-molded between the base 1a and the skin 1b to form a roof module Y.

The bus bar 6b extends from the inside of the electrical component 3 substantially parallel to the main body 6c of the bus bar 6b while abutting on the lower surface portion 3c of the electrical component 3, and is bent at an angle of about 90 ° at the bent portion 6g. The portion of the press contact terminal 6i is extended upward. A flat wire harness 2a is pierced into the roof module Y on which the insert molding is performed from the tip end 6d of the press contact terminal 6i provided on the bus bar 6b to perform press connection. In this manner, the conductor 2b of the flat wire harness 2a and the slit 6e of the press contact terminal 6i come into contact with each other and become energized.

More specifically, when the electrical component 3 and the roof module Y are assembled to form the roof module Z, the roof module 1 includes the roof module 1 and the roof module Y having the flat wire harness 2a insert-molded into the roof module 1. When a press contact terminal 6i provided on the bus bar 6b of the electrical component 3 is pierced into a predetermined portion from the tip 6d, the press contact terminal 6i breaks through the molded module Y and enters the inside, and a portion of the slit 6e of the press contact terminal 6i. And the conductor 2b of the flat wire harness 2a provided inside the molded body module Y are press-connected to each other to be able to conduct electricity.

By doing so, for example, FIG.
As shown in FIG. 20 and FIG. 20, there is no need to attach the connector 10 to the flat wire harness 2a of the roof module Y, and further, it is not necessary to provide a connector around the electric circuit on the electrical component 3 side. Therefore, FIG.
As compared with the conventional roof module Y shown in FIG. 20 and FIG. 20, the connector 10 becomes unnecessary, and the number of parts can be significantly reduced.

Here, as shown in FIG.
It is preferable that the main body 6c of the bus bar 6b extends from the inside of the electrical component 3 substantially in parallel with the lower surface portion 3c of the electrical component 3 from the inside of the electrical component 3 so that a good pressure connection can be performed. More specifically, the roof module Y
Is pressed down toward the distal end 6d of the press contact terminal 6i as shown in the mounting direction E, and the distal end 6
Even if d breaks through the skin 1b of the roof module Y and press-fitting connection is started, since the main body 6c of the bus bar 6b is received by the lower surface 3c of the electrical component 3, the bus bar 6
b can receive the resistance force applied to the press contact terminal 6i at the time of press connection without being deformed. Therefore, it can be expected that the pressure connection can be performed well.

Further, two pilot holes 9 provided in the roof module Y and two male locks 7 provided in the electrical component 3 are prepared so as to be fitted. The male lock 7 is also provided on the frame 3a of the electrical component 3.
And a cover 8 having a lock hole 8a and a hinge portion 8b, that is, a lid 8 is integrally provided on the upper surface portion 3b of the electrical component 3.

Here, the male lock 7 and the pilot hole 9 according to the present invention will be briefly described. As shown in FIG. 9, the male lock 7 refers to a column-shaped portion, and has a fitting through hole or a non-penetrating shape provided in another part for fitting and fixing with the pillar. This hole is called a pilot hole 9 here. Then, the two separate parts are securely assembled by the male lock 7, the pilot hole 9, and the cover 8 provided with the lock hole 8a for holding and fixing the part provided with the pilot hole 9. Becomes possible.

The roof module Y is pushed down in the mounting direction E as shown by the arrow E, and the pair of male locks 7 provided in the electric component 3 are inserted into the pair of pilot holes 9 provided in the roof module Y. Insert and mate, then
The cover 8 is closed by moving the cover 8 in the rotation direction F as shown by the arrow F, and the lock hole 8a of the cover 8 and the locking portion 7c of the male lock 7 are fitted to form the roof module Z. .

Further, looking at the roof module Z in detail, the electrical component 3 is provided with a cover 8 having a male lock 7 and a lock hole 8a, and the roof liner 1 constituting the roof module Y is provided with a pilot hole 9 mainly. The electrical component 3 and the roof module Y are assembled and integrated with the male lock 7, the cover 8 and the pilot hole 9 as described above.

By doing so, the roof module Y and the electrical component 3 can be mechanically fixed securely. In this way, the roof module Y and the electrical component 3 are more securely mechanically attached,
If the fixing means as described above is used, the roof module Y
The more reliable positioning operation between the electronic component 3 and the electronic component 3 can also be easily performed.

Specifically, the roof module Y
Is provided with a pilot hole 9, so that the male lock 7 provided on the electric component 3 is inserted into the pilot hole 9,
Further, since the lock hole 8a of the cover 8 provided in the electrical component 3 and the male lock 7 are fitted, the roof module Y and the electrical component 3 are positioned with the male lock 7 and the pilot hole 9 in a state. It will be surely assembled.

Further, if such a fixing means is employed, the roof module Y is inadvertently pulled out of the pressure contact terminal 6i of the bus bar 6b provided on the electric component 3 due to, for example, vibration, and the power cannot be supplied. It is conceivable that the occurrence of such a problem can be prevented beforehand.

Thus, the male lock 7 and the cover 8
The lock hole 8a provided in the roof module Y and the pilot hole 9 provided in the roof module Y are fixed, and the roof module Y in which the flat wire harness 2a is insert-molded in the roof liner 1 is assembled with the electric component 3 and pressed. The connections are made simultaneously and a roof module Z is formed.

Here, a male lock 7 provided in the frame 3a of the electrical component 3, a lock hole 8a provided in the cover 8,
FIGS. 9, 11 and 12 show a method and a form for securely fixing the roof module Y and the electrical component 3 by the pilot holes 9 provided in the roof module Y.
This will be described in detail with reference to FIG.

FIG. 11 is an enlarged perspective view when the male lock 7 is attached to the pilot hole 9. FIG.
11 is an enlarged perspective view showing another example different from that of FIG. 11, and specifically, is an enlarged perspective view showing a relationship between the pilot hole 9 and the male lock 7 shown in FIG.

As shown in FIG. 9, the distal end 7a of the male lock 7 is formed with an inclined portion 7b and provided with a locking portion 7c. As shown in FIG. 9, a roof module Y having a predetermined shape is prepared, and a pilot hole 9 provided at a predetermined position of the roof module Y is engaged with the male lock 7.

At this time, the diameter 7 of the locking portion 7c of the male lock 7 is
d is a pilot hole 9 provided in the roof module Y.
Once set to a diameter larger than 9d in diameter,
When the pilot hole 9 of the roof module Y is engaged with the male lock 7, the roof module Y is prevented from easily falling off the male lock 7.

Here, the diameter 7e of the column 7f from the base 7g of the male lock 7 to the locking portion 7c will be described in detail.
Is set to a size substantially equal to the diameter 9d of the pilot hole 9 provided in the first hole. If importance is attached to the attachment between the two, it is preferable that the dimension of the diameter 7e of the column 7f constituting the male lock 7 be set to a dimension smaller than the diameter 9d of the pilot hole 9. On the other hand, if emphasis is placed on the fitting and holding properties of the two, the diameter 7e of the column 7f constituting the male lock 7 is set to a diameter larger than the diameter 9d of the pilot hole 9. Is preferred.

As shown in FIG. 11, at least one slit 9a is formed in the pilot hole 9 provided in the roof module Y so that the male lock 7 can be easily fitted into the pilot hole 9. The male lock 7 provided on the electrical component 3 may be provided with at least one slit 7h as shown in FIG.

As shown in FIG. 12, the male lock 7 shown in FIG. 9 is provided with about three slits 7h so as to divide the male lock 7 into three equal parts. Further, a slit 9a is provided in the pilot hole 9 shown in FIG.
Are provided at two locations so as to equally divide the pilot hole 9. This is preferable because the locking portion 7c at the head of the male lock 7 can be easily inserted into the pilot hole 9 and passed therethrough. Note that, depending on the flexibility of the roof module Y, the male lock 7 shown in FIG. 11 without the slit 7h is replaced with the male lock 7 shown in FIG.
May be used for the male lock 7.

Further, according to the present invention, the dimension setting value of each diameter of the male lock 7 and the slit 7h provided on the male lock 7 and the slit 9a provided with the pilot hole 9 of the roof module Y are provided. By properly setting the roof module Y in consideration of the flexibility of the roof module Y in combination with various shapes, the roof module Z having excellent flexibility, assembling property, stable fixing property, and the like can be obtained.

Next, the process of attaching the pilot hole 9 of the roof module Y to the male lock 7 provided on the electric component 3 from the state shown in FIG. 9 will be described in detail. First, while the diameter 7d of the locking portion 7c of the male lock 7 is slightly reduced, and the pilot hole 9 provided in the roof module Y is pushed open by the locking portion 7c of the male lock 7, the male lock 7 is forcedly inserted. The lock 7 is inserted into the pilot hole 9.

At this time, since the inclined portion 7b is provided at the tip portion 7a of the male lock 7, the locking portion 7c of the male lock 7 is inserted into the pilot hole 9 with an appropriate force even if it is in a forced state. Will be done. Further, as described above, when the plurality of slits 9a are provided in the pilot hole 9 as shown in FIG. 11 or when the plurality of slits 7h are provided in the male lock 7 as shown in FIG. ,
This is preferable because the male lock 7 can be easily inserted into the pilot hole 9.

Thereafter, the locking portion 7c of the male lock 7 passes through the pilot hole 9 and reaches the upper surface Y1 of the roof module Y. Then, the forced insertion state ends, and the male lock 7 and the roof module Y are temporarily fixed. By setting the dimensions of the diameters 7d, 7e, and 9d as described above,
The roof module Y and the electrical component 3 are securely assembled.

Next, the cover 8 is pivoted around the hinge 8b.
Is moved in the rotation direction F as shown by the arrow F and closed, and the lock hole 8a provided in the cover 8 and the male lock 7 are fitted. In the case of the cover 8 having the hinge portion 8b as described above, when the roof module Y and the electrical component 3 are fixed, the cover 8 is pushed in the rotation direction F as indicated by an arrow F and the cover 8 is closed. It is preferable because both can be easily assembled.

Here, the diameter 7 of the locking portion 7c of the male lock 7 is
d has a diameter larger than the diameter 9 d of the pilot hole 9. In this way, once the cover 8 is closed and the male lock 7 is engaged with the lock hole 8a, the cover 8 is not easily released from the male lock 7 by the locking portion 7c.

The state in which the male lock 7 and the lock hole 8a formed in the cover 8 are engaged will be described in detail. First, the cover 8 is pivoted about the hinge 8b of the cover 8 as shown by an arrow F in FIG. If you move it in the rotation direction F and try to close it,
The lock hole 8a of the cover 8 contacts the inclined portion 7b of the distal end portion 7a of the male lock 7, but the fitting has not been performed yet.

Next, when the cover 8 is strongly pressed down with a hand or the like, the diameter 8d of the lock hole 8a provided in the cover 8 slightly expands, and the diameter 7d of the locking portion 7c of the male lock 7 shrinks slightly. , For a moment, it is in the forced state as described above. Thereafter, the locking portion 7c passes through the lock hole 8a of the cover 8 and passes through to the upper surface of the cover 8, that is, the upper surface portion 3b of the electrical component 3 here, and the locking is completed.

Here, as shown in FIG. 12, a plurality of slits 7h are provided in the entire male lock 7, and at least one slit is provided in a lock hole 8a provided in the cover 8. The locking portion 7c on the head of the male lock 7 is preferable because it can be easily inserted into the lock hole 8a provided in the cover 8.

In this way, the male lock 7 and the cover 8
The lock hole 8a provided on the roof module Y and the pilot hole 9 provided on the roof module Y are fixed, and the roof module Y in which the flat wire harness 2a is insert-molded into the roof liner 1 and the electric component 3 are assembled. Finishing, the roof module Z is formed.

Also, on the upper surface Y1 of the roof module Y,
By fixing the cover 8 provided on the electrical component 3 to the male lock 7, the base 1 a of the roof liner 1 is crushed to such an extent that flexibility and restorability are not completely lost. The roof module Y is compressed and crushed mainly between the inner surface 8c of the cover 8 and the support plate 3d at the base 7g of the male lock 7. That is, the support 7f of the male lock 7
Is mainly compressed and crushed in the vicinity of the surrounding area, whereby a restoring force is generated in the roof liner 1.

As described above, since the roof module Y which has been appropriately crushed has a restoring force for returning to the original thickness T1 of the roof module Y, the upper surface Y1 of the roof module Y is attached to the inner surface of the cover 8. As a result, the locking portion 7c provided on the head of the male lock 7 and the lock hole 8a provided on the cover 8 are securely fixed, and the cover 8 is finely shaken by vibration or the like, thereby causing a difference. It does not cause noise or the like.

For this purpose, as shown in FIGS. 9 and 14, for example, the length L2 from the locking portion 7c to the root 7g of the male lock 7 is set to be equal to the total thickness T1 of the roof module Y. What is necessary is just to make it less than the length which added the thickness T3 of the cover 8. By doing so, for example, FIG.
7, the cover 8 is closed, the male lock 7, the cover 8 having the lock hole 8a, and the male lock 7
When the electrical component 3 and the roof module Y are assembled and fixed by the pilot holes 9 with respect to the roof module Y, the roof module Y is appropriately compressed and the restoring force of the base material 1a of the roof liner 1 is appropriately generated. , A good bonding state is maintained.

The cover 8 in the closed state will be described in detail. The electrical component 3 and the roof module Y are connected by the male lock 7, the cover 8 having the lock hole 8a, and the pilot hole 9 for the male lock 7. It is assembled, integrated and fixed. In this way, as shown in FIG.
And the cover 8 forms the upper surface portion 3b of the electrical component 3.

As shown in FIGS. 9 and 14, for example, the length L1 of the press contact terminal 6i is preferably smaller than the total thickness T1 of the roof module Y. By doing so, when the insulation displacement terminal 6i is pierced into the roof module Y to perform insulation displacement connection, the insulation displacement terminal 6i
This is preferable because the tip portion 6d of the first component does not penetrate the roof module Y and can contribute to the miniaturization and downsizing of the roof module Z including the electrical components 3.

The hinge 8b of the cover 8 provided on the upper surface 3b of the electrical component 3 has, for example, a substantially V-shaped cross section provided on the upper portion of the cover 8, that is, the upper surface 3b of the electrical component 3 here. It is formed of a constricted portion 8f having a substantially arc-shaped cross section of the constricted portion 8e and the inner portion 8c of the cover 8.

If the frame 3a constituting the outer frame of the electrical component 3 is made of a flexible synthetic resin or the like, the integrated electrical component 3 with the movable cover 8 can be obtained. , Electrical components 3 with cover 8 without increasing the number of parts
This is preferable because the frame 3a can be manufactured. Hinge part 8b
Is not limited to the shape described above, and the cover 8
The hinge portion 8b may have any shape as long as the hinge portion 8b can be moved in the rotation direction F around the center axis b or the cover 8 can be opened and closed.

Further, the male lock 7 together with the cover 8 is provided.
Also, the electric component 3 may be integrally formed with the frame 3 a with a material such as a synthetic resin of the same type as the frame 3 a and provided at a predetermined position of the electric component 3. When the male lock 7 and the cover 8 are integrally formed with the frame 3a of the electrical component 3 in this manner, the resin electrical component 3 having the male lock 7 and the cover 8 can be formed without increasing the number of parts. It is preferable because it is possible. Depending on the use and shape of the electrical component 3, the male lock 7 or the cover 8 may be attached to the frame 3a of the electrical component 3.
And may be provided separately.

If the fixing means as described above is adopted, the conductor 2b of the flat wire harness 2a provided inside the roof module Y due to vibration and the slits 6e of the press contact terminals 4a, 6h, 6i provided in the electric component 3 are provided. It is possible to prevent the occurrence of such a problem that the electrical contact portion with the portion always moves due to resonance or the like, thereby causing an electrical contact failure. Further, it can be expected to prevent a problem that the roof module Y is inadvertently removed from the electrical component 3 due to, for example, vibration and the power cannot be supplied.

Here, the cross-sectional shape of the post 7f from the root 7g of the male lock 7 to the locking portion 7c will be described. The cross-sectional shape of the post 7f shown in FIGS. It is a so-called cylindrical shape with
In the present invention, the cross-sectional shape of the column 7f may be an elliptical shape, a triangular shape, or a rectangular cross-sectional shape such as a quadrangular prism shape as shown in FIG. There may be.

Further, with respect to the head of the male lock 7, in order to easily fit the pilot hole 9 provided in the roof module Y and the lock hole 8a provided in the cover 8,
It is preferable that at least one or more slits 7h are provided in the head around the locking portion 7c of the male lock 7.

As shown in FIGS. 9 and 11 to 17, in order to secure even a little mechanical strength around the root 7g of the male lock 7 provided on the support plate 3d of the electrical component 3. , Support plate 3 including the vicinity of the periphery of root 7g of male lock 7
If a curved or straight overlay is provided on d, stress concentration and the like can be reduced, and the mechanical strength of the root 7g of the male lock 7 can be improved.

In this way, when the male lock 7 and the pilot hole 9 of the roof module Y are fitted and the electric component 3 and the roof module Y are assembled, the male lock 7 is removed from the support plate 3d. It is expected that the occurrence of defects such as breakage can be reduced as much as possible.

In FIGS. 9, 11 and 12, the shape from the engaging portion 7c to the tip 7a of the male lock 7, that is, the head shape of the male lock 7 is conical. As shown in FIGS. 13 to 17, the head 7 has a shape similar to a roof having at least two or more slopes, and may have a shape similar to an umbrella. Here, as also shown in FIGS. 11 to 13, the distal end portion 7 a of the male lock 7 has a shape having a curvature surface so as not to inadvertently injure a hand or the like when handling the electrical component 3. I have.

Next, the process until the male lock 7 shown in FIG. 13 is fixed to the roof module Y and the cover 8 will be described.
This will be described with reference to FIGS. FIG. 13 is an enlarged perspective view showing another example when the male lock 7 provided in the electric component 3 is attached to the pilot hole 9 provided in the roof module Y.

FIG. 14 shows the electrical component 3 shown in FIG.
FIG. 10 is a vertical cross-sectional view when assembling the male lock 7 provided in the vehicle and the pilot hole 9 provided in the roof module Y, and is a vertical cross-sectional view showing another example of the embodiment shown in FIG. 9. 14 to 17 are explanatory views of assembling the electric component 3 and the roof module Y.
FIG. 9 is a longitudinal sectional view showing a process of forming a roof module Z by assembling a roof module Y with a roof module Y.

As shown in FIG. 13, the male lock 7 shown in FIG. 14 is provided with a tip portion 7a, an inclined portion 7b similar to a roof shape, a locking portion 7c, and a lower portion of the locking portion 7c. Fixing projections 7i are provided. And
The inclined portion 7b, the locking portion 7c, and the fixing protrusion 7i are provided at about two places and provided as a pair. here,
The distal end portion 7a, the inclined portion 7b, the locking portion 7c, and the fixing projection 7i of the male lock 7 are collectively called an umbrella portion 7j.

As shown in FIG. 15, when the male lock 7 starts to be inserted into the pilot hole 9, the umbrella portion 7j of the male lock 7
Is closed, and while the pilot hole 9 provided in the roof module Y is pushed open by the umbrella portion 7j of the male lock 7, the male lock 7 is inserted into the pilot hole 9 in a so-called forced insertion state.

At this time, the male lock 7 is provided with an inclined portion 7b at the distal end 7a, and the head of the male lock 7 is in the closed state of the umbrella. The locking portion 7c of the lock 7 is inserted into the pilot hole 9 with an appropriate force. Further, the press contact terminals 6i provided on the bus bar 6b are in a state of about to pierce the roof module Y.

Thereafter, as shown in FIG. 16, the umbrella portion 7j provided at the head of the male lock 7 passes through the pilot hole 9 and reaches the upper surface Y1 of the roof module Y. Then, the forcibly inserted state is terminated, and the inclined portion 7b of the umbrella portion 7j is opened slightly so that the fixing projection 7i is fitted inside the pilot hole 9, so that the male lock 7 and the roof module Y are temporarily fixed.

At this time, the press contact terminal 6i provided on the bus bar 6b penetrates through the skin 1b of the roof module Y from the tip 6d and enters the inside of the base 1a.
Further, the insulating coating 2c of the flat wire harness 2a is cut off by the press contact terminal 6i, and the conductor is formed by the slit 6e of the press contact terminal 6i and the conductor 2b of the flat wire harness 2a provided inside the molded body module Y. 2b is in a state of starting to come into pressure contact.

As shown in FIG. 16, the bus bar 6b is connected to the main body 6c of the bus bar 6b from the inside of the electrical component 3.
Extend substantially parallel to the lower surface portion 3c of the electrical component 3 with a small gap X. Bus bar 6 shown in FIG.
b, the main body 6c of the bus bar 6b is the lower surface 3 of the electrical component 3.
The bus bar 6b shown in FIGS. 14 to 17 has a small gap X with the lower surface portion 3c of the electrical component 3, although the bus bar 6b shown in FIG.

Here, for example, when an automobile is used in a usage state in which the temperature and humidity change greatly in the midwinter or rainy season, moisture generated by dew condensation or the like causes the lower surface 3c of the electrical component 3 to be removed. It is also expected that some will accumulate. However, if a small gap X is secured between the bus bar 6b and the lower surface portion 3c of the electrical component 3, moisture generated due to dew condensation or the like comes into contact with the bus bar 6b, for example, causing an electrical contact failure. It can be expected that the occurrence of defects can be prevented.

Then, the roof module Y is connected to the insulation displacement terminal 6.
i, is pressed down as shown in the mounting direction E toward the distal end 6d, so that even when the distal end 6d of the press contact terminal 6i breaks through the skin 1b of the roof module Y and the press connection is started, the bus bar 6b is still connected to the electrical equipment. Since only a small gap X is left with the lower surface portion 3c of the product 3, the lower portion of the bent portion 6g of the bus bar 6b is slightly deformed elastically when the main body portion 6c of the bus bar 6b is deformed during the press-contact connection. By contacting the lower surface 3c of the electrical component 3, the press contact terminal 6i can receive the resistance force applied at the time of press connection. Therefore, also in this case, it is considered that the pressure connection can be performed well.

Further, the upper surface of the bus bar 6b and the support plate 3d
The main body 6c of the bus bar 6b may be set so that the upper surface of the bus bar 6b and the upper surface of the bus bar 6b are at the same height. As described above, the bus bar 6b is located inside the electrical component 3,
It may be appropriately set to a part that is easy to provide.

Next, the cover 8 is pivoted around the hinge 8b as a central axis.
Is closed and the lock hole 8a provided in the cover 8 and the male lock 7 are fitted. Here, when the umbrella portion 7j provided at the head of the male lock 7 is closed, the dimension from one locking portion 7c to the other locking portion 7c of the male lock 7 is 9d in diameter of the pilot hole 9. It has a larger diameter dimension than that. In this way, once the cover 8 is closed and the male lock 7 is engaged with the lock hole 8a, the cover 8 is not easily released from the male lock 7 by the locking portion 7c. Conceivable.

The state when the male lock 7 and the lock hole 8a provided in the cover 8 are engaged will be described in detail. First, when the cover 8 is closed with the hinge 8b of the cover 8 as the central axis, The lock hole 8a of the cover 8 is
, But the fitting has not yet been performed.

Next, when the cover 8 is strongly pressed down with a hand or the like, the diameter 8d of the lock hole 8a provided in the cover 8 is slightly widened, and the umbrella portion 7j of the male lock 7 is slightly shrunk. , And it becomes a forced state as described above. Thereafter, the umbrella portion 7j passes through the lock hole 8a of the cover 8 and passes through to the upper surface of the cover 8, that is, the upper surface portion 3b of the electrical component 3 here, and the locking is completed. At the same time, the pressure contact connection between the pressure contact terminal 6i, which has entered the interior of the roof module Y, and the conductor 2b of the flat wire harness 2a is completed, and a current can be supplied.

If the pressure connection is made in this manner, there is no need to attach the connector 10 to the flat wire harness 2a of the roof module Y as described in the prior art, and furthermore, the electric circuit on the electrical component 3 side. The necessity of providing a connector in the peripheral portion is also eliminated. Therefore, the connector 10 is not required as compared with the conventional roof module Y, and the number of components can be significantly reduced.

Thus, as shown in FIG. 17, the male lock 7 and the lock hole 8a provided in the cover 8 are provided.
A roof module Y in which a pilot hole 9 provided in the roof module Y is fixed, and a flat wire harness 2a is insert-molded in the roof liner 1;
Assembling with the electrical component 3 and press-connecting are performed simultaneously, and the roof module Z is formed.

Further, on the upper surface Y1 of the roof module Y,
By fixing the cover 8 provided on the electrical component 3 to the male lock 7, the base 1a of the roof liner 1 is crushed to such an extent that the flexibility and the restoring property are not completely lost as shown in FIG. ing. The roof module Y is compressed and crushed mainly between the inner surface 8c of the cover 8 and the support plate 3d at the base 7g of the male lock 7. That is, the male lock 7 is mainly compressed and crushed in the vicinity of the periphery of the column 7f, whereby a restoring force is generated in the roof liner 1.

In FIG. 17, the total thickness T1 of the roof module Y or the thickness T2 of the base material 1 of the roof liner 1 is shown.
The roof module Y has a thickness not less than １ ／ of each of the original thicknesses T1 and T2 and less than the original thicknesses T1 and T2.
Is in a state of being appropriately crushed and generating a restoring force.

Here, the overall thickness T1 of the roof module Y and the thickness T2 of the base 1a of the roof liner 1 will be described in detail. Such thicknesses T1 and T2 are, for example, those of the roof liner 1 made of a flexible molded body 1. In a state where the formed roof module Y is left almost naturally without being crushed or deformed by another external force, or under a state where it is hardly affected by external force, It refers to the thickness that is measured and measured.

As described above, since the roof module Y that has been appropriately crushed has a restoring force to return to the original thickness T1 of the roof module Y, the upper surface Y1 of the roof module Y is attached to the inner surface of the cover 8. 8c. As a result, the pair of locking portions 7c of the umbrella portion 7j provided on the head of the male lock 7 are brought into contact with the upper surface portion of the cover 8, that is, the upper surface portion 3b of the electrical component 3 with an appropriate force. And, together with this, the pair of locking portions 7c
The fixing projection 7i provided at the lower portion of the cover 8 is securely fixed to the inner peripheral portion of the lock hole 8a provided in the cover 8, and the cover 8 may be finely shaken by vibration or the like, which may cause abnormal noise. Absent.

If such a fixing means is adopted, the conductor 2b of the flat wire harness 2a provided inside the roof module Y due to vibration and the electrical component 3
6e of pressure contact terminals 4a, 6h, 6i provided in
It is possible to prevent the occurrence of such a problem that the electrical contact portion with the portion always moves due to resonance or the like, thereby causing an electrical contact failure. Further, for example, the roof module Y is moved from the electrical component 3 by vibration or the like.
Can be expected to prevent the occurrence of such a problem that the power supply is inadvertently disconnected and power cannot be supplied.

Description of the hinge portion 8b of the cover 8 shown in FIGS. 14 to 16 is substantially the same as that described above with reference to FIG. The cover 8 shown in FIG. 17 is in a state where the cover 8 shown in FIGS.

The cover 8 in the closed state will be described in detail. The electrical component 3 and the roof module Y are assembled by the male lock 7, the cover 8 having the lock hole 8a, and the pilot hole 9 for the male lock 7. It is in a state of being integrated and fixed. In this way, as shown in FIG. 17, the cover 8 is in a state parallel to the upper surface 3 b of the electrical component 3, and the cover 8 forms the upper surface 3 b of the electrical component 3.

The method of assembling the electric component 3 and the roof module Y described above is an example of the present invention.
In the present invention, in addition to the method of manufacturing the roof module Z described above with reference to FIGS. 9 and 14 to 17, a flat wire harness 2 a provided inside the roof module Y and the electric component 3 are further provided. For example, a manufacturing method may be adopted in which the pressure contact connection with the bus bar 6b is performed, for example, by closing the cover 8, so that the fixing and the electrical connection are simultaneously performed.

The operation steps will be briefly described in order with reference to the drawings. After shifting from the state of FIG. 14 to FIG. 15, the operation step of FIG. 16 is omitted and the state shown in FIG. 17 is obtained. More specifically, referring to FIGS. 14, 15, and 17, the cover 8 is closed in the state shown in FIG. 15 after the process is shifted from the state shown in FIG. 14 to the step shown in FIG. Enter the operation.

Then, the upper surface Y1 of the roof module Y starts to be pressed by the inner surface 8c of the cover 8, and the distal end 6d of the press contact terminal 6i provided on the bus bar 6b is provided on the lower surface Y2 of the roof module Y. Epidermis 1b
And the press contact terminal 6i starts to enter the interior of the roof module Y.

When the cover 8 is further pressed against the roof module Y, the male lock 7 goes deep into the pilot hole 9 and at the same time, the press contact terminal 6i cuts off the insulating coating 2c of the flat wire harness 2a. The slit 6e and the conductor 2b start to contact. At the same time, when the cover 8 is further pushed against the roof module Y, the locking portion 7c provided on the head of the male lock 7
It passes through the pilot hole 9 of the roof module Y and enters the lock hole 8a provided in the cover 8.

Thereafter, the locking portion 7c provided on the head of the male lock 7 passes through the lock hole 8a provided in the cover 8, and as shown in FIG.
And the roof module Y and the electrical components 3
Is assembled. And with this busbar 6
b and the flat wire harness 2a inside the roof module Y are disconnected from the pressure contact terminal 6i, and a state where power can be supplied is established.

By assembling the electrical component 3 and the roof module Y in such a procedure, it is possible to fix both more quickly, so that the assembling work can be quickly performed in the manufacturing process, which is preferable. Such an assembling method may be applied to the assembling method of the electric component 3 and the roof module Y shown in FIG. 9, and in this case, the relationship between the pilot hole 9 and the male lock 7 is shown in FIG. In addition to the form shown in FIG. 11, the form shown in FIG. 11 may be used, and any other form may be used.

FIGS. 8 and 10 are enlarged perspective views of the press contact terminals 6h and 6i provided on the bus bar 6b. The bus bar 6b shown in FIG. 10 is different from the bus bar 6b shown in FIG.
In another embodiment, the bus bar 6b shown in FIG. 10 is formed into a shape that is more easily pierced into the roof module Y and is press-connectable. 8 and FIG. 10 will be described below, but the contents of FIG. 8 and FIG. 10 may have many common parts, and the common parts will be described together in the two figures.

When the roof module Y having the flat wire harness 2a therein and the electrical component 3 are assembled, press-fitting connection is performed to make it possible to conduct electricity. By using the press contact terminal 6i having the shape shown in FIG. 10, the flat wire harness 2a provided inside the roof module Y shown in FIG. 3 and FIG. it can.

The press contact terminals 6h or 6i provided on the bus bar 6a will be described in detail with reference to FIG.
Are provided with a substantially U-shaped slit 6e portion, and the electric wire 2a such as a flat wire harness 2a covered with this slit 6e portion is pressed by a pressure welding tool. By press-fitting with the use of, for example, the insulating coating 2
b can be connected at the same time.

Then, the tip 6 of the press contact terminal 6h or 6i
d has two inclined portions 6f around the slit 6e.
Is provided. That is, a so-called pair of inclined portions 6f are formed at the tip portions 6d of the press contact terminals 6h and 6i, and the press contact terminals 6i shown in FIG. 10 have a tapered and sharp tip shape. Here, the slit 6e
Is set such that the cut ends at a portion before the bent portion 6g of the bus bar 6b, and thus the strength of the press contact terminal 6h or 6i is secured.

The tip 6 of the press contact terminal 6h shown in FIG.
Since the entirety of the wire d has the sharp tip shape as described above, the insulating cover 2c of the flat wire harness 2a is peeled by piercing the base material 1a of the roof liner 1 having a flexible property, and the inside of the electric wire 2a is removed. The reliable electrical connection with the conductor 2b is quickly made. Thus, the electrical component 3
And the flat wire harness 2a can be electrically connected quickly and easily.

The bus bar 6 shown in FIGS.
b mainly includes the press contact terminals 6h and 6i and the main body 6c.
And two sites. As shown in FIGS. 8 and 10, the press contact terminals 6 h and 6 i of the bus bar 6 b and the main body 6 c are bent at a bent portion 6 g, and the bent portion outside the bent portion 6 g is bent at a gentle curvature. However, the inner bent portion of the bent portion 6g is bent with a slightly steeper curvature than the outer bent portion, and the bent portion 6g is bent.
g is bent at a substantially right angle as a whole.

Here, the term “gradual curvature shape” refers to a curvature shape that does not cause a problem such as a crack or a curved surface in a metal plate or the like that forms the bus bar 6b and the press contact terminal 4a. For example, as described above, the outer bent portion of the bent portion 6g has a gentle curvature shape, but the inner bent portion has a sharp right-angled shape like the bent portion shape. May be a bent portion. Such a shape is likely to be the above-described bent portion shape during the press working described later. As described above, the numerical value of the curvature of the bent portion 6g may be set in any manner while considering various factors such as the processing method, the material of the plate material, and the thickness dimension.

For example, when a metal plate or the like forming the bus bar 6b is processed by, for example, press working, the curvature is set so that the curvature is not unnecessarily small so-called a sharp curve. By performing the press working, it is not necessary to perform an excessive bending process on a metal plate or the like, and a large internal stress such as distortion is not left on the plate. Then, the bus bar 6b can be manufactured while forming a curvature to the extent that so-called cracks such as cracks do not occur in the metal plate material.

As described above, if the bent portion 6g is formed as described above, the bus bar 6b is manufactured by press working, and the handleability is improved in the subsequent forming step, assembling step, and the like. Even if the above-mentioned pressed parts are handled carelessly in each of the above manufacturing steps, the risk of injury to hands and the like can be reduced as much as possible.

As shown in FIG. 10, if the pressure contact terminal 6i is tapered and has a sharp tip,
When the roof module Y shown in FIGS. 3, 9, and 11 to 17 is pierced and electrically connected, it is considered that the resistance applied to the tip end 6d of the press contact terminal 6i is small.

Regarding this, when making the pressure contact connection,
This is because, for example, it is considered that it is unlikely that the roof module Y shown in FIG. 3, FIG. 9, and FIGS.
As a result, it can be expected that a decrease in the yield of the productivity relating to the roof module Y can be suppressed as little as possible.

Next, the above-described roof module Z
As an embodiment of the manufacturing process according to the above, a method of manufacturing a molded body module Z including the roof liner 1, the flat wire harness 2a insert-molded into the roof liner 1 and integrated, and the electrical component 3 will be described in detail. As an example of the present invention, a plurality of each of three types of roof modules Y shown in FIGS. 1 to 3 were manufactured.

More specifically, in the roof module Z of the present invention, a predetermined flat wire harness 2a is set in a cavity of a mold in which a predetermined roof liner 1 can be formed. A raw material such as a liquid foamable resin or urethane is filled in a cavity of a mold, cured by heating and pressurizing, and insert molding of a roof liner 1 and electric wires 2a such as a flat wire harness 2a to form a roof module Y. . Then, after a required cooling time, the press contact terminals 4a, 6h, 6i and the flat wire harness 2a are used by using the press contact terminals 4a, 6h, 6i provided in the predetermined electrical component 3.
It is manufactured in such a procedure that the conductor 2b is press-connected to enable electrical conduction.

If the roof module Z is manufactured and assembled in such a procedure, the flat wire harness 2a is insert-molded inside the roof liner 1 to manufacture the roof module Y, and then the flat wire harness 2a is formed. The work of attaching the attached connector to the connector 10 on the side of the electrical component 3 and making an electrical connection with each other can be simplified, and the roof module Y and the electrical component can be easily connected to each other by a simple connection method of performing pressure connection using pressure terminals. Since the product 3 can be connected, the speed of the manufacturing process can be increased.

When the roof module Z is manufactured by such a manufacturing method, the roof liner 1
The roof module Z can be quickly and easily assembled by integrally assembling the flat wire harness 2a and the electrical component 3. Accordingly, it is possible to speed up the assembly work of finishing the predetermined part by separately attaching the roof liner 1, the flat wire harness 2a, and the electric component 3 as in the related art, and to save labor associated with this. Workability in manufacturing Z is improved.

The roof module Y shown in FIG.
Is a flat wire harness 2 for insert molding.
The flat wire harness 2a extends from the inside of the roof liner 1 to the outside of the roof liner 1 from the end face 1d of the opening 1c, which is the electrical component mounting portion 1c, without attaching the connectors 10 to the roof liner 1a. In addition, the flat wire harness 2a is provided in a molding die so as to extend toward the inside of the opening 1c, and insert molding is performed.

In the case of the roof module Y shown in FIG. 2, the connectors 10 are not attached to the three conductors 2b at the time of insert molding, and each of the conductors 2b is moved from inside the roof liner 1 to the roof module Y. Opening 1c
A conductor 2b is provided in a molding die so as to extend from the end face 1d of the molding die so as to protrude outside the roof liner 1 and extend toward the inside of the opening 1c. Manufactured in the procedure to be.

Then, the protruding portion of the flat wire harness 2a or the conductor 2b and the press contact terminals 4a and 6h provided on the electrical component 3 were connected by press contact to assemble the roof module Z. Specifically, the roof module Y described above and shown in FIG.
The crimping connection was made as shown in FIG.

By performing such a manufacturing method, desired roof modules Y and Z can be easily manufactured. In the prior art, the work of setting the flat wire harness 2a with the connector 10 as shown in FIGS. 19 and 20 in the cavity of the mold is troublesome, complicated, and inefficient. It was not practical to proceed.

Even if such an operation is actually imposed on an operator, the operator sets the flat wire harness 2a with the connector 10 correctly in the mold cavity, or attaches the connector 10 at that time. It was anticipated that skilled work procedures and great care would be required to set without having to bite into the mold.

Further, in order to carry out such a manufacturing method, it is necessary to produce and prepare a dedicated mold having a complicated shape, and such a mold becomes an expensive mold and costs are increased. It was not realistic from the point of view. However, if the above-described manufacturing method is performed, the roof module Z can be easily manufactured without performing the complicated and difficult work as described above.

The electric wires 2a such as the flat wire harness 2a and the conductor 2b are transferred from the inside of the roof liner 1 to the outside of the roof liner 1 by a predetermined length from the end face 1d of the opening 1c serving as the electrical component mounting portion 1c. In order to protrude and extend, a predetermined flat wire harness 2a
It is preferable to provide a space capable of accommodating the length of the electric wires 2a such as the wire and the conductor 2b.

When performing the insert molding of the flat wire harness 2a and the roof liner 1, the wires 2a such as the flat wire harness 2a and the conductor 2b having a predetermined length are placed in a predetermined space provided in a mold. What is necessary is just to shape it so that it may be accommodated. With this configuration, it is considered that the above-described manufacturing method can be performed by a relatively simple modification of the mold without making the mold a complicated mechanism.

[0216] Of the plurality of products described above, the roof module Y shown in FIG. 3 is subjected to a trimming process on the roof module Y after the insert molding. The burrs left around the end face 1d of the opening 1c of the roof liner 1 and the flat wire harness 2a protruding outside the roof liner 1 from the end face 1d of the opening 1c of the roof module Y are trimmed at the same time to perform the roof module Y Was manufactured.

By manufacturing the roof module Z in this manner, the connector 10, 10a to 10f can be trimmed as in the case of the conventional roof module Y shown in FIGS. This makes it possible to solve the problem that the trimming process is not established due to, for example, the biting of a peripheral member such as a mold, a tool, or a jig.

That is, after the flat wire harness 2a is insert-molded into the roof liner 1 to form the roof module Y, workability related to the trimming processing of the roof module Y can be greatly improved, and labor saving in the manufacturing process can be achieved. , I was able to speed up.

When handling the conventional roof module Y as shown in FIGS. 19 and 20, the worker takes care not to damage the electric wires 2a such as the connectors 10, 10a to 10f and the flat wire harness 2a. However, the necessity of performing a trimming process, that is, a deburring operation, is eliminated, and a large amount of attention and a complicated operation such as labor imposed on an operator can be significantly reduced. Accordingly, the workability of the deburring process is improved, and labor and speed in the manufacturing process can be reduced.

Further, among the plurality of products described above, the roof module Y shown in FIG. 3 has the roof liner 1 and the roof liner 1 as shown in FIGS. Flat wire harness 2a
Lower surface Y2 of roof module Y comprising
From the side b, the press contact terminal 6i was directly pierced into the roof module Y to perform press contact connection to produce a molded module Z.

The press connection process will be described in detail. The bus bar 6 of the electrical component 3 is mounted on a predetermined portion of the roof module Y including the roof liner 1 and the flat wire harness 2a insert-molded into the roof liner 1.
When the pressure contact terminal 6i provided at the point b is pierced from the distal end portion 6d, the pressure contact terminal 6i breaks through the molded body module Y and enters the inside, and is provided in the slit 6e portion of the pressure contact terminal 6i and inside the molded body module Y. The flat wire harness 2a is pressed and connected to the conductor 2b of the flat wire harness 2a, and can be energized. Accordingly, electrical connection can be easily performed, and workability during assembly can be improved.

Here, when assembling the roof module Z according to the present invention, for example, the electric wire 2 such as a factory for manufacturing the roof liner 1 or the flat wire harness 2a is used.
It may be carried out at a manufacturing factory of the type a, or at an assembly line factory of an automobile. If the surrounding environment for forming the roof module Z is provided,
It may be performed in any manufacturing plant.

For example, a roof module Y manufactured by insert-molding electric wires 2a such as a flat wire harness 2a into the roof liner 1 and an electrical component 3 are separately prepared in advance, and these two components are prepared. May be assembled on a predetermined automobile ceiling at an automobile assembly line factory.

[0224] Two parts, a roof module Y manufactured by insert-molding an electric wire 2a such as a flat wire harness 2a on the roof liner 1 and an electrical component 3, are provided.
The roof module Z may be prepared in an assembled state in advance, and the roof module Z thus assembled in advance may be attached to a ceiling of a predetermined vehicle at a vehicle assembly line factory.

As a material of the molded body 1 such as the roof liner 1 used in the present invention, any material such as a hard material and a flexible material may be used. For example, a foaming resin or a soft resin produced from urethane or a liquid material is used as a foam material for the base material 1a, or at least the indoor side or both sides of the flexible molded body 1 such as the roof liner 1 is used. Use a thin resin film material for the skin 1b used,
Furthermore, a nonwoven fabric material or the like may be used.

It is preferable that the material has a certain degree of flexibility and cushioning property and that it has a good touch, and any material having such characteristics may be used. For example, a foamable material such as a urethane foam sheet has the above-described characteristics and also has an effect of preventing generation of abnormal noise in a vehicle interior. Therefore, a foamable material such as a urethane foam sheet constitutes the roof module Y of the present invention. For the roof liner 1 for use.

Also, the roof module Y shown in FIGS. 3, 9, and 11 to 17 and the pressure contact terminals 6i provided on the bus bar 6b of the electrical component 3 shown in FIGS. When the roof module Z is formed as described above, it is preferable that the material of the roof liner 1 be a flexible molded body 1.

The press contact terminal 6i provided on the bus bar 6b of the electrical component 3, that is, the press contact bus bar, breaks through the base material 1a of the roof liner 1 in order to conduct with the flat wire harness 2a provided inside the roof module Y. In addition, the insulating cover 2c of the electric wire 2a must also be peeled off so that an electric connection with the conductor 2b inside the electric wire 2a can be reliably established. To do so, as shown in FIG. 10, the bus bar 6b has a sharp tapered tip shape.

In one embodiment of the present invention, the roof liner 1
Is a molded body 1 having a mainly flexible property, the pressure contact terminal 6i provided on the bus bar 6b of the electric component 3 breaks through the roof liner 1 and press-connects with the electric wire 2a therein. Becomes possible.

Furthermore, the press contact terminal 4a or the bus bar 6a shown in FIG. 4 and the press contact terminal 6a shown in FIG. 8 or FIG.
Hereinafter, a method for manufacturing the bus bar 6b including h and 6i will be described. First, a flat metal sheet having conductivity is subjected to punching with a press machine or the like to form a terminal metal material having a predetermined developed shape.

At this time, the portion of the press contact terminal 4a to be the press contact piece 4b, the portion to be the press contact piece 4c, the portion to be the elastic contact piece 4d, the portion to be the window 4f, and the press contact terminals 6h and 6i of the bus bar 6b. A terminal having a predetermined developed shape by punching out such portions in advance so as to be manufactured by punching a portion which becomes the main portion 6c, a portion which becomes the bent portion 6g, and the like. Produce metal fittings. Then, punching processing is performed in advance to make them into a terminal fitting material made of a thin metal plate.

In order to apply the terminal fitting material thus punched out and having a predetermined developed shape to the respective embodiments, for example, regarding the bus bar 6b, the bending process is performed at each bending portion 6g. By performing the above, the bus bar 6b having the shape shown in FIGS. 8 and 10 is formed. here,
Before and after the above-described pressing process, a rolling process may be performed as necessary on a metal base material or a terminal fitting material, but if there is no particular need, such a rolling process is omitted. Is also good.

As described above, the press contact terminal 4a or the bus bar 6a shown in FIG.
In the manufacturing process of the bus bar 6b shown in FIG. 5, a press-connecting terminal 4a and bus bars 6a and 6b having a predetermined shape are manufactured through a punching process and a bending process by a press machine or the like. In the above-described punching and bending processes, a metal base material made of a continuous thin metal plate, that is, a long object is set at the entrance of a press working machine, and the press working machine progressively works.

The base material made of a thin metal plate is punched into a developed state in a predetermined shape by a press die such as a hammer and an anvil provided in a press machine, and is subjected to bending and the like. Then, the press contact terminals 4a and the bus bars 6a, 6b having a predetermined shape are finished.

With regard to a series of operations such as punching and bending by the above series of press working machines, at least one or a plurality of the above series of press working steps are prepared by one type of press working machine. If this is done, one type of busbar with a predetermined shape can be
It can be manufactured by one or a plurality of press machines.

For example, a metal base material made of a continuous thin metal plate, that is, a long object, is set at the entrance of the press machine, and the machining process is advanced for each stroke. At the exit of the press machine, a predetermined shape is formed. Press contact terminals 4a, 6
h, 6i, and the bus bars 6a, 6b, the above-described manufacturing method is performed using a press machine capable of manufacturing the press-connecting terminals 4a, 6h, 6i efficiently and quickly. However, in the manufacturing method according to the present invention, depending on production conditions and the like, various press working machines that perform different manufacturing steps are used to finish the shape of the predetermined press contact terminals 4a, 6h, and 6i. Alternatively, the bus bars 6a and 6b may be finished.

Examples of the material of the press contact terminal 4a or the bus bars 6a and 6b used in the present invention include copper-based materials such as bronze and copper alloy, and aluminum alloys. The terminal 4a or the busbars 6a and 6b may be made of a metal material having a current-carrying function, or any other conductor that can conduct electricity well. It may be processed.

However, the press contact terminal 4a or the bus bar 6
For example, as shown in FIGS. 4 to 8, a and 6b may have complicated shapes. Therefore, the material of the press contact terminal 4a or the bus bars 6a and 6b according to the present invention includes punching, bending and the like. It is preferable to use a material which is excellent in plastic workability, excellent in mass production, and satisfies various properties comprehensively, and also satisfies price.

As such a material, specifically, bronze, a copper alloy, an aluminum alloy, or the like as described above can be preferably mentioned. From the viewpoint of labor saving and price reduction, It is preferable that the surface protection treatment is omitted. Therefore, as the material of the press contact terminal 4a or the bus bars 6a and 6b of the present invention, the press contact terminal 4a or the press contact terminal 4a selected from at least one kind of metal material of at least bronze, copper alloy, and aluminum alloy used in one embodiment It is preferable to employ the bus bars 6a, 6b in the present invention.

The electric wire used in the present invention is, for example, an electric wire used in a flat wire harness 2a such as a flexible flat circuit body, a flexible printed circuit body, a circuit body made of a round conductor ribbon wire, and a circuit body made of a flat wire. 2a and the like, and any form of electric wire may be used.

However, since the roof liner 1 mainly uses the electric wire in a limited thin space such as the ceiling of an automobile, the electric wire used in the present invention has a flat and freely bendable as shown in FIG. 1 or FIG. It is preferable to use a wire having a certain degree of flexibility, and it is preferable to use a flat wire harness 2a as such a wire 2a.

The electric wire 2a such as the flat wire harness 2a is mainly composed of a conductor 2b and an insulating cover 2c. As shown in FIGS. 1 to 3, the electric wire 2a is bent at a substantially right angle to form a bent portion 2e. Used as provided.
Therefore, the material of the conductor 2b is preferably a metal wire that has not only good electrical conductivity but also characteristics that can withstand repeated bending. Further, in order to further increase the insulating property of the surface of the conductor 2b made of a metal wire, the conductor 2b coated with the enamel material 2c 'may be used for the electric wire 2a such as the flat wire harness 2a.

Then, the insulating cover 2 protecting the conductor 2b
c is also preferably an insulating material having a property that can withstand repeated bending as described above,
As such a material, for example, an insulating coating material 2c made of a synthetic resin material, a rubber material, or a mixture thereof may be used for the electric wire 2a such as the flat wire harness 2a.

The electrical components used in the present invention include, in addition to the indoor lights such as the various lamps described above, sensors such as smoke sensors and geomagnetic sensors, and electric circuits used for sunroofs. Electrical components, and all types of electrical components can be used in the present invention.

As the molded article 1 of the present invention, in addition to the roof liner 1 described above, peripheral parts of an instrument panel, door peripheral parts such as a normal door, a sliding door, a rear door, and a rear package tray The present invention can also be applied to a molded article used in a peripheral part or the like, and can be developed as a module at any location, and various kinds of components described above can be used as a molded article module.

When such a molded article is used, for example, in an automobile, it is in a limited space of a room, so that it serves as a cushion even if it is accidentally hit with a hand or a head. It is preferable that the molded article has a flexible property.

Thus, the molded article module of the present invention
As described above, it can be applied to any use. However, it is relatively time-consuming to attach the roof liner 1, the flat wire harness 2a, and the various electric components 3 to the ceiling portion of the vehicle at the time of assembling the vehicle. If the present invention is applied to a roof module around the roof liner 1 attached to the ceiling of an automobile to make a roof module, the assembly work becomes easy and the manufacturing process can be speeded up. it can.

[0248] Accordingly, simplification of the assembling process can be achieved at the same time, whereby the assembling site in the factory can be organized. In this way, it is possible to comprehensively reduce the price, so it can be said that the present invention is preferably applied to the roof modules Y and Z.

[0249]

As described above, according to the molded article module of the present invention, it is possible to reduce the number of parts as compared with the conventional molded article module, and to reduce the weight and cost of the molded article module. The price can be reduced.

Further, according to the molded article module of the present invention, it is possible to integrally assemble the molded article, the electric wire, and the electric component, and separate the molded object, the electric wire, and the electric component separately from each other as in the related art. Assembly work such as mounting and finishing a predetermined portion can be performed easily and quickly. In addition, it is possible to provide a molded body module that can be easily attached to a predetermined portion and has excellent assemblability.

Further, according to the method for manufacturing a molded body module of the present invention, a molded body module is manufactured by insert-molding an electric wire inside a molded body, and then a connector attached to the electric wire is manufactured. The work of attaching to the connector on the electrical component side and making an electrical connection with each other can be simplified, and the compact module and the electrical component can be connected by a simple connection method called pressure connection, which speeds up the manufacturing process. be able to.

[Brief description of the drawings]

FIG. 1 is an enlarged perspective view showing a periphery of an electrical component mounting portion of a roof module.

FIG. 2 is an enlarged perspective view of another example showing a periphery of an electrical component mounting portion of the roof module.

FIG. 3 is an enlarged perspective view of another example showing a periphery of an electrical component mounting portion of the roof module.

FIG. 4 is an enlarged perspective view showing a state when electric components and a roof module are assembled.

FIG. 5 is a sectional view taken along the line SS in FIG. 4;

FIG. 6 is an explanatory diagram when the press contact terminal is attached to the connector housing.

FIG. 7 is a top view showing a state where the electric component and the roof module are assembled.

FIG. 8 is an enlarged perspective view of a press contact terminal provided on a bus bar.

FIG. 9 is a longitudinal sectional view showing another example when assembling the electrical component and the roof module.

FIG. 10 is an enlarged perspective view showing another example of the press contact terminal provided on the bus bar.

FIG. 11 is an enlarged perspective view when attaching a male lock to a pilot hole.

FIG. 12 is an enlarged perspective view showing a relationship between a pilot hole and a male lock shown in FIG. 9;

FIG. 13 is an enlarged perspective view showing another example of attaching a male lock to a pilot hole.

FIG. 14 is a longitudinal sectional view showing another example when assembling the electrical component and the roof module.

FIG. 15 is an explanatory diagram when assembling the electrical component and the roof module.

FIG. 16 is an explanatory view when assembling the electric component and the roof module.

FIG. 17 is an explanatory view when assembling the electric component and the roof module.

FIG. 18 is an exploded perspective view showing an example of a conventional automobile roof liner and a wire harness attached thereto.

FIG. 19 is a perspective view of a conventional roof liner in which a flat wire harness is insert-molded into a roof liner.

FIG. 20 is a sectional view taken along line AA of FIG. 19;

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Molded body (roof liner) 1a Base material 1b Skin 1c Electrical equipment mounting part (opening) 1d End face 1e Mounting hole 2 Electric wire (wire harness) 2a Electric wire (flat wire harness) 2b Conductor 2c Insulating coating 2c 'Insulating coating ( Enamel material) 2d Diameter 2e Bending part 3 Electrical equipment 3a Frame 3b Upper surface part 3c Lower surface part 3d Support plate 3e Housing chamber 4 Connector 4a Pressure contact terminal 4b Pressure contact piece 4c Crimping piece 4d Elastic contact piece 4e Locking projection 4f Window part 4g Engagement hole 5 Connector housing 5a Flexible locking arm 5b Locking projection 5c Attachment 6a, 6b Bus bar 6c Main body 6d Tip 6e Slit 6f Inclined portion 6g Bend 6h, 6i Pressure contact terminal 6j For engagement Hole 6k Contact tab 7 Male lock 7a Tip 7b Inclined part 7c Locking part 7d, 7e Diameter 7f Column g Root 7h Slit 7i Fixing projection 7j Umbrella 8 Cover 8a Lock hole 8b Hinge 8c Inner surface 8d Diameter 8e, 8f Neck 9 Pilot hole 9a Slit 9d Diameter 10, 10a-10f Connector 10g Connector housing 10h Release rod 11 Terminal 11a Conductor connection part 11b Coated crimping piece 12 Tape for converging various electric wires 13 Fixing tape B Blade E Mounting direction F Rotation direction G1 Caulking direction G2 Insertion direction L1 Length of press-contact terminal L2 Locking part of male lock Length from base to root T1 Overall thickness of roof module T2 Thickness of base material of roof liner T3 Thickness of cover X Gap amount Y, Z Molded module (roof module) Y1 Upper surface Y2 Lower surface

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) H01R 43/01 B60R 16/02 620Z 5G355 H02G 1/14 B29K 105: 22 5G361 3/30 B29L 31:30 5G363 3/38 31:34 // B60R 16/02 620 H01R 9/07 B B29K 105: 22 23/66 D B29L 31:30 23/68 E 31:34 H02G 3/26 H 3/28 F F term (reference ) 4F206 AA31 AA42 AB02 AD03 AD15 AG20 AH17 AH34 JA07 JB12 JB17 JF05 JL02 JP30 JW23 5E012 AA08 AA14 AA41 5E023 AA04 AA11 AA16 AA30 BB01 BB07 BB08 BB23 DD01 EE07 BB27 DD15 EE27 FF27 BB27 FF04 GG05 HH02 HH07 JJ11 JJ20 5G355 AA03 BA01 BA02 BA20 CA23 5G361 BA03 BA06 BB01 BC01 BC02 5G363 AA16 BA02 DA13 DC02

Claims (13)

[Claims] 1. A molded body module comprising a molded body and an electric wire insert-molded in the molded body, wherein the molded body module is configured to be capable of being press-connected to a press-contact terminal provided on a predetermined electrical component. Molded module. 2. The electric component is further attached to the molded body module, and the conductor of the electric wire and the press-connecting terminal provided on the electric component are press-connected to enable electrical conduction. Item 2. A molded article module according to Item 1. 3. The electric wire extends a predetermined length from the end face of the electrical component mounting portion to the outside of the molded body from the inside of the molded body, and extends toward the inside of the electrical component mounting portion. The press-fit connection using the press-connecting terminal at a portion of the electric wire extending and extending the predetermined length to the outside of the molded body. The molded article module according to 1 or 2. 4. The molding according to claim 1, wherein the electric wire is provided so as to be arranged on an end face of an electrical component mounting portion of the molded body and to fit inside the molded body. Body module. 5. The press-connecting device according to claim 1, wherein the press-contact terminal pierces the press-formed module by piercing the press-formed module.
Or the molded article module according to any one of 4. 6. A male lock, a cover having a lock hole for engaging the male lock, and a pilot hole for inserting the male lock into the molded body, wherein the male lock is provided on the electrical component. The electric component and the molded body are assembled and integrated by a lock, the cover having the lock hole, and the pilot hole for the male lock. A molded article module according to item 1. 7. The molded module is sandwiched between the inner surface of the cover and the frame at the root of the male lock, is compressed and generates a restoring force, and is provided on the cover by the restoring force. The molded module according to claim 6, wherein the lock hole and the locking portion of the male lock are fixed. 8. The molded article module according to claim 1, wherein a roof module is formed using a roof liner attached to a ceiling of an automobile as the molded article. 9. A predetermined electric wire is set in a cavity of a mold capable of forming a predetermined molded body, and then at least a raw material serving as a base material of the molded body is filled in the cavity to form the molded body and the molded body. A method for manufacturing a molded body module, comprising: inserting an electric wire into a wire; thereafter, press-connecting a predetermined electrical component and the electric wire to each other by using a press-connecting terminal to allow current to flow. 10. In the insert molding, a predetermined length of the electric wire is extended from the end face of the electrical component mounting portion to the outside of the molded body from the inside of the molded body. The wire according to claim 9, wherein the wire is disposed in the mold so as to extend toward the inside of the product mounting portion, insert-molded, and then a protruding portion of the wire is pressure-welded. A method for manufacturing a molded body module. 11. Following the insert molding, the molded body is subjected to a trimming process, and at the time of the trimming process,
Burr left around the end surface of the electrical component mounting portion of the molded body and the electric wire protruding outside the molded body from the end surface of the electrical component mounting portion of the molded body are simultaneously trimmed. The method for manufacturing a molded article module according to claim 9 or 10, wherein 12. The crimping connection according to claim 9, wherein the crimping connection is performed by piercing the crimping terminal into a compact module comprising the compact and the electric wire. 13. The method for producing a molded article module according to the above item. 13. The roof module according to claim 9, wherein a roof module is mounted on the roof of an automobile as the molded body.
13. The method for producing a molded article module according to the above item.