JP2003016843A - Wire harness, and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent contact resistance from increasing by vibration of a connection portion for a plurality of electric wires. SOLUTION: Coatings 2b, 3b in prescribed portions of the plurality of electric wires 2, 3 are removed to form core-exposed parts 2a, 3a. A curved part 6 is formed at least in a core-exposed part 4 of one electric wire 2 among the plurality electric wires 2, 3. A core-exposed part 5 of the other electric wire 3 is overlapped in the curved part 6, and the overlapped fellow core-exposed parts 4, 5 are connected and fixed integrally by a conductive injection material 8.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wire harness for connecting a plurality of electric wires to each other to form a branch portion, and a method for manufacturing the same.

[0002]

2. Description of the Related Art As a conventional wire harness of this type, for example, Japanese Patent Laid-Open No. 9-27 shown in FIGS.
The one disclosed in Japanese Patent No. 377 is known.

As a method of manufacturing this wire harness,
As shown in FIGS. 5 and 6, the intermediate portion of the trunk line 51 and the coatings 51b and 52b of the branch line 52 are peeled off to remove the core line 51.
After exposing a and 52a, the core wire 51a portion of the main wire 51 is overlapped with the core wire 52a portion of the branch wire 52, and the overlapped portion has upper and lower electrode chips 54 and 5 having flat holding surfaces.
Sandwiched in a pressurized state by 5, and both electrode tips 54, 5
By passing a current between the two, the two electric wires 51 and 52 are welded while melting the overlapping portion by resistance heating, thereby forming a branch portion as shown in FIG.

[0004]

By the way, when the above-mentioned wire harness 50 is used for wiring of an automobile or the like,
Since it is fixed to the inner wall surface of the body using a clamp, etc.,
The wire harness 50 is given a considerably large vibration generated when the vehicle is running.

However, in the conventional wire harness 50,
Since the core wires 51a and 52a of the electric wires 51 and 52 are circular in cross section, the area of the connecting portion is reduced, and the tension generated on the electric wires 51 and 52 in the direction indicated by the arrow A in FIG. When a force or a twisting force generated in the direction indicated by the arrow B is applied, the contact resistance due to the vibration of the connecting portions of the core wires 51a and 52a of the electric wires 51 and 52 increases, which may cause poor contact or disconnection. was there.

Therefore, an object of the present invention is to provide a wire harness capable of preventing an increase in contact resistance due to vibration of a connecting portion of a plurality of electric wires and a method for manufacturing the same.

[0007]

In order to achieve the above-mentioned object, the invention of claim 1 peels off the coating of a predetermined portion of a plurality of electric wires to form a core wire exposed portion, and at least one of the plurality of electric wires is A curved portion is provided on the exposed core portion of one of the electric wires, and the exposed core portions of the other electric wires are overlapped on the curved portion, and the overlapped exposed core wires are integrally connected and fixed by a conductive injection material. It is characterized by being.

In the wire harness having such a structure, a curved portion is provided at the core wire exposed portion of at least one of the plurality of electric wires, and the core wire exposed portions of the other electric wires are superposed on the curved portion and these wires are superposed. By integrally connecting and fixing the combined exposed core portions with a conductive injection material, the area of the connecting portion of the plurality of electric wires is increased, and the holding force in the rotating direction of the electric wires is increased. Therefore, it is possible to prevent the contact resistance from increasing due to the rotation of the electric wire and the accompanying vibration. Therefore, in the invention according to the first aspect, it is possible to prevent the contact failure or the disconnection of the connection portion due to the vibration.

According to a second aspect of the present invention, a step of peeling off a coating on a predetermined portion of a plurality of electric wires to form a core wire exposed portion, and a curved portion on the core wire exposed portion of at least one of the plurality of electric wires. Is provided, a step of superimposing a core wire exposed portion of another electric wire on the curved portion, and a step of adhering a conductive injection material to the superposed core wire exposed portion.

In this method for manufacturing a wire harness, at least one of the plurality of electric wires is provided with a curved portion on the exposed portion of the core wire, and the exposed portion of the exposed portion of another electric wire is superposed on the curved portion.
Since the exposed exposed portions of the core wires are integrally connected and fixed by the conductive injection material, the area of the connection portion of the plurality of electric wires is increased, and the contact resistance due to vibration can be prevented from increasing.

[0011]

DETAILED DESCRIPTION OF THE INVENTION An embodiment of a wire harness according to the present invention will be described below with reference to FIGS.

FIG. 1 is a perspective view showing a wire harness 1 according to one embodiment.

The wire harness 1 is formed by intersecting two electric wires 2 and 3 and connecting the respective intermediate portions to each other.

At the intermediate portion of one of the electric wires 2 and 3, a core wire exposed portion 4 is formed by exposing the core wire 2a by peeling off the coating 2b, and at the middle of the other electric wire 3. The core wire exposed portion 5 is also formed in the portion in which the core wire 3a is exposed by removing the coating 3b.

The core wire exposed portions 4 and 5 of the electric wires 2 and 3 are provided with concave curved portions 6 and 7, respectively.

Then, one electric wire 2 is crossed with the other electric wire 3 so that the curved portion 6 of the one electric wire 2 and the curved portion 7 of the other electric wire 3 are overlapped with each other. The electric wires 2 and 3 are connected by attaching the conductive injection material 8 and integrally connecting and fixing the same.

Next, the manufacturing procedure of the wire harness 1 will be described with reference to FIGS.

First, as shown in FIG. 2 (a), in the first step, the coatings 2b and 3b at the intermediate portions of the electric wires 2 and 3 are stripped off to expose the core wires 2a and 3a to expose the core wire exposed portions 4, 4. 5
To form.

Next, in the second step, as shown in FIG. 2 (b), the core wire exposed portions 4 and 5 formed in the intermediate portions of the electric wires 2 and 3 in the first step respectively have concave curved portions 6 respectively. , 7 are provided.

Next, in the third step, as shown in FIG. 2C, on the tray base 9 for receiving the conductive injection material 8, the bending portion 6 of one electric wire 2 is bent and the other electric wire 3 is bent. Part 7
Overlap.

Then, in the fourth step, the curved portions 6 and 7 of the electric wires 2 and 3 superposed on the tray base 9 in the third step are pressed by the pressure lid 10 having a nozzle (not shown). The conductive injection material 8 is injected from the nozzle and attached to the curved portions 6 and 7 (core wire exposed portions 4 and 5).

The wire harness 1 of this embodiment is manufactured through the first to fourth steps as described above.

As the conductive injection material 8, for example, a conductive plastic as disclosed in Japanese Patent Laid-Open No. 11-255904 can be used. This conductive plastic is a thermoplastic resin, lead-free solder whose melting point is adjusted to an alloy component within a temperature range where the thermoplastic resin is thermoplasticized, and the lead-free solder is finely dispersed in the thermoplastic resin. It is composed of a conductive resin composition containing a dispersion medium for assisting the above, does not cause decrease in conductivity even in various environments with extremely high conductivity, and there are no large metal particles that hinder molding. It is highly reliable.

In this wire harness 1, the core wire exposed portions 4 and 5 formed in the intermediate portions of the electric wires 2 and 3 are provided with the curved portions 6 and 7, respectively, and the curved portion 6 of the electric wire 2 is overlapped with the curved portion 7 of the electric wire 3. Together, the curved portions 6 and 7 (core wire exposed portions 4 and 5) that have been overlapped are integrally connected and fixed by the conductive injection material 8, so that the area of the connection portion of the electric wires 2 and 3 is increased, It is possible to prevent an increase in contact resistance due to vibration.

Therefore, contact failure or disconnection of the contact portion due to vibration will not occur.

In this embodiment, the core wire exposed portion 5 of the other electric wire 3 is also provided with the curved portion 7, but the other electric wire 3 is also provided.
The core wire 3a may be exposed to form the core wire exposed portion 5.

That is, when connecting the core wire exposed portions 4 and 5 of the plurality of electric wires 2 and 3, it is sufficient to provide the curved portion 6 to the core wire exposed portion 4 of at least one electric wire 2.

FIG. 3 shows a wire harness 1 according to another embodiment.
It is a perspective view showing 1. The same components as those of the wire harness 1 shown in FIG. 1 will be described with the same reference numerals.

This wire harness 11 includes one electric wire 2
Is formed by connecting the end portions of the other electric wires 12 to each other in the middle portion of the.

At the intermediate portion of one of the electric wires 2, a core wire exposed portion 2a is formed by exposing the core wire 2a by peeling off the coating 2b. The core wire exposed portion 4 is provided with a concave curved portion 6. ing.

The other end of the electric wire 12 has a coating 12b.
A core wire exposed portion 13 is formed by peeling off the core wire 12a to expose the core wire 12a, and the core wire exposed portion 13 is provided with a concave curved portion 14.

Then, one electric wire 2 is crossed with the other electric wire 12, and the curved portion 6 of the one electric wire 2 is connected to the other electric wire 12.
Are overlapped with each other along the curved portion 13 of the end portion, and the conductive injection material 8 is attached to the overlapped portion to be integrally connected,
Both wires 2 and 12 are connected by being fixed.

In this wire harness 11, the core wire exposed portions 4 and 13 formed at the intermediate portion of the electric wire 2 and the terminal portion of the electric wire 12.
The curved portions 6 and 14 are provided respectively, the curved portion 6 of the electric wire 2 is overlapped with the curved portion 14 of the electric wire 12, and the curved portions 6 and 14 (core wire exposed portions 4 and 13) thus overlapped are electrically injected. Wires 2 and 12 are connected and fixed together with material 8.
The area of the connecting portion of the device becomes large, and it is possible to prevent an increase in contact resistance due to vibration.

Therefore, contact failure or disconnection of the contact portion due to vibration will not occur.

In this embodiment, the curved portion 14 is also provided in the core wire exposed portion 13 of the end portion of the other electric wire 12, but the other electric wire 12 exposes the core wire 12a to expose the core wire exposed portion 13. It may be formed only.

(Other Embodiments) The embodiments have been described above, but the present invention is not limited to these, and various changes accompanying the gist of the configuration can be made.
For example, in the above embodiment, the case where two electric wires are connected has been described, but the present invention can be applied to the case where three or more electric wires are connected.

Further, as in the wire harness 21 shown in FIG. 4, the core wire exposed portions 22a of the terminals of the two electric wires 22 and 23,
23a are curved together so that the core wire exposed portions 22a, 2a
Conductive injection material 2 with 3a being intertwined with each other
The exposed core portions 22a and 23a may be connected and fixed at 4.

Further, in the wire harness 1 of the above-described embodiment, the electric wires 2 and 3 are substantially orthogonal to each other, but the angle formed by the electric wires is not limited to this.

[0039]

As is apparent from the above description, according to the invention of claim 1, at least one electric wire of a plurality of electric wires is provided with a curved portion in the core wire exposed portion, and the curved portion is provided with another curved portion. Since the exposed cores of the electric wires are superposed and the superposed exposed cores are integrally connected and fixed by a conductive injection material,
The area of the connecting portion of the plurality of electric wires is increased, and it is possible to prevent an increase in contact resistance due to vibration.

Therefore, contact failure or disconnection of the contact portion due to vibration will not occur.

According to the invention of claim 2, it is possible to easily manufacture a wire harness having a branch portion.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a wire harness according to the present invention.

2A is a side view showing a first step of the method for manufacturing the wire harness shown in FIG. 1, FIG. 2B is a side view showing the second step, and FIG. 2C is a third step. It is a perspective view which shows a 4th process.

FIG. 3 is a perspective view showing another embodiment of the wire harness according to the present invention.

FIG. 4 is a perspective view showing another embodiment of the wire harness according to the present invention.

FIG. 5 is a side view showing a method for manufacturing a conventional wire harness.

FIG. 6 is a perspective view showing a conventional wire harness.

[Explanation of symbols]

1,11,21 ... Wire harness 2, 3, 12, 22, 23 ... Electric wire 2a, 3a, 12a ... Core wire 2b, 3b, 12b ... coating 4, 5, 13, 22a, 23a ... Exposed portion of core wire 6, 7, 14 ... Curved part 8 ... Conductive injection material

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) H01R 43/02 H01R 43/02 AZ H02G 1/14 H02G 1/14 B 15/08 15/08 K F Term (reference) 5E051 KA10 KB01 5E085 BB02 BB03 CC08 DD01 DD05 EE33 EE34 EE36 FF03 FF08 HH15 JJ12 JJ31 JJ36 5G309 AA05 5G355 AA03 BA01 BA11 CA17 CA23 5G375 AA02 CA02 CA12 DB09 EA17

Claims (2)

[Claims] 1. A core wire exposed portion is formed by peeling off a coating of a predetermined portion of a plurality of electric wires, and a curved portion is provided in the core wire exposed portion of at least one of the plurality of electric wires, and the curved portion is provided. A wire harness, in which exposed core portions of other electric wires are superposed, and the exposed exposed core wires are integrally connected and fixed by a conductive injection material. 2. A step of peeling off a coating of a predetermined portion of a plurality of electric wires to form a core wire exposed portion, and a step of providing a curved portion on the core wire exposed portion of at least one of the plurality of electric wires, A method for manufacturing a wire harness, comprising: a step of superimposing a core wire exposed portion of another electric wire on the curved portion; and a step of attaching a conductive injection material to the superposed core wire exposed portion.