JP2007172847A - Wire harness and method of manufacturing flat shape of wire harness - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a wire harness capable of suppressing increase in width dimension of a flat shape portion even if a plurality of electric wires with different diameter are arranged in flat shape. <P>SOLUTION: The wire harness 1 has a first electric wire 31 and a plurality of second electric wires with a smaller diameter than the first electric wire converged. The plurality of second electric wires 32 which are laminated so that the width in lamination direction Y may be close to that of the first electric wire 31 and the first electric wire 31 are installed in a direction X crossing at right angles the lamination direction Y, and the installation portion has a flat shape portion F formed by pinching by an adhesive sheet 7. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a wire harness having a flat shape portion and a flat shape manufacturing method of the wire harness.

  Various electronic devices are mounted on automobiles or the like as moving bodies. For this reason, the automobile or the like is wired with a wire harness in order to transmit electric power from a power source or the like or a control signal from a computer or the like to the electronic device. The wire harness includes a plurality of electric wires and connectors attached to ends of the electric wires.

  The electric wire includes a conductive core wire and a covering portion made of an insulating synthetic resin that covers the core wire. The electric wire is a so-called covered electric wire. The connector includes a conductive terminal fitting and an insulating connector housing. The terminal fitting is attached to an end portion of the electric wire and is electrically connected to the core wire of the electric wire. The connector housing is formed in a box shape and accommodates the terminal fitting.

  Moreover, what separated the wire harness into the group of every electric wire or the arbitrary number of electric wires, and formed this isolation | separation part in the flat shape is conventionally known. In accordance with the wiring space of the wire harness and the shape of the counterpart component, the wire harness is partially flattened to improve the wiring workability.

  Patent Documents 1 and 2 describe a harness manufacturing method in which a wire harness is partially wired as a flat shape. First, according to Patent Document 1, the wire harness has been configured to form a flat portion by attaching a separated covered electric wire to an adhesive surface provided on a flat substrate. Thus, by making it possible to easily change the size, width, etc. of the flat substrate, it has been possible to accurately cope with the size and width of the wiring harness wiring space.

According to Patent Document 2, a pair of guides is used to spread each electric wire in a flat shape in the front-rear direction to form a flat shape portion, and a synthetic resin adhesive sheet folded from the center is attached to the flat shape portion. The wires were sandwiched from above and below, and each wire was fixed in a spread state. Thereby, even if the flat shape part is removed from the jig, the flat state is maintained.
Japanese Patent Laid-Open No. 10-12047 Japanese Patent Laid-Open No. 10-275529

  As described above, the wiring harness has been partially flattened by a flat substrate or an adhesive sheet so as to satisfy the spatial conditions. However, when individual cables are routed in parallel, the number of circuits, that is, the number of wires There is a problem that the width of the flat portion increases as the number increases.

  Therefore, in view of the problems described above, the present invention provides a wire harness that can suppress an increase in the width of a flat shape portion even when a plurality of electric wires having different diameters are wired in a flat shape, and a flat shape manufacturing of the wire harness. The challenge is to provide a method.

  The wire harness according to claim 1, which is made according to the present invention to solve the above problem, is a wire harness formed by converging a first electric wire and a plurality of second electric wires having a diameter smaller than the diameter of the first electric wire. The plurality of second electric wires and the first electric wires laminated so that the width in the laminating direction is close to that of the first electric wires are juxtaposed in a direction perpendicular to the laminating direction, and the juxtaposed portion is made adhesive. It has a flat shape portion formed by being sandwiched between sheets.

  According to the wire harness of the present invention described in claim 1, the plurality of second electric wires and the first electric wires laminated so that the width in the laminating direction is close to that of the first electric wires are arranged in a direction orthogonal to the laminating direction. Since the flat portion is formed by sandwiching the juxtaposed portion with an adhesive sheet, the width of the flat portion in the direction orthogonal to the stacking direction is present even when there are a plurality of second electric wires. Increase can be suppressed.

  According to a second aspect of the present invention, in the wire harness according to the first aspect, a plurality of the second electric wires laminated in the laminating direction are arranged in parallel in the orthogonal direction. It is characterized by.

  According to the wire harness of the present invention described in claim 2, since the plurality of second electric wires laminated in the lamination direction are arranged in parallel in the direction orthogonal to the lamination direction, the number of second electric wires increases. However, an increase in the width of the flat portion in the direction orthogonal to the stacking direction can be minimized.

  The flat shape manufacturing method of the wire harness according to claim 3 made in accordance with the present invention to solve the above-mentioned problem, converges the first electric wire and a plurality of second electric wires having a diameter smaller than the diameter of the first electric wire. In the flat shape manufacturing method of a wire harness that forms a flat shape portion in a part of the wire harness, the plurality of second electric wires are stacked such that the width in the stacking direction is close to the first electric wire, The second electric wire and the first electric wire are juxtaposed in a direction perpendicular to the laminating direction, and the juxtaposed portion is sandwiched between adhesive sheets to form a flat portion.

  According to the flat shape manufacturing method of the wire harness of the present invention described in claim 3, when the plurality of second electric wires are laminated so that the width in the lamination direction is close to the first electric wire, the plurality of laminated electric wires The second electric wire and the first electric wire are juxtaposed in a direction orthogonal to the stacking direction. Then, the juxtaposed portion is sandwiched between adhesive sheets to form a flat portion.

  As described above, according to the wire harness of the present invention described in claim 1, the plurality of second electric wires and the first electric wires laminated so that the width in the laminating direction is close to that of the first electric wires are orthogonal to the laminating direction. Since the flat portion is formed by sandwiching the juxtaposed portion with an adhesive sheet, the flat shape in the direction perpendicular to the stacking direction is present even when there are a plurality of second electric wires. Since the width | variety of a part can be narrowed, even if it arrange | positions several electric wires from which a diameter differs in a flat shape, the increase in the width | variety of a flat shape part can be suppressed. Therefore, even if the number of electric wires increases, an increase in the width of the flat portion can be suppressed. Moreover, since the width | variety in the orthogonal direction of a 1st electric wire and a 2nd electric wire can be reduced rather than before, a sheet | seat can be reduced in size and the cost of sheet | seat components can be reduced. Furthermore, if the difference in the circuit configuration of the wire harness is not large, the sheet can be shared.

  According to the invention of claim 2, in addition to the effect of the invention of claim 1, a plurality of second electric wires laminated in the lamination direction are arranged in parallel in a direction orthogonal to the lamination direction. Even if the number of the second electric wires increases, an increase in the width of the flat portion in the direction orthogonal to the stacking direction can be suppressed to a minimum, which can contribute to downsizing the flat portion.

  As described above, according to the flat shape manufacturing method of the wire harness of the present invention described in claim 3, a plurality of second electric wires are laminated so that the width in the laminating direction is close to the first electric wire, and the laminated Since the plurality of second electric wires and the first electric wires are juxtaposed in a direction perpendicular to the laminating direction, and the juxtaposed portion is sandwiched between adhesive sheets to form a flat portion, the second electric wire Even if there are multiple wires, the width of the flat portion in the direction perpendicular to the stacking direction can be reduced, so even if multiple wires with different diameters are wired in a flat shape, the width of the flat portion is increased. Can be suppressed. Therefore, even if the number of electric wires increases, an increase in the width of the flat portion can be suppressed. Moreover, since the width | variety in the orthogonal direction of a 1st electric wire and a 2nd electric wire can be reduced rather than before, a sheet | seat can be reduced in size and the cost of sheet | seat components can be reduced. Furthermore, if the difference in the circuit configuration of the wire harness is not large, the sheet can be shared.

  Hereinafter, an embodiment of a wire harness according to the present invention will be described with reference to the drawings of FIGS.

  As shown in FIG. 1, the wire harness 1 has a plurality (two in FIG. 1) of sub-wire harnesses 2 and a plurality (two in FIG. 1) of sheets 7. In the illustrated example, the first sub-wire harness 2 a and the second sub-wire harness 2 b are shown as the sub-wire harness 2. In the best mode, the case of two sub-wire harnesses 2a and 2b will be described, but the number of sub-wire harnesses can be arbitrarily set.

  Each of the sub-wire harnesses 2 includes a plurality of electric wires 3 and a connector 6 attached to an end 3a of the electric wires 3. The electric wire 3 includes a coaxial cable 31 that is a first electric wire and a general wire 32 that is formed with a diameter smaller than the diameter of the coaxial cable 31 and that is a second electric wire.

  As is well known, the coaxial cable 31 includes an inner conductor 31a, a braid 31b made of a conductor concentrically surrounding the inner conductor 31a, an insulator 31c such as polyethylene interposed therebetween, and an insulating synthetic resin covering the braid 31c. And a covering portion 31d made of the like.

  As is well known, the general wire 32 has a conductive core wire 32a made of a metal wire such as copper or aluminum, and a covering portion 32b made of an insulating member covering the core wire 32a. The outer diameter of the general line 32 is about half that of the coaxial cable 31. The core wire 32a may be a core wire group in which a plurality of metal wires are bundled.

  The sub-wire harness 2a has two coaxial cables 31 and one general line 32. The sub-wire harness 2b has one coaxial cable 31 and one general line 32. In addition, each structure of subwire harness 2a, 2b can be set arbitrarily.

  Each of the connectors 6A, B, and C includes a connector housing and a terminal metal fitting (not shown). The connector housing is made of insulating synthetic resin and is formed in a box shape. The connector housing has a terminal accommodating chamber for accommodating a terminal fitting. The terminal fitting is made of a conductive sheet metal and is attached to the end 3 a of the electric wire 3. The terminal fitting is electrically connected to the inner conductor 31 a or the core wire 32 a of the electric wire 3.

  The connector 6A is connected to one side of each of the sub-harnesses 2a and 2b. The connector 6B is connected to the other side of the sub-wire harness 2a. The other side of the sub-wire harness 2b is connected to the connector 6C. That is, the sub-wire harness 2a and the sub-wire harness 2b are connected by the connector 6A.

  Three coaxial cables 31 and two general wires 32 are connected to the connector 6A. Two coaxial cables 31 and one general line 32 are connected to the connector 6B. One coaxial cable 31 and one general line 32 are connected to the connector 6B.

  The sheet 7 is formed in a rectangular plate shape that can be folded in half with a synthetic resin or the like. An adhesive surface is formed on the sheet 7 by applying an adhesive or the like to one surface thereof, that is, a bent surface. The sheet 7 is bent from the center, sandwiches a portion where the plurality of electric wires 3 are arranged in parallel, fixes each electric wire 3 in an expanded state, and forms a flat portion F. And the sheet | seat 7 maintains the flat state with the adhesive force in an adhesive surface.

  In the best mode, the case where the sheet 7 is realized by one sheet member will be described. However, the present invention is not limited to this. For example, the plurality of electric wires 3 are spread by two sheet members. Various forms such as clamping in a state can be employed.

  Next, in the wire harness 1 having the above-described configuration, an example in which the flat shape manufacturing method of the present invention is applied when the flat shape portion F is formed near the connector 6A will be described below.

  First, the coaxial cables 31 and the general wires 32 that constitute the sub-wire harnesses 2a and 2b are locked to one or a pair of electric wire holding jigs 10 shown in FIG. The electric wire holding jig 10 has a base portion 11 formed in a rectangular flat plate shape, and a plurality of (five in FIG. 3) guides 12 erected from the base portion 11. Each of the guides 12 is arranged at equal intervals in the orthogonal direction X shown in FIG. The intervals between the plurality of guides 12 are all the intervals corresponding to the outer shape of the coaxial cable 31, but the intervals between the guides 12 where the general lines 32 are arranged can also be set according to the outer shapes of the general lines 32. .

  Thus, by using the electric wire holding jig 10, at least in the portion where the sheet 7 is provided, the coaxial cable 31 and the general line 32 of the sub-wire harnesses 2a and 2b are spread in a flat shape and are equally spaced in the orthogonal direction X. Are arranged side by side in a separated state.

  In the laminating process P1 shown in FIG. 4, the two general lines 32 are laminated by an operator's manual work, a machine work, or the like so that the width in the laminating direction Y shown in FIG. Here, when the two general wires 32 are stacked, the width in the stacking direction Y and the outer diameter of the coaxial cable 31 become substantially equal, so the two general wires 32 are stacked.

  In addition, about the lamination | stacking of the general line 32, based on each size of the coaxial cable 31 and the general line 32, the number of the general lines 32 to laminate | stack so that the width | variety of the lamination direction Y may become close to the coaxial cable 31, for example Three or more can be determined. Moreover, about the lamination | stacking of the general line 32, the adjacent general lines 32 may be laminated | stacked like this best form, or the separated general lines 32 may be laminated | stacked.

  In the side-by-side process P2, at least in the portion where the coaxial cable 31 and the sheet 7 of the general line 32 are provided, the two general lines 32 and the three coaxial cables 31 that are stacked, as shown in FIGS. By arranging them side by side in the orthogonal direction X orthogonal to the stacking direction Y, a side-by-side portion is formed in the wire harness 1. A predetermined gap is formed between each of the two general wires 32 and the three coaxial cables 31 that are stacked, but the presence or absence of the predetermined gap can be arbitrarily determined.

  In the clamping process P3, as shown in FIG. 2, the sheet 7 is sandwiched between the upper and lower sides in the stacking direction Y in the juxtaposed portion, and the flat surfaces F are formed by bonding the adhesive surfaces of the sheets 7 to each other. Is done. Thereby, it is possible to maintain a state in which the two laminated general wires 32 and the three coaxial cables 31 are arranged in parallel in the orthogonal direction X. The folded sheet 7 has a width W1 with respect to the orthogonal direction X.

  On the other hand, when all of the three coaxial cables 31 and the two general lines 32 are arranged side by side in the orthogonal direction X, as shown by the broken line in FIG. The width W2 with respect to X is the size obtained by adding the width W3 to the width W1 described above. That is, by applying the present invention to the wire harness 1, the flat portion F can be reduced by the width W3.

  As described above, according to the wire harness 1, the two general wires (second electric wires) 32 and the three coaxial cables laminated so that the width in the lamination direction Y is close to the coaxial cable (first electric wire) 31. 31 are juxtaposed in the orthogonal direction X perpendicular to the stacking direction Y, and the juxtaposed sheet is sandwiched between the adhesive sheets 7 to form the flat portion F, so that there are a plurality of general lines 32. However, since the width W1 of the flat shape portion F in the orthogonal direction X orthogonal to the stacking direction Y can be reduced, the width of the flat shape portion F can be reduced even if a plurality of electric wires 3 having different diameters are wired in a flat shape. Can be suppressed.

  Therefore, even if the number of the electric wires 3 increases, an increase in the width of the flat portion F can be suppressed. Further, since the width in the orthogonal direction X between the coaxial cable 31 and the general line 32 can be reduced as compared with the conventional one, the seat 7 can be reduced in size, and the cost of the seat parts can be reduced.

  Furthermore, if the difference in the circuit configuration of the wire harness 1 is not large, the sheet 2 can be shared. For example, in the wire harness 1 shown in FIG. 1 described above, the above-described sheet 7 can also be used when the flat shape portion F is formed in the sub-wire harness 2a. Since the sub-wire harness 2a has only one general line 32, the above-described seat 7 is provided in the juxtaposed portion in which two coaxial cables 31 and one general line 32 are arranged in the orthogonal direction X. Can be sandwiched from above and below in the stacking direction Y to form a flat portion F ′. Accordingly, the flat shape portion F ′ has a width W1 with respect to the orthogonal direction X, similarly to the flat shape portion F described above. The sheet 7 can be shared with other wire harnesses 1 as well.

  In the above-described best mode, the case where two general lines 32 are stacked has been described. However, the present invention is not limited to this, and the present invention is also applicable to a larger number of general lines 32. The invention can be applied.

  For example, the case where the two coaxial cables 31 and the four general wires 31 are arranged in parallel using the coaxial cable 31 and the general wire 32 described above will be described. In addition, although the sheet | seat 7 mentioned above folded one sheet member in half, the sheet | seat 7 is set as the structure which has the sheet member 7a of the rectangular plate shape of 2 sheets here. The sheet member 7a has an adhesive surface formed by applying an adhesive or the like on one surface thereof. And the flat shape part F is formed by adhere | attaching a mutual adhesion surface.

  In the stacking process P1 shown in FIG. 4, the two general lines 32 adjacent to each other so that the width in the stacking direction Y is close to the coaxial cable 31 are stacked by an operator's manual work, machine work, or the like. And in the parallel arrangement step P2, two sets of the second electric wires 32 laminated in the lamination direction Y are arranged in parallel in the orthogonal direction Y, and they are arranged in parallel with the two coaxial cables 31. A juxtaposed portion is formed.

  In the sandwiching step P3, as shown in FIG. 6A, the juxtaposed portion is sandwiched by a pair of sheet members 7a and 7a from above and below in the stacking direction Y, and the respective adhesive surfaces are bonded to each other. A flat portion F is formed. Thereby, it is possible to maintain a state in which two sets of the two laminated general wires 32 are juxtaposed and the two coaxial cables 31 are juxtaposed in the orthogonal direction X. The sheet 7 has a width W4 with respect to the orthogonal direction X.

  On the other hand, when the two coaxial cables 31 and the four general lines 32 are all arranged in the orthogonal direction X without applying the present invention, as shown in FIG. The width W5 with respect to the orthogonal direction X is the size obtained by adding the width W6 to the width W4 described above. That is, by applying the present invention to the wire harness 1, the flat portion F can be reduced by the width W6.

  Further, since the width W6 in the orthogonal direction X corresponds to about two of the general lines 32, the width W6 is larger than the width W3 described above, and the flatness in the orthogonal direction X is increased even if the number of the general lines 32 increases. Since the increase in the width W4 of the shape portion F can be minimized, it is possible to contribute to the downsizing of the flat shape portion W4.

  In the above-described best mode, the case where the coaxial cable 31 is used for the first electric wire and the general wire 32 is used for the second electric wire has been described. However, the present invention is not limited to this, and the first electric wire, The same coaxial cable 31 or the general wire 32 having different diameters can be used for each of the two electric wires.

It is a mimetic diagram showing a schematic structure of a wire harness concerning the present invention. It is a section perspective view showing the flat shape part of the wire harness concerning the present invention. It is a figure for demonstrating the holding example of a 1st electric wire and a 2nd electric wire. It is a flowchart which shows an example of the flat shape manufacturing method of the wire harness which concerns on this invention. It is a cross-sectional perspective view which shows the other flat shape part of a wire harness. It is sectional drawing which shows the flat shape part at the time of using four 2nd electric wires, (a) has each shown the case where (b) this invention is not applied, when this invention is applied.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Wire harness 2 Sub wire harness 7 Sheet | seat 31 Coaxial cable (1st electric wire)
32 General wire (second electric wire)
F Flat shape portion W1, 4 Width of flat shape portion X orthogonal direction Y stacking direction

Claims (3)

In a wire harness formed by converging a first electric wire and a plurality of second electric wires having a diameter smaller than the diameter of the first electric wire,
The plurality of second electric wires and the first electric wires laminated so that the width in the laminating direction is close to that of the first electric wires are juxtaposed in a direction perpendicular to the laminating direction, and the juxtaposed portion is made adhesive. A wire harness comprising a flat portion formed by being sandwiched between sheets.   2. The wire harness according to claim 1, wherein the flat-shaped portion includes a plurality of the plurality of second electric wires stacked in the stacking direction in the orthogonal direction. In the flat shape manufacturing method of the wire harness that forms the flat shape portion in a part of the wire harness formed by converging the first electric wire and the plurality of second electric wires having a diameter smaller than the diameter of the first electric wire,
Laminating the plurality of second electric wires so that the width in the laminating direction is close to the first electric wires,
The plurality of stacked second electric wires and first electric wires are juxtaposed in a direction perpendicular to the laminating direction,
A flat shape manufacturing method of a wire harness, wherein the flat portion is formed by sandwiching the juxtaposed portions with an adhesive sheet.

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