JP2003323819A - Flat furnace and production process thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To unify production steps to permit simple and mass production and make of common use of a part. <P>SOLUTION: The flat furnace 1 comprises a flat cable 2 composed of a plurality of conductors 4 covered with an insulating coating and arranged in parallel in a flat form and a plurality of common connectors 3 at least two of which are common. The respective conductors 4 of the flat cable 2 form, for example, signal conductors different from one another. The common connectors 3 are formed in the same form, equipped with a pressure-welded terminal connected to a connecting terminal built in a connector joint of each auxiliary machine mounted on a module 90 and composed of a connector body having a built-in pressure welded terminal and a retainer fitted to the connector body. The pressure-welded terminal is connected to each of the conductors 4 of the flat cable 2. When arrangement of the connecting terminal built in the connector joint of each auxiliary machine is constructed so as to be connected to a pressure-welded terminal connected to the conductor 4 forming a necessary signal conductor, various auxiliary machines can be connected by one flat furnace 1. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention comprises a flat cable (FC) or a flexible flat cable (FFC) for connecting electrical components (auxiliaries) mounted on an automobile or the like. The present invention relates to a flat harness, and more particularly, to a flat harness that can be easily manufactured in a large amount and can share parts, and a manufacturing method thereof.

[0002]

2. Description of the Related Art At present, wire harnesses are mainly used for connecting electrical components (auxiliaries) of automobiles and the like. A wire harness is a harness-like bundle of electric wires that connect between auxiliary machines. Usually, a crimp terminal is attached to the end of each electric wire that forms the harness, and these crimp terminals are used for each auxiliary machine. It is built in a connector that is connected to the connector and the like provided in the. The connector of the wire harness is formed in a different shape for each accessory,
It is designed to prevent mistakes in connection.

FIG. 19 is a flowchart showing a manufacturing process of such a wire harness. First, the strands of each electric wire forming the harness are twisted (S100), individually extruded to form an insulating coating (S101), the extruded wire rods are assembled (S102), and the assembled wire rods are sorted (S103). . The process up to this point is, for example, an extrusion process. Next, the distributed wire rods are individually weighed according to the auxiliary equipment to be connected (S200), the weighed wire rods are cut (S201), the insulating coating of the terminal is removed to expose the bare wires ( ) (S202), crimp terminals are individually crimped to the exposed wires (S203), wire rods crimped to the crimp terminals are collected (S204), and the collected wire rods are sorted (S205). The process up to this point is, for example, a pressure bonding process. Then, if necessary, the insulating coating at a predetermined position between the ends of the wire is removed to expose the strand (intermediate exit) (S3
00), crimping the joint terminal for branching (S3
01), gather the wire materials with the joint terminals crimped (S
302) and sort the assembled wire rods (S303).
The process up to here is a joint process, for example. In this way, each terminal of the wire rod to which each terminal is attached is inserted into the connector or the like (S400), and temporarily assembled to perform the sub-assembly (S / A).
ssy) is formed (S401), and the formed sub-assemblies are assembled (S402). The process up to this point is referred to as, for example, a sub-assembly process. After forming a sub-assembly, a branch is formed (S500) and a terminal is inserted (S50).
1) Wrap a tape such as an insulating tape around the wire (S50
2) Then, various outer packagings are attached to form a wire harness (W / H) (S503), and the formed wire harnesses are assembled (S504). The steps up to this point are called assembling steps.
Then, the completed inspection of the assembled wire harness is performed (S600), and the product number and lot are attached (S60).
1) Finally, the wire harness is shipped (S602).
This process is called an inspection and shipping process. As described above, in order to manufacture a wire harness, it is necessary to roughly perform various processes such as an extrusion process, a pressure bonding process, a joint process, a sub-assembly process, an assembly process, and an inspection and shipping process.

[0004]

However, in the wire harness manufactured through such steps, for example, a large number of connectors are used also in the branch portion and the joint portion, and if the number of auxiliary machines to be connected increases. Since the number of parts such as wires (electric wires) and connectors that constitute the harness also increases, the harness becomes thicker and heavier, and the number of parts increases, which is disadvantageous in terms of cost. Also, when manufacturing a harness, it is necessary to individually manufacture wire rods of different lengths depending on conditions such as the system of the auxiliary machine to be connected and the mounting position, or to attach a connector of a different shape to each auxiliary machine to be connected. Therefore, the number of steps in the manufacturing process may increase dramatically.

The present invention has been made in view of the above circumstances, and provides a flat harness in which the manufacturing process is unified, mass production is possible in a simple manner, and parts can be shared, and a manufacturing method thereof. The purpose is to

[0006]

A flat harness according to the present invention has a cable in which a plurality of conductors are covered with an insulating coating and arranged in a plane, and a connection terminal connected to each conductor of the cable. However, a plurality of common connectors connected to each of the plurality of auxiliary machines are provided.

In the method for manufacturing a flat harness according to the present invention, a plurality of common conductors having a plurality of conductors covered with an insulating coating and arranged side by side in a plane and a connecting terminal connected to each conductor of the cable are provided. A method of manufacturing a flat harness including a connector, a sending step of sending out each conductor forming the plurality of conductors, and an assembling step of collectively arranging the respective conductors sent out in the sending step in a plane shape, The insulating coating is extruded on the conductors that are collectively arranged in this gathering step, formed by laminating or coating, and a coating forming step for manufacturing the cable, and the cable manufactured in this coating forming step, the conductor Connected,
A connector mounting step of mounting the plurality of common connectors connected to each of a plurality of auxiliary machines, and measuring and cutting the cable mounted with the plurality of common connectors to a predetermined length in the connector mounting step. Measuring and cutting process,
An inspection step of performing a completion inspection of each of the conductors and the common connector of the cable cut in the measuring / cutting step.

According to the present invention, the flat harness is
A cable in which a plurality of conductors are covered with an insulating coating and arranged in a plane is provided, and a plurality of common connectors that are connected to each of the plurality of auxiliaries and that have connection terminals that are connected to each conductor of this cable. Since it is provided, it is possible to connect the auxiliary machines that use different signal line circuits with one flat harness, and to share the parts and reduce the cost. As a result, the applicable range of the flat harness can be expanded and the manufacturing cost can be significantly reduced.

In the flat harness of the present invention, the cable forming the flat harness has an insulating coating having a structure in which each of a plurality of conductors is covered with an insulating coating and the insulating coatings are connected to each other. Inter-connection type flat cable, or insulation-insulating non-bonding flat cable having a structure in which the insulation coatings are not coupled to each other and independent of each other, or an insulation coating formed by laminating or extruding a plurality of conductors in a planar manner. A flexible flat cable having a split structure is preferable.

In this case, when the cable is a flat cable between insulating coatings or a non-bonding flat cable between insulating coatings, the conductor is preferably a round conductor single wire or a stranded wire, which is flexible. When the conductor is a flat cable, the conductor is preferably a single conductor of a rectangular conductor. The conductor forming the cable is preferably made of Cu or Al.

The plurality of common connectors are preferably arranged at equal intervals along the longitudinal direction of the cable.

Further, when the flat harness is provided with a plurality of cables arranged for each system of the auxiliary equipment (for example, front lamp system, power window system, turn lamp system, etc.), a plurality of conductors forming each cable is used. It is preferable that each conductor constitutes a corresponding signal line having the same configuration.

In this case, the plurality of common connectors may be arranged at positions corresponding to the mounting positions of the accessories of the cables arranged in different ways for each system.

Further, the plurality of common connectors bite into the insulation coating of the cable, press-contact terminals that sandwich the conductor and press-contact, or penetrate the insulation coating of the cable and the conductor, and caulk the penetrating tip to form a conductor. It is preferable to have a built-in piercing terminal to be connected.

The accessory has a connector connecting portion to which a common connector is fitted, and the connector connecting portion is a signal necessary for the accessory among pressure contact terminals and piercing terminals built in the common connector and connected to the conductor. It is preferable to have a connection terminal connected to either one of the pressure contact terminal and the piercing terminal forming the wire.

Further, as another auxiliary machine to which the flat harness of the present invention is applied, a plurality of common auxiliary machines mounted on an automobile (for example, a common left / right lamp unit mounted on the automobile, a common left / right clearance sonar sensor, etc.) ) Is considered in this case, the connector connection portion of the common auxiliary equipment includes connection terminals arranged in a common arrangement, and the common connector fitted with the connector connection portion of the common auxiliary equipment configures different signal lines. It is preferable that one of the pressure contact terminal and the piercing terminal connected to the conductor is incorporated. With this configuration, the flat harness can be applied when a plurality of common auxiliaries attached to different positions of an automobile or the like require or output different signals.

In the cable, the slits of a predetermined length are formed along the conductors at positions where the cables are bent in the conductor arrangement direction, the slits penetrating the insulating coating between the conductors of the plurality of conductors. It is preferable that a plurality of them are provided in the direction.

Further, as another cable, slits of a predetermined length formed along the conductor are formed at predetermined intervals in the length direction of the conductor and penetrate through the insulating coating between the conductors of the plurality of conductors. It is preferable that a plurality of conductors are provided in the arrangement direction of the conductors.

When a plurality of these slits are provided in the conductor arranging direction, a plurality of slit forming portions of the cable may be bent in a crank shape in the conductor arranging direction. By doing this, there is no need to bend the cable in a state where the front and back surfaces of the cable alternate.
The degree of freedom in wiring is improved.

Of the plurality of conductors forming the cable, the conductor forming a predetermined signal line is cut at a predetermined position between both ends in the longitudinal direction of the cable, and each predetermined signal line cut at this cut portion. A plurality of common connectors are attached to connect the conductors that form the signal line and the conductors that form the other signal line, respectively, and the conductors that form the cut predetermined signal line are different signal lines through the plurality of common connectors. The circuit may be changed so as to form

The flat harness manufacturing method of the present invention preferably further comprises a molding step of resin-molding the cable at a predetermined position. In this case, the resin used in the molding step is a thermoplastic resin. preferable.

The conductors sent out in the sending step are
Round conductor single wire or stranded wire made of Cu or Al,
Or, it is preferable that the conductor is a single wire of a rectangular conductor, and in the cable manufactured in the coating forming step, when each conductor sent out in the sending step is a round conductor single wire or stranded wire, each conductor of the plurality of conductors is insulated. A flat cable between insulation coatings, which is covered with a coating and has a structure in which the insulation coatings are coupled to each other, or a non-bonding flat cable between insulation coatings, which has a structure in which the insulation coatings are not coupled to each other Is preferred.

Further, in the cable manufactured in the coating forming step, when each conductor sent out in the feeding step is a single wire of a rectangular conductor, a plurality of conductors are covered with an insulating coating formed in a plane by lamination or extrusion. It is preferable that the flexible flat cable has a different structure.

The plurality of common connectors mounted in the connector mounting step are preferably arranged at equal intervals along the longitudinal direction of the cable, or are arranged in advance at positions corresponding to the mounting positions of the auxiliary equipment. .

Further, the plurality of common connectors mounted in the connector mounting step dig into the insulation coating of the cable,
It is preferable that a pressure contact terminal that sandwiches the conductor and presses it, or a piercing terminal that penetrates through the insulating coating and the conductor of the cable and pierces the penetrated tip end and caulks the penetrated tip end to connect to the conductor is incorporated.

In the cable manufactured in the coating forming step, a plurality of slits having a predetermined length along the conductors are formed in the conductor arranging direction so as to penetrate the insulating coating between the conductors of the plurality of conductors, or The method further includes a slit forming step of forming a plurality of slits of a predetermined length along the conductor, which penetrate the insulating coating between the conductors of the plurality of conductors at predetermined intervals in the length direction of the conductor, in the conductor array direction. You may do it.

Further, a cutting process for cutting a conductor forming a predetermined signal line among a plurality of conductors forming the cable manufactured in the coating forming process at predetermined positions at both ends in the longitudinal direction of the cable is further provided. The connector mounting step includes a step of mounting a plurality of common connectors at the cutting portion and connecting the conductors forming the respective predetermined signal lines and the conductors forming the other signal lines, which are cut in the cutting processing step, respectively. Is also good.

It is preferable that the sending step, the assembling step, the coating forming step, and the connector mounting step are constituted by one manufacturing line. In this case, the molding step may be further included in one manufacturing line. The processing steps may be included in one production line.

Further, the scale / cutting process and the inspection process are 1
It is preferable to be composed of one production line.

Further, in some cases, it is preferable that the sending step, the assembling step, the coating forming step, the connector mounting step, the measuring / cutting step and the inspection step are constituted by one manufacturing line. In this case, the molding process and the cutting process may be further included in one manufacturing line.

[0031]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a perspective view showing a flat harness according to an embodiment of the present invention.
The flat harness 1 includes a flat cable 2 including a plurality of conductors 4 which are covered with an insulating coating 5 and arranged in a plane.
And at least 2 attached to this flat cable 2
Module 9 having a plurality of common connectors 3 of which one is common, and each auxiliary machine (not shown) having a connector connecting portion described later to which the common connector 3 is fitted.
It is attached to 0, etc. and electrically connects each auxiliary machine.

As shown in FIG. 2, the flat cable 2 comprises a conductor 4 made of a wire such as a single conductor or a stranded wire of a round conductor made of Cu or Al, polyethylene terephthalate (PET), polyethylene naphthalate (PE).
N), polyimide (PI) and polyvinyl chloride (PV
C) or the like, which is covered with an insulating coating 5 made of an insulating resin, and the insulating coatings 5 are connected to each other by a bridge portion 5a made of an insulating resin similar to the insulating coating 5. Each conductor 4 of the flat cable 2 constitutes a different signal line, for example, as follows.

That is, the conductor 4 forming the signal line of
A left / right high beam / low beam common headlight power source is connected, and a low beam left / right common headlight switch is connected to the conductor 4 forming the signal line. Further, the high beam left / right common headlight switch is connected to the conductor 4 forming the signal line, and the plus (+) side of the left / right common side light is connected to the conductor 4 forming the signal line. . Furthermore, the conductor 4 that constitutes the signal line of
Is connected to the plus (+) side of the high / low common horn, and the common ground (-) is connected to the conductor 4 forming the signal line.

On the other hand, the common connector 3, as shown in FIG. 3 (a), is a connector commonly mounted on the flat cable 2 and has the same shape. The common connector 3 includes a plurality of pressure contact terminals 6 as connection terminals to be connected to the connection terminals provided in the connector connection portion of each auxiliary machine. As shown in FIG. 6 includes a connector body 7 containing 6 and a retainer 8 attached to the connector body 7, and FIG.
As shown in FIG. 2, the flat cable 2 is sandwiched in the vertical direction in FIG.

As shown in FIG. 4 (a), these pressure contact terminals 6 are respectively connected to the conductors 4 of the flat cable 2 constituting the signal lines (1) to (4), and their connecting portions are shown in FIG. As shown in b), the connection portion 6 with the conductor 4
Since the connecting end of a is formed into a bifurcated shape, the branched portion digs into the insulating coating 5 of each conductor 4 of the flat cable 2, penetrates the bridge portion 5a, and causes the conductor 4 to have a spring force. It has a structure of sandwiching and pressing.
It should be noted that FIG. 2B shows only one pressure contact terminal 6 in a simplified manner in order to simply explain the connection structure of the plurality of pressure contact terminals 6 built in the common connector 3 (not shown) with the flat cable 2. It is shown.

The common connector 3 is a connecting portion 6 of the press contact terminal 6.
Since a is attached to the flat cable 2 simply by inserting a into the flat cable 2, the common connector 3
Can be mounted extremely easily as compared with the conventional connector mounting method in which the connector is mounted after the normal crimp terminal or the joint terminal is mounted.

In the flat harness 1 of this example,
The description has been given using the flat cable 2 having the inter-insulation-coupling flat cable structure in which each conductor 4 is covered with the insulation coating 5 and the insulation coatings 5 are coupled to each other by the bridge portion 5a. (A)
As shown in FIG. 2, the flat cable 2 has a structure made of a wire material such as a single wire or a stranded wire of a round conductor, each conductor 4 is covered with an insulating coating 5, and the insulating coatings 5 are independent of each other without being coupled. A flat cable 2a having a non-coupling flat cable structure between insulating coatings, or as shown in FIG. 1B, each conductor 4 is composed of a single wire of a rectangular conductor 4a having a rectangular cross section, and is planarized by lamination or extrusion. A flexible flat cable 2b having a structure covered with the formed insulating coating 5 may be used.

When the flat cable 2a is used, the connection portion of the pressure contact terminal 6 built in the common connector 3 is built in the common connector 3 applied to the flat cable 2 as shown in FIG. When the flexible flat cable 2b is used, the connection portion 6b has a structure and shape substantially similar to the connection portion 6a of the pressure contact terminal 6.
The connection portion of the press-contact terminal 6 built in the common connector 3 is preferably a connection portion 6c having a shape matched with the rectangular conductor 4a, as shown in FIG. Also, the flat cable 2a
The conductor 4 may be an enameled wire having a structure in which an insulating coating 5 is formed by coating on a round conductor single wire or stranded wire. When the flat cable 2a is used, since the insulating coatings 5 covering the conductors 4 are not coupled and independent, the work of connecting the pressure contact terminals 6 to the conductors 4 and attaching the common connector 3 is performed by the flat cable 2a. It becomes easier than in the case.

In this example, the pressure contact terminal 6 is used as the connection terminal built in the common connector 3, but in addition to this pressure contact terminal 6, as shown in FIG.
For example, the connection portion 6a penetrates the insulating coating 5 and the conductor 4 of the flat cable 2 and bites into the flat cable 2, and the tip portion 6a ′ of the penetrating connection portion 6a is caulked to have a built-in piercing terminal 6 ′. May be. According to this piercing terminal 6 ', since the tip portion 6a' is crimped, the connection reliability with the conductor 4 can be further improved. The piercing terminal 6 ′ used for the single wire or the twisted wire of the round conductor that constitutes each conductor 4 of the flat cables 2 and 2 a has a connecting portion 6 as shown in FIG.
It is preferable that the bifurcated end portion 6a 'of a is connected so as to penetrate in a direction orthogonal to the arrangement direction of the conductors 4 (longitudinal direction of the conductor 4). Further, as shown in FIG. 7C, the piercing terminal 6 ′ can also be applied to the flexible flat cable 2 b, and in this case as well, the insulating coating 5 and the conductor 4 of the flexible flat cable 2 b are connected to the connecting portion 6 a.
Since the tip end portion 6a 'is connected so as to penetrate therethrough and the penetrated tip end portion 6a' is caulked, the connection reliability can be improved. At least one of the pressure contact terminal 6 and the piercing terminal 6'is built in the common connector 3.

When the flat harness 1 is constructed by using the flat cable 2 other than the flat cable 2a and the flexible flat cable 2b, as will be described later, for example, the conductor 4 which penetrates the insulating coating 5 between the conductors 4 is connected to the conductor 4. A slit (not shown) of a predetermined length along the conductor 4
A plurality of conductors 4 are formed in the arrangement direction of the conductor 4 or penetrate the insulating coating 5 between the conductors 4 at predetermined intervals in the length direction of the conductor 4.
A flat cable 2 and a flexible flat cable 2b constituting the flat harness 1 are formed by forming a plurality of slits having a predetermined length in the arrangement direction of the conductors 4 along the
May be bent in the arrangement direction of the conductors 4. By forming the slits, the cables 2 and 2b can be easily bent, so that the wiring layout of the flat harness 1 can be easily changed without bending the cables 2 and 2b. Since the flat cable 2a has a non-coupling flat cable structure between insulating coatings, it can be easily bent without such a slit.

Further, as shown in FIG. 7, the common connectors 3 may be arranged at regular intervals A along the longitudinal direction of the flat cable 2 at regular intervals. By mass-producing the flat harness 1 in which the common connector 3 is arranged as described above and changing the common connector 3 to be connected to the applicable vehicle type, the flat harness 1 having the same configuration can be used for various vehicle types. For example, depending on the mounting position of the mounted auxiliary equipment, in the vehicle type A, the common connectors 3c, 3e, 3g
, The common connector 3b, 3f, 3g
, And in the vehicle model C, common connectors 3b, 3d, 3f
In the case of connecting with each other, it becomes possible to connect a horn, a sensor, a fan motor and the like with the flat harness 1 having the same configuration. By arranging the common connectors 3 at equal intervals in this way, it is possible to widen the range of application to auxiliary machines of vehicle types having different layouts.

FIG. 8 is a view for explaining the connection between the common connector 3 mounted on the flat harness 1 and each auxiliary machine. Although the pressure contact terminal 6 will be described below as the connection terminal built in the common connector 3, the connection terminal is not limited to this, and the piercing terminal 6'may be used. Since the pressure contact terminals 6 built in the common connector 3 of the flat harness 1 are connected to the conductors 4 forming the signal lines (see FIG. 2), the connector connection portions 9 of the auxiliary machines are provided. Pressure contact terminal 6
By changing the arrangement of the connection terminals 9a to be connected with, various auxiliary machines can be connected. For example, FIG.
As shown in FIG. 5, the connection terminal 9a in the connector connecting portion 9 provided in the vehicle side light 10 as an auxiliary machine was connected to the conductor 4 forming the signal line (the plus side of the left and right common vehicle width light). The pressure contact terminal 6 and the pressure contact terminal 6 connected to the conductor 4 forming the signal line (common ground) of the pressure contact terminal 6 are respectively connected.

Further, as shown in FIG. 3B, the connection terminal 9a in the connector connecting portion 9 provided in the horn 11 as an auxiliary machine is connected to the signal line (the plus side of the high / low common horn). The horn 11 is connected to the ground 12 while being connected to the pressure contact terminal 6 connected to the constituent conductor 4. As described above, by using the common connector 3, it is possible to connect a large number of different auxiliary machines with the same flat harness 1, and it is not necessary to manufacture different connectors or connector connecting portions depending on the type of the auxiliary machine. It is possible to reduce the manufacturing cost by sharing the first component.

In this case, the connection mode of the pressure contact terminal 6 in the common connector 3 of the flat harness 1 to each conductor 4 is the same, and the connection terminal 9a in the connector connection portion 9 of each auxiliary machine is the same.
Although the arrangement of each auxiliary machine can be connected by changing the arrangement, the connector connection portion of each auxiliary machine is changed by changing the connection mode of the pressure contact terminal 6 in the common connector 3 of the flat harness 1 to each conductor 4. 9 can have the same structure, and the connection terminals 9a in the connector connecting portion 9 can be connected to a common auxiliary machine having the same structure.

FIG. 9 is a diagram for explaining the connection between the sockets of the left and right turn valves as common accessories and the common connector 3. As shown in FIGS. 3A and 3B, the right turn valve 13 and the left turn valve 14 are attached to the socket 15 (15a, 15b) as the connector connecting portion 9 in which the connecting terminals 9a are built in the same arrangement. Has been. The common connector 3 includes, for example, a conductor 4 forming a signal line (common left and right clearance), a conductor 4 forming a signal line (right turn), and a conductor 4 forming a signal line (GND), (10 2) is mounted on a flat cable 2'comprising a conductor 4 forming a signal line (left turn). In addition, (10) of the signal line of (10)
Are represented by circled numbers in the figure. The numbers in parentheses in the specification will be represented by circled numbers in the drawings.

Sockets 15a and 15b having these common specifications
The common connectors 3 (3a, 3b) to be fitted with are formed in the same shape, but the arrangement of the pressure contact terminals 6 incorporated therein is different. That is, in the common connector 3a fitted in the socket 15a of the right turn valve 13 shown in FIG. 7A, a plurality of pressure contact terminals 6 connected to the signal line and the conductor 4 forming the signal line are provided. The socket 15b of the left turn valve 14 that is built in and is shown in FIG.
The common connector 3b fitted to
A plurality of pressure contact terminals 6 respectively connected to the conductors 4 forming the signal line (10) are incorporated.

Therefore, the connection terminal 9a of the socket 15a
Is connected to the signal lines of and, and the connection terminal 9a of the socket 15b is connected to the signal line of (10). Therefore, even if the sockets 15a and 15b having the same arrangement having the connection terminals 9a of the same arrangement are used. The turn valves 13 and 14 can be connected to different signal line circuits, respectively. In this way, by changing the arrangement of the pressure contact terminals 6 of the common connector 3, it is possible to apply to the common auxiliary machine in which the shape of the connector connection portion 9 of the auxiliary machine and the arrangement of the connection terminals 9a are made common, so that the above-mentioned effect is obtained. Similarly, it is possible to standardize parts and reduce the manufacturing cost, and it is possible to supply and output different signals to a plurality of common auxiliaries mounted at different positions.

FIG. 10 is a diagram for explaining the flat harness 1 in which the circuit configuration of the flat cable 2 is changed. As shown in FIG. 10A, the flat cable 2 ″ that constitutes the flat harness 1 includes a conductor 4 that constitutes a signal line (battery (B) power source) of (11),
The conductor 4 forming the signal line (12) (ignition (IG) power supply) and the signal line (13) (engine (EN)
(G) signal) and the signal line (G) of (14)
ND) and the conductor 4 which constitutes ND). Also,
The flat cable 2 ″ has a plurality of common connectors 3
(3a to 3e) are attached respectively.

The flat cables 2 ″ (11) to (1)
Among the conductors 4 forming the signal line of 4), the conductors forming the signal line of (11) and the signal line of (12) are cut at a predetermined position between both ends in the longitudinal direction of the flat cable 2 ″. The common connectors 3b and 3c are attached to the cut portions, respectively. These common connectors 3b and 3c have
For example, a PWM (Pulse Width Modulation) electronic control unit (PWM-ECU) 16 which is a predetermined input / output unit having a circuit switching function is connected as an auxiliary machine.

The pressure contact terminals 6 (not shown) built in the common connectors 3a to 3e are connected to the conductor 4 as follows. That is, the pressure contact terminals built in the common connectors 3a and 3b are connected to all the conductors 4 forming the signal lines (11) to (14), and the pressure contact terminals built in the common connector 3c are (11). The pressure contact terminals connected to the conductors 4 forming the signal lines of (12) and incorporated in the common connector 3d are connected to the conductors 4 forming the signal lines of (11) and (14), and are connected to the common connector 3e. The built-in pressure contact terminal is connected to the conductor 4 forming the signal lines (12) and (14). That is, a dot ● in FIG. 10A indicates a pressure contact terminal (not shown) and a conductor 4 in each common connector 3.
Indicates that there is a connection with.

The flat harness 1 thus constructed
Then, as shown in FIG.
It is possible to change the circuit configuration without changing the cable width or the number of cables of ´. That is, the common connector 3
Input to PWM-ECU 16 from a and 3b (11)
Of the signals formed by the signal lines (14) to (14), PWM-E
The signal formed by the signal line (11) ′ output from the common connector 3c after the circuit is changed in the CU 16 is used as a motor power source supplied to the common connector 3d and output from the common connector 3c (12) ′. The signal formed by the signal line is used as a motor power source supplied to the common connector 3e.

As a result, the operation control of the motor 17a connected to the common connector 3d and the motor 17b connected to the common connector 3e in the PWM-ECU 16 can be performed using one flat harness 1. In this way, by connecting an input / output unit having a circuit switching function as an auxiliary machine to the flat harness 1, different circuit configurations can be realized with the same flat harness 1 without changing the cable width or the number of cables of the flat cable 2 ″. can do.

FIG. 11 is a view for explaining the manner in which the flat cables 2 of the flat harness 1 are separately laid out for each system of the auxiliary equipment, and FIG. 12 is a plurality of common cables attached to each flat cable 2. Pressure contact terminal 6 in connector 3
It is a figure which shows the connection example of. Note that FIG. 11 (a) shows how the flat cables 2 are routed to the lamp module, FIG. 11 (b) to the back of the shroud, and FIG. 11 (c) to the shroud front. Further, FIG. 3D corresponds to FIG. 2A, FIG. 2E corresponds to FIG. 2B, and FIG. 2F corresponds to FIG. 2C. It is a figure which shows the flat cable 2 made.

As shown in FIGS. 11 and 12, the flat cables 2 to 1 are routed for each system of the auxiliary machines, and each flat cable 2 is (1
5) to (18) are provided with a plurality of conductors 4 (not shown) that form the signal lines. For example, the flat cable 2 of is applied to a headlight system, the flat cable 2 of is applied to a turn lamp system, the flat cable 2 of is applied to a power window motor system, and the flat cable 2 of is a power window system. The flat cable 2 is applied to a switch system, and the flat cable 2 is applied to a horn system.

Further, the pressure contact terminals 6 (not shown) in the plurality of common connectors 3 attached to the flat cables 2 are conductors forming the signal lines (15) to (18) in the state shown in FIG. 4 is connected. Further, each common connector 3 of each flat cable 2 is arranged at a position corresponding to the mounting position of each auxiliary machine to be connected, and the pressure contact terminals 6 built in each common connector 3 are connected. The conductors 4 are connected to the conductor 4 in a predetermined arrangement configuration and a connection mode which are different for each accessory.

As described above, the flat cables 2 constituting the flat harness 1 are separately arranged for each system of the applied auxiliary machines, and the connection mode of the pressure contact terminals 6 in the common connector 3 connected to each auxiliary machine is connected. Can be changed to have the same configuration as the case where all the auxiliary components of the system are connected by using one flat harness 1, and the cable width and the number of cables of the flat cable 2 of the flat harness 1 can be pranked. Therefore, the work of wiring the flat harness 1 can be facilitated and the flat harness 1 having the same configuration can be applied to various auxiliary machines.

FIG. 13 is a flowchart showing a manufacturing process of a flat harness according to an embodiment of the present invention, FIG.
4 is a process diagram schematically showing a part of the manufacturing process in section. It should be noted that the description that is the same as that already described will be omitted. The flat harness 1 of this example is composed of a flat cable 2 including four conductors 4. First, the conductor 4 as a wire rod made of Cu or Al wound around the supply rolls 20a to 20d is sent out from each of the supply rolls 20a to 20d (S1), and the conductors 4 are arranged side by side in a plane in the collecting machine 21. (S2) as described above, and PET, PE around each of the assembled conductors 4
The insulating coating 5 made of insulating resin such as N, PI and PVC is formed, and the conductors 4 are laminated or extruded by using the coating forming machine 22 so as to bond the insulating coatings 5 to each other to form the insulating coating 5. (S3), the flat cable 2 is manufactured. In this case, as the conductor 4 on which the insulating coating 5 is laminated or extruded, a round conductor single wire or a stranded wire is used, but when the flexible flat cable 2b is manufactured, the conductor on which the insulating coating 5 is laminated or extruded. As the wire 4, a single wire of a rectangular conductor is used. Further, when manufacturing the non-coupling type flat cable 2a between insulating coatings, a single wire or a twisted wire of a round conductor is used as the conductor 4 on which the insulating coating 5 is formed in step S3, but in this case, Insulation coating 5 as so-called enamel can be formed by coating in addition to lamination and extrusion.

Next, a plurality of common connectors 3 are attached to the manufactured flat cable 2 by using the connector attaching device 23 (S4), and the connecting portion of each attached common connector 3 with the flat cable 2 is required. In accordance with the above, the molding device 24 is used to perform molding with, for example, a hot melt resin to form the molding portion 26 (S9). Then, the flat cable 2 is cut to a predetermined length and then cut (S
5), a plurality of flat harnesses 1 are manufactured, and finally, a completion inspection such as a continuity test of the flat cable 2 and the common connector 3 of each flat harness 1 is performed using the inspection machine 25 (S6). Complete.

The molding step of step S9 may be omitted if it is not necessary. However, for example, as shown in FIG. 15A, if the molding portion 26 is formed by the molding step, it is connected to the auxiliary machine 30. It is possible to reinforce the connection portion between the common connector 3 and the flat cable 2 that are connected to each other and to waterproof the connection portion.

If a molded portion 26 is formed so as to cover the outer peripheral surface of the insulating coating 5 of the flat cable 2 in a portion other than the connecting portion between the common connector 3 of the flat cable 2 and the flat cable 2, that portion of the flat cable 2 is formed. It is also possible to strengthen the protection of the flat cable 2 against external damage.

Further, as shown in FIGS. 7A and 7B, if the flat cable 2 is mounted and fixed to the supporting member 31 such as the frame of the automobile by the molded portion 26, the mounting work of the flat harness 1 is automated. It is also possible to carry out the work such that the waterproof treatment is followed by the mounting and fixing, the mounting and fixing is followed by the enhanced protection, and the enhanced protection is followed by the waterproof treatment. In this way, the flat harness 1 can be waterproofed, fixed, and protected adaptively in the molding process of step S9. Note that, for example, instead of waterproofing / fixing / protecting the flat harness 1 by the mold portion 26, it is possible to waterproof / fix / protect the flat harness 1 by using a self-fusion tape (not shown).

When it is necessary to connect auxiliary equipment such as the above-mentioned input / output unit to the flat harness 1, the flat cable 2 is formed on the flat cable 2 manufactured in the coating forming step of step S3. Of the plurality of conductors 4, the conductor 4 forming a predetermined signal line is cut at a predetermined position between both ends in the longitudinal direction of the flat cable 2 (S7), and is cut in this step in the connector mounting step of step S4. Conductor 4 that constitutes the predetermined signal line of
The flat harness 1 may be manufactured by connecting a plurality of common connectors 3 to each other at a cut portion between the conductor 4 and another conductor 4 that constitutes another signal line.
By doing so, as described above, it is possible to manufacture the flat harness 1 capable of changing the circuit configuration without changing the width or the number of cables.

Further, the steps from the sending step of step S1 to the connector mounting step of step S4 may be constituted by one manufacturing line, and the manufacturing step includes the molding step of step S9 to manufacture the flat harness 1. You may make it comprise a process. Further, the measuring / cutting process and the inspection process of steps S5 and S6 may be configured by one manufacturing line.
It goes without saying that all of these steps may be configured in one manufacturing line.

When the cable manufactured in the coating forming step of the above step S3 is the flat cable 2 and the flexible flat cable 2b other than the non-insulating flat cable 2a (see FIG. 5A). In order to change the layout by bending the flat cable 2 and the flexible flat cable 2b, as shown in FIG. 16, bend the cables 2 and 2b in the arrangement direction of the conductors 4 of both cables 2 and 2b. These cables 2, 2b need to be changed
The thickness of the cable increases and both cables 2, 2b
In some cases, the cable surfaces 2x, 2y are replaced with each other on the same surface side, which makes the wiring work difficult. Therefore, FIG.
As shown in (a), a plurality of slits 29, which penetrate the insulating coating 5 (bridge portion 5a) between the conductors 4 and have a predetermined length along the conductors 4, are formed in the arrangement direction of the conductors 4, or As shown in FIG. 18, slits 29 of length y along the conductors 4 penetrate through the insulating coating 5 (bridge portion 5a) between the conductors 4 at intervals of a predetermined distance x in the length direction of the conductors 4. Is formed in the arrangement direction of the conductors 4 (S8), and the flat cable 2 and the flexible flat cable 2b are bent in the arrangement direction of the conductors 4 as shown in FIG. 17B as described above. Also good. Note that, for example, when forming a plurality of slits 29 having a length y at predetermined intervals x, as shown in FIG. 18, the length y of the slits 29 is preferably smaller than the distance x of the predetermined intervals. This is because if the length y of the slit 29 is smaller than the distance x at a predetermined interval, it is possible to make the flat cable 2 and the flexible flat cable 2b both easy to bend and maintain shape.

Also, the common connector 3 is attached to the flat cable 2 and the flexible flat cable 2b where the slits 29 are formed, and the connecting portion 6b of the press contact terminal 6 is
If the connection is made so that 6c is inserted in the slit 29 portion, it is possible to make pressure contact as easily as when the pressure contact terminal 6 is inserted into the flat cable 2a. The slit forming step of step S8 may be included in the one manufacturing line. Flat harness 1
By manufacturing, the manufacturing process can be unified and mass production can be realized at an extremely high speed.

[0066]

As described above, according to the present invention,
A flat harness includes a cable in which a plurality of conductors are covered with an insulating coating and arranged in a plane, and a plurality of connecting terminals that are connected to each of a plurality of auxiliary machines and are connected to each conductor of the cable. Since it has a common connector,
It is possible to connect auxiliary machines that use different signal line circuits with one flat harness, and to reduce the cost by sharing the parts. As a result, the applicable range of the flat harness can be expanded and the manufacturing cost can be significantly reduced.

[Brief description of drawings]

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

FIG. 2 is a diagram for explaining a flat cable that constitutes a flat harness.

FIG. 3 is a diagram for explaining a common connector that constitutes a flat harness.

FIG. 4 is a diagram for explaining a connection structure between a common connector forming a flat harness, a pressure contact terminal built in the common connector, and a conductor of the pressure contact terminal.

FIG. 5 is a diagram for explaining another cable forming the flat harness.

FIG. 6 is a diagram for explaining a connection structure between a piercing terminal and a conductor of a cable.

FIG. 7 is a diagram for explaining an arrangement example of common connectors that form a flat harness.

FIG. 8 is a diagram for explaining a connection between a common connector mounted on a flat harness and each auxiliary device.

FIG. 9 is a diagram for explaining a connection between a socket of a left / right turn valve as a common accessory and a common connector.

FIG. 10 is a diagram for explaining a flat harness in which the circuit configuration of the flat cable is changed.

FIG. 11 is a diagram for explaining a manner in which the flat cables of the flat harness are separately arranged for each system of the auxiliary equipment.

FIG. 12 is a view showing a connection example of pressure contact terminals in a common connector mounted on each flat cable.

FIG. 13 is a flowchart showing a manufacturing process of the flat harness according to the embodiment of the present invention.

FIG. 14 is a process diagram schematically showing a part of the manufacturing process in section.

FIG. 15 is a diagram for explaining various mold parts formed in the molding process.

FIG. 16 is a diagram showing how to change the layout of the flat cable and the flexible flat cable.

FIG. 17 is a diagram for explaining a slit formed in the slit forming step.

FIG. 18 is a diagram for explaining a slit formed in the slit forming step.

FIG. 19 is a flowchart showing a manufacturing process of the wire harness.

[Explanation of symbols]

1 ... Flat harness, 2, 2a ... Flat cable,
2b ... Flexible flat cable, 3 ... Common connector, 4 ... Conductor, 5 ... Insulation coating, 5a ... Bridge part, 6 ...
Pressure contact terminal, 6 '... Piercing terminal, 6a, 6b, 6c
... Connecting part, 6a '... Tip part, 7 ... Connector body part, 8 ...
Retainer, 9 ... Connector connection part, 9a ... Connection terminal, 10
... side light, 11 ... horn, 12 ... earth, 13 ... right turn valve, 14 ... left turn valve, 15 ... socket, 16 ... PWM-ECU, 17 ... motor, 20 ... supply roll, 21 ... collecting machine, 22 ... coating forming machine, 23 ... connector mounting device, 24 ... molding device, 25 ... inspection machine, 2
6 ... Mold part, 29 ... Slit.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) H01B 13/00 513 H01B 13/00 513A 519 519 H01R 43/00 H01R 43/00 B J (72) Inventor Daisuke Mako 1-5-1, Kiba, Koto-ku, Tokyo F-term in Fujikura Ltd. (reference) 5E051 BA07 BB01 5G309 AA06 AA11 EA02 EA07 EA10 5G311 CA01 CA05 CF02 CF03

Claims (38)

[Claims] 1. A cable having a plurality of conductors covered with an insulating coating and arranged in a plane, and a connection terminal connected to each conductor of the cable, and connected to each of a plurality of auxiliary machines. A flat harness comprising a plurality of common connectors. 2. The cable is an inter-insulation-coupling flat cable having a structure in which each conductor of the plurality of conductors is covered with an insulation coating, and the insulation coatings are coupled to each other. The flat harness according to claim 1. 3. The cable is a flat cable between insulating coatings, wherein each conductor of the plurality of conductors is covered with an insulating coating, and the insulating coatings are not coupled to each other and are independent of each other. The flat harness according to claim 1, wherein: 4. The flat harness according to claim 1, wherein the cable is a flexible flat cable having a structure in which the plurality of conductors are covered with an insulating coating formed in a plane by lamination or extrusion. . 5. The flat harness according to claim 1, wherein the conductor is a round conductor single wire or a stranded wire, or a rectangular conductor single wire. 6. The flat harness according to any one of claims 1 to 5, wherein the conductor is made of Cu or Al. 7. The flat harness according to any one of claims 1 to 6, wherein the plurality of common connectors are arranged at equal intervals along the longitudinal direction of the cable. 8. A plurality of said cables arranged for each system of said auxiliary equipment are provided, and each conductor of said plurality of conductors constituting each cable constitutes a corresponding signal line of the same configuration. The flat harness according to any one of claims 1 to 7, characterized in that. 9. The plurality of common connectors are respectively arranged at positions corresponding to mounting positions of the accessories of the respective cables arranged in different ways for each system. The flat harness according to claim 8. 10. The plurality of common connectors have a built-in pressure contact terminal that bites into the insulating coating of the cable and sandwiches the conductor for pressure contact. The flat harness according to item 1. 11. The plurality of common connectors have a built-in piercing terminal that penetrates into the insulating coating and the conductor of the cable and bites into the cable, and caulks the penetrating end portion to connect to the conductor. Claim 1
The flat harness according to any one of 9 above. 12. The auxiliary machine includes a connector connecting portion to which the common connector fits, and the connector connecting portion is connected to the conductor and is built in the common connector. The flat according to any one of claims 1 to 11, further comprising a connection terminal that is connected to either one of the pressure contact terminal and the piercing terminal that form a signal line necessary for the auxiliary machine. Harness. 13. The auxiliary machine is a plurality of common auxiliary machines mounted on an automobile, and a connector connecting portion of the common auxiliary machine is
The common connector including the connection terminals arranged in a common arrangement, and the common connector fitted with the connector connection portion of the common auxiliary device,
The flat harness according to any one of claims 1 to 11, wherein any one of the pressure contact terminal and the piercing terminal connected to the conductors forming different signal lines is built in. 14. The cable has a predetermined length, which is formed along the conductor, at a position where the cable is bent in the arrangement direction of the conductors, and penetrates the insulating coating between the conductors of the plurality of conductors. 5. A plurality of slits are provided in the arrangement direction of the conductors.
The flat harness according to claim 1. 15. The cable has a predetermined length formed along the conductor and penetrates the insulating coating between the conductors of the plurality of conductors at predetermined intervals in a length direction of the conductor. The flat harness according to any one of claims 1, 2, 4 to 13, wherein a plurality of slits are provided in the arrangement direction of the conductors. 16. The flat harness according to claim 14, wherein a plurality of the slit forming portions of the cable are bent in a crank shape in an arrangement direction of the conductors. 17. Among the plurality of conductors forming the cable, a conductor forming a predetermined signal line is cut at a predetermined position between both ends in the longitudinal direction of the cable, and each of the predetermined pieces cut at the cut portion. The conductors forming the signal lines and the conductors forming the other signal lines are respectively connected by mounting the plurality of common connectors, and the cut conductors forming the predetermined signal lines are connected to the plurality of common connectors. The flat harness according to any one of claims 1 to 16, wherein the circuit is changed so as to configure different signal lines via the flat harness. 18. A flat harness including a cable in which a plurality of conductors are covered with an insulating coating and arranged in a plane, and a plurality of common connectors each having a connection terminal connected to each conductor of the cable. A method of sending out the conductors forming the plurality of conductors; an assembling step of collectively arraying the conductors sent out in the sending step in a plane; and The insulation coating is extruded on each conductor and formed by laminating or coating, and a coating forming step for manufacturing the cable, and the cable manufactured in this coating forming step is connected to the conductor, and each of a plurality of auxiliary machines A connector mounting step of mounting the plurality of common connectors to be connected to the cable, and a cable mounting the plurality of common connectors in the connector mounting step. A measuring step and a cutting step of measuring the length to a length and cutting, and an inspection step of performing a completion inspection of the conductors and the common connector of the cable cut in the measuring and cutting step. Method for manufacturing flat harness. 19. The method of manufacturing a flat harness according to claim 18, further comprising a molding step of performing resin molding on a predetermined position of the cable. 20. The method of manufacturing a flat harness according to claim 19, wherein the resin used in the molding step is a thermoplastic resin. 21. Each of the conductors sent out in the sending step is a round conductor single wire or stranded wire made of Cu or Al, or a rectangular conductor single wire. A method for manufacturing a flat harness according to the item. 22. In the cable manufactured in the coating forming step, when each conductor sent out in the sending step is one of a single wire and a stranded wire of the round conductor, each conductor of the plurality of conductors is 22. A flat harness according to any one of claims 18 to 21, wherein the flat cable is an inter-insulation-coupling flat cable having a structure in which the insulation coatings are respectively covered and the insulation coatings are coupled to each other. Method. 23. In the cable manufactured in the coating forming step, when each conductor sent out in the sending step is one of a single wire and a stranded wire of the round conductor, each conductor of the plurality of conductors is The flat cable according to any one of claims 18 to 21, which is a non-bonding flat cable between insulating coatings, each of which is covered with an insulating coating and has a structure in which the insulating coatings are not coupled to each other and are independent of each other. Harness manufacturing method. 24. In the cable manufactured in the coating forming step, in the case where each conductor sent out in the sending step is a single wire of the rectangular conductor, the plurality of conductors are flatly formed by lamination or extrusion. The method of manufacturing a flat harness according to any one of claims 18 to 21, which is a flexible flat cable having a structure covered with a coating. 25. The plurality of common connectors mounted in the connector mounting step are arranged at equal intervals along a longitudinal direction of the cable.
25. The method for manufacturing a flat harness according to any one of 24. 26. The plurality of common connectors mounted in the connector mounting step are arranged in advance at a position corresponding to a mounting position of the auxiliary machine.
25. The method for manufacturing a flat harness according to any one of 24. 27. The plurality of common connectors mounted in the connector mounting step have a built-in pressure contact terminal that bites into the insulating coating of the cable to sandwich the conductor for pressure contact. Claims 18 to 2
7. The method for manufacturing the flat harness according to any one of 6 above. 28. The plurality of common connectors mounted in the connector mounting step have a built-in piercing terminal for penetrating and penetrating the insulation coating and the conductor of the cable, and caulking the penetrating end to connect to the conductor. 27. Any one of claims 18 to 26, characterized in that
Flat harness described in paragraph. 29. In the cable manufactured in the coating forming step, slits having a predetermined length along the conductors, which penetrate the insulating coating between the conductors of the plurality of conductors, are arranged in the conductor arranging direction. 23 to 24, further comprising a slit forming step of forming a plurality of slits.
9. The method for manufacturing the flat harness according to any one of 8 above. 30. In the cable manufactured in the coating forming step, along the conductor, which penetrates the insulating coating between the conductors of the plurality of conductors at predetermined intervals in the length direction of the conductor. 29. The method for manufacturing a flat harness according to claim 18, further comprising a slit forming step of forming a plurality of slits having a predetermined length in the arrangement direction of the conductors. 31. A cutting step of cutting a conductor forming a predetermined signal line among a plurality of conductors forming the cable manufactured in the coating forming step at predetermined positions at both ends in the longitudinal direction of the cable. Further, in the connector mounting step, the plurality of common connectors are mounted at a cutting portion between the conductors forming the predetermined signal lines and the conductors forming the other signal lines, which are cut in the cutting step. The method according to claim 1, further comprising a step of connecting each.
The manufacturing method of the flat harness according to any one of 8 to 30. 32. The manufacturing of a flat harness according to claim 18, wherein the sending step, the assembling step, the coating forming step, and the connector mounting step are constituted by one manufacturing line. Method. 33. The method of manufacturing a flat harness according to claim 32, wherein the molding step is further included in the one manufacturing line. 34. The method of manufacturing a flat harness according to claim 32, wherein the cutting process is further included in the one manufacturing line. 35. The measuring / cutting step and the inspection step,
32. The flat harness manufacturing method according to claim 18, wherein the flat harness is manufactured by one manufacturing line. 36. Any one of claims 18 to 31, wherein the sending step, the assembling step, the coating forming step, the connector mounting step, the measuring / cutting step and the inspection step are constituted by one manufacturing line. A method for manufacturing a flat harness according to item 1. 37. The method of manufacturing a flat harness according to claim 36, wherein the molding step is further included in the one manufacturing line. 38. The method of manufacturing a flat harness according to claim 36, wherein the cutting process is further included in the one manufacturing line.