JP2013243078A - Manufacturing method of wire harness - Google Patents

Manufacturing method of wire harness Download PDF

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JP2013243078A
JP2013243078A JP2012116513A JP2012116513A JP2013243078A JP 2013243078 A JP2013243078 A JP 2013243078A JP 2012116513 A JP2012116513 A JP 2012116513A JP 2012116513 A JP2012116513 A JP 2012116513A JP 2013243078 A JP2013243078 A JP 2013243078A
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welding
body member
main body
electric wire
wire harness
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Yuta Kataoka
裕太 片岡
Keiichi Ouchi
啓一 大内
Shinya Hayashi
真也 林
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Hitachi Cable Ltd
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Hitachi Cable Ltd
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Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a wire harness which integrates multiple resin members forming a housing with welding conducted by ultrasonic excitation without inserting electric wires into a horn ultrasonically vibrating and dividing the horn into multiple members.SOLUTION: A female side housing 10 of a wire harness 100 is formed by integrating a body member 2, which includes a cylindrical part 21 having an opening 210 allowing a terminal 12 to face the exterior, with a welding member 3 from which electric wires 11 are led out and welded to the body member 2. A manufacturing method of the wire harness includes a placement process where the body member 2 and the welding member 3 are placed along an axial direction of the electric wires 11 so as to face each other; a contact process where an ultrasonic horn 81 is placed in contact with the body member 2; and a welding process where the body member 2 is welded to the welding member 3 through excitation caused by the ultrasonic horn 81. In the contact process, the ultrasonic horn 81 is placed in contact with an opening side end surface 21a of the opening 210 in the body member 2.

Description

本発明は、電線の端部に接続された端子を樹脂からなるハウジングに収容してなるワイヤハーネスの製造方法に関する。   The present invention relates to a method for manufacturing a wire harness in which a terminal connected to an end of an electric wire is housed in a housing made of resin.

従来、電線と、電線の端部が挿入される挿入孔が形成された樹脂からなるハウジングと、このハウジングに収容された端子とを備えたワイヤハーネスの製造方法として、このハウジングの挿入孔を、超音波加振によってハウジングの本体部に溶着される樹脂からなる溶着部材によって塞ぐ製造方法が知られている（例えば、特許文献１参照）。   Conventionally, as a method of manufacturing a wire harness including an electric wire, a housing made of resin in which an insertion hole into which an end portion of the electric wire is inserted, and a terminal accommodated in the housing, A manufacturing method is known in which a welding member made of a resin welded to a main body portion of a housing by ultrasonic vibration is used (see, for example, Patent Document 1).

特許文献１に記載のワイヤハーネスの製造方法では、超音波振動するホーンに電線を挿通させる孔を形成し、この孔に電線を挿通させた状態で溶着部材の一端にホーンの端面を接触させることにより、溶着部材を加振する。ハウジングの本体部には、溶着部材を嵌合するための凹部が予め形成され、この凹部の底面に溶着部材の先端部が加振されながら押圧されることで、溶着部材の先端部が熱によって溶融し、この溶融した樹脂によってハウジングの挿入孔が気密に封止される。   In the method for manufacturing a wire harness described in Patent Document 1, a hole through which an electric wire is inserted is formed in a horn that vibrates ultrasonically, and the end surface of the horn is brought into contact with one end of a welding member in a state in which the electric wire is inserted into the hole. Thus, the welding member is vibrated. A concave portion for fitting the welding member is formed in the main body portion of the housing in advance, and the distal end portion of the welding member is pressed by the bottom surface of the concave portion while being vibrated, so that the distal end portion of the welding member is heated. When melted, the insertion hole of the housing is hermetically sealed by the melted resin.

特開２０１１−１００５８２号公報JP 2011-100582 A

特許文献１に記載のワイヤハーネスの製造方法では、ホーンに電線が挿通された状態で溶着部材を加振するので、ホーンの構造が複雑となると共に、ホーンに電線を挿通させ、かつホーンの端面が溶着部材に当接するようにホーンをセットする作業の工数が増大する。また、ホーンを２部材から構成し、この２部材によって電線を挟んだ状態で溶着部材を加振することも考えられるが、この場合には２部材を組み合わせる作業が新たに発生する。   In the method of manufacturing the wire harness described in Patent Document 1, the welding member is vibrated in a state where the electric wire is inserted through the horn, so that the structure of the horn is complicated, the electric wire is inserted through the horn, and the end surface of the horn. The man-hour of the operation | work which sets a horn so that may contact | abut to a welding member increases. Further, it may be possible to construct the horn from two members and vibrate the welding member in a state where the electric wire is sandwiched between the two members. In this case, a new operation for combining the two members occurs.

またさらに、電線の太さや溶着部材の大きさ等が異なる複数の機種ごとにホーンを用意しなければならないので、ホーンの作成に要するコストが嵩むと共に、ワイヤハーネスの機種に応じて超音波振動子にホーンを付け替える作業の工数も増大する。   Furthermore, since it is necessary to prepare a horn for each of a plurality of models having different wire thicknesses, welding member sizes, etc., the cost required for creating the horn increases, and an ultrasonic transducer according to the wire harness model. The number of man-hours for replacing the horn increases.

そこで、本発明は、超音波振動するホーンに電線を挿通させることなく、またホーンを複数の部材に分割することなく、ハウジングを構成する複数の樹脂部材を超音波加振による溶着によって一体化することが可能なワイヤハーネスの製造方法を提供することを目的とする。   Therefore, the present invention integrates a plurality of resin members constituting the housing by welding by ultrasonic vibration without inserting an electric wire through the ultrasonically vibrating horn and without dividing the horn into a plurality of members. An object of the present invention is to provide a method of manufacturing a wire harness that can be used.

本発明は、上記課題を解決することを目的として、電線、前記電線の端部に接続された端子、及び前記端子を収容する樹脂からなるハウジングを有するワイヤハーネスの製造方法であって、前記ハウジングは、前記端子を外部に臨ませる開口を有する筒状部を含む本体部材と、前記本体部材に溶着され、前記電線が導出される溶着部材とを一体化してなり、前記本体部材と前記溶着部材とを前記電線の軸線方向に沿って向い合わせて配置する配置工程と、前記本体部材に超音波ホーンを接触させる接触工程と、前記超音波ホーンによる加振によって前記本体部材と前記溶着部材とを溶着させる溶着工程とを有し、前記接触工程は、前記超音波ホーンを前記開口における前記本体部材の開口側端面に接触させる工程であるワイヤハーネスの製造方法を提供する。   In order to solve the above-described problems, the present invention provides a method for manufacturing a wire harness having an electric wire, a terminal connected to an end of the electric wire, and a housing made of a resin that accommodates the terminal. Is formed by integrating a main body member including a cylindrical portion having an opening that exposes the terminal to the outside, and a welding member that is welded to the main body member and from which the electric wire is led out, and the main body member and the welding member Are arranged so as to face each other along the axial direction of the electric wire, a contact step in which an ultrasonic horn is brought into contact with the main body member, and the main body member and the welding member by vibration with the ultrasonic horn. A wire harness that is a step of bringing the ultrasonic horn into contact with the opening-side end surface of the body member in the opening. The law provides.

また、前記本体部材及び前記溶着部材のうち少なくとも一方の部材は、前記電線の軸線方向に沿って突出し、その先端部ほど前記軸線方向に直交する断面における断面積が小さくなる突起を有し、前記配置工程は、前記突起の先端部を前記一方の部材に向かい合う他方の部材に接触させて前記本体部材と前記溶着部材とを配置する工程であるとよい。   In addition, at least one member of the main body member and the welding member has a protrusion that protrudes along the axial direction of the electric wire, and a tip portion thereof has a small cross-sectional area in a cross section orthogonal to the axial direction, The disposing step may be a step of disposing the main body member and the welding member by bringing the tip of the protrusion into contact with the other member facing the one member.

また、前記溶着部材は、前記電線を挿通させる挿通孔が形成された筒状の筒部を有し、前記突起は、前記筒部の一端部及び他端部のうち前記本体部材側の一端部に形成されているとよい。   Further, the welding member has a cylindrical tube portion in which an insertion hole through which the electric wire is inserted is formed, and the protrusion is one end portion on the main body member side among the one end portion and the other end portion of the tube portion. It is good to be formed.

また、前記溶着部材は、前記筒部の前記他端部に前記筒部と一体に形成され、前記筒部の外周側に張り出した基部を有し、前記突起は、前記筒部の前記一端部、及び前記基部の前記本体部材側に形成されているとよい。   In addition, the welding member has a base portion that is integrally formed with the cylindrical portion at the other end portion of the cylindrical portion, and protrudes to the outer peripheral side of the cylindrical portion, and the protrusion is the one end portion of the cylindrical portion. And it is good to be formed in the main body member side of the base.

また、前記溶着部材の前記基部には、前記突起として、前記本体部材側に突出する環状の外周突起部、及び前記外周突起部の内側に形成された環状の内周突起部が形成され、前記外周突起部は、前記内周突起部よりも前記基部からの高さが高く形成されているとよい。   Further, the base of the welding member is formed with an annular outer peripheral protrusion protruding toward the main body member and an annular inner peripheral protrusion formed inside the outer protrusion as the protrusion, It is preferable that the outer peripheral protrusion is formed to have a height higher from the base than the inner peripheral protrusion.

また、前記筒部の前記一端部は、その外周面がテーパ面として形成され、前記本体部材には、前記筒部を収容すると共に前記電線を挿通させる挿通孔が形成され、前記本体部材の前記挿通孔は、その少なくとも一部が前記筒部の前記一端部における前記テーパ面と向かい合うテーパ状に形成されているとよい。   Further, the one end portion of the cylindrical portion has an outer peripheral surface formed as a tapered surface, and the main body member is formed with an insertion hole for accommodating the cylindrical portion and allowing the electric wire to pass therethrough. It is preferable that at least a part of the insertion hole is formed in a tapered shape facing the tapered surface at the one end portion of the cylindrical portion.

また、前記溶着部材は、互いに溶着される複数の部材からなり、前記溶着工程は、前記本体部材及び前記溶着部材を構成する前記複数の部材を共に溶着させて一体化する工程であるとよい。   The welding member may include a plurality of members that are welded together, and the welding step may be a step of welding and integrating the body member and the plurality of members constituting the welding member together.

本発明に係るワイヤハーネスの製造方法によれば、超音波振動するホーンに電線を挿通させることなく、またホーンを複数の部材に分割することなく、ハウジングを構成する複数の樹脂部材を超音波加振による溶着によって一体化することが可能となる。   According to the method for manufacturing a wire harness according to the present invention, a plurality of resin members constituting a housing are ultrasonically applied without passing an electric wire through a horn that vibrates ultrasonically and without dividing the horn into a plurality of members. It can be integrated by welding by vibration.

本発明の第１の実施の形態に係る製造方法によって製造されたワイヤハーネスを示し、（ａ）は雌コネクタと雄コネクタの嵌合前の状態を示す側面図、（ｂ）は雌コネクタと雄コネクタとが嵌合された状態を示す斜視図である。The wire harness manufactured by the manufacturing method which concerns on the 1st Embodiment of this invention is shown, (a) is a side view which shows the state before fitting of a female connector and a male connector, (b) is a female connector and a male. It is a perspective view which shows the state by which the connector was fitted. 複数の電線の軸線を含む断面における雌コネクタの断面図である。It is sectional drawing of the female connector in the cross section containing the axis line of a some electric wire. 本体部材を示し、（ａ）は外観斜視図、（ｂ）は（ａ）のＢ−Ｂ線断面における断面斜視図である。A main body member is shown, (a) is an external appearance perspective view, (b) is a cross-sectional perspective view in the BB sectional view of (a). 溶着部材を示し、（ａ）は外観斜視図、（ｂ）は（ａ）のＣ−Ｃ線断面図である。A welding member is shown, (a) is an external appearance perspective view, (b) is CC sectional view taken on the line of (a). （ａ）及び（ｂ）は、ワイヤハーネスの製造工程を示す模式図である。（ｃ）は、ワイヤハーネスの製造工程に用いる支持台を示す模式図である。(A) And (b) is a schematic diagram which shows the manufacturing process of a wire harness. (C) is a schematic diagram which shows the support stand used for the manufacturing process of a wire harness. 第１の実施の形態の変形例に係る溶着部材を示す上面図である。It is a top view which shows the welding member which concerns on the modification of 1st Embodiment. 本実施の形態に係る雌コネクタを示し、（ａ）は開口側端面側から見た正面図、（ｂ）は複数の電線の軸線を含む断面における断面図である。The female connector which concerns on this Embodiment is shown, (a) is the front view seen from the opening side end surface side, (b) is sectional drawing in the cross section containing the axial line of a some electric wire. 本体部材を示し、（ａ）は外観斜視図、（ｂ）は（ａ）のＤ−Ｄ線断面における断面斜視図、（ｃ）は（ａ）のＥ矢視図である。A main body member is shown, (a) is an external appearance perspective view, (b) is a cross-sectional perspective view in the DD sectional view of (a), (c) is an E arrow view of (a). 第２溶着部材を示し、（ａ），（ｂ）は斜視図、（ｃ）は（ａ）のＦ−Ｆ線断面図である。The 2nd welding member is shown, (a), (b) is a perspective view, (c) is an FF line sectional view of (a). 第１溶着部材を示し、（ａ）は斜視図、（ｂ）は（ａ）のＧ−Ｇ線断面図である。The 1st welding member is shown, (a) is a perspective view, (b) is the GG sectional view taken on the line of (a). （ａ）及び（ｂ）は、ワイヤハーネスの製造工程を示す模式図である。(A) And (b) is a schematic diagram which shows the manufacturing process of a wire harness. （ａ）は、第２の実施の形態の変形例に係る第２溶着部材を示す上面図、（ｂ）は第２の実施の形態の変形例に係る第１溶着部材を示す上面図である。(A) is a top view which shows the 2nd welding member which concerns on the modification of 2nd Embodiment, (b) is a top view which shows the 1st welding member which concerns on the modification of 2nd Embodiment. .

［第１の実施の形態］
図１は、本発明の第１の実施の形態に係る製造方法によって製造されたワイヤハーネス１００、及びこのワイヤハーネス１００の雌コネクタ１に嵌合される雄コネクタ９を示し、（ａ）は雌コネクタ１と雄コネクタ９の嵌合前の状態を示す側面図、（ｂ）は雌コネクタ１と雄コネクタ９とが嵌合された状態を示す斜視図である。図２は、複数の電線１１の軸線を含む断面における雌コネクタ１の断面図である。 [First Embodiment]
FIG. 1 shows a wire harness 100 manufactured by the manufacturing method according to the first embodiment of the present invention, and a male connector 9 fitted to the female connector 1 of the wire harness 100. FIG. The side view which shows the state before the fitting of the connector 1 and the male connector 9, (b) is a perspective view which shows the state by which the female connector 1 and the male connector 9 were fitted. FIG. 2 is a cross-sectional view of the female connector 1 in a cross section including the axes of the plurality of electric wires 11.

このワイヤハーネス１００は、例えば車両の走行用の駆動力を発生する駆動源としての電動モータに、駆動電流としての三相交流電流を供給するために用いられる。この場合、ワイヤハーネス１００は電動モータとインバータとの間を電気的に接続する。図１及び図２では、ワイヤハーネス１００の一方の端部を示している。   This wire harness 100 is used, for example, to supply a three-phase alternating current as a drive current to an electric motor as a drive source that generates a driving force for running the vehicle. In this case, the wire harness 100 electrically connects the electric motor and the inverter. In FIG.1 and FIG.2, one edge part of the wire harness 100 is shown.

ワイヤハーネス１００は、複数（本実施の形態では３本）の電線１１と、複数の電線１１のそれぞれの端部に接続された複数の端子１２（図２に示す）と、複数の端子１２を収容する樹脂からなる雌側ハウジング１０を有する雌コネクタ１とを備えている。雌側ハウジング１０は、樹脂からなる本体部材２と、同じく樹脂からなる溶着部材３とを一体化して構成されている。図２では、本体部材２と溶着部材３とが融合した境界線を破線で示している。   The wire harness 100 includes a plurality (three in the present embodiment) of electric wires 11, a plurality of terminals 12 (shown in FIG. 2) connected to respective end portions of the plurality of electric wires 11, and a plurality of terminals 12. And a female connector 1 having a female housing 10 made of a resin to be accommodated. The female housing 10 is formed by integrating a main body member 2 made of resin and a welding member 3 made of resin. In FIG. 2, a boundary line where the main body member 2 and the welding member 3 are fused is indicated by a broken line.

本実施の形態では、本体部材２及び溶着部材３が同一の樹脂材料からなる。この樹脂材料としては、例えばＰＢＴ（ポリブチレンテレフタレート）、ＰＰＳ（ポリフェニレンスルファイド）、ＰＡ（ポリアミド）等を用いることができる。   In the present embodiment, the main body member 2 and the welding member 3 are made of the same resin material. As this resin material, for example, PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), PA (polyamide) or the like can be used.

雄コネクタ９は、雌側ハウジング１０に嵌合される雄側ハウジング９０を有し、この雄側ハウジング９０に複数（本実施の形態では３本）の電線９１の一端が収容されている。雄側ハウジング９０は、例えばインバータやモータ等の機器のケース（図示せず）に雄側ハウジング９０を固定するためのフランジ部９０１と、フランジ部９０１に対して直交する方向に突出する筒部９０２と、筒部９０２の内外を連通させる貫通孔が形成された円筒部９０３と、筒部９０２の外方に突出する係合突起９０４と、フランジ部９０１の他側（筒部９０２の反対側）に突出して形成され、電線９１が導出される導出部９０５とを有している。   The male connector 9 has a male housing 90 fitted into the female housing 10, and one end of a plurality (three in this embodiment) of electric wires 91 is accommodated in the male housing 90. The male housing 90 includes, for example, a flange portion 901 for fixing the male housing 90 to a case (not shown) of a device such as an inverter or a motor, and a cylindrical portion 902 protruding in a direction orthogonal to the flange portion 901. A cylindrical portion 903 formed with a through-hole that communicates the inside and outside of the cylindrical portion 902, an engaging projection 904 that protrudes outward from the cylindrical portion 902, and the other side of the flange portion 901 (the opposite side of the cylindrical portion 902) And a lead-out portion 905 from which the electric wire 91 is led out.

筒部９０２には、複数の電線９１のそれぞれの端部に接続された複数の端子（図示せず）が収容されている。この端子は、雌コネクタ１と雄コネクタ９とが嵌合されたとき、雌コネクタ１の端子１２に電気的に接続される。雌コネクタ１の端子と雌コネクタ１の端子１２とは、円筒部９０３の内面に螺合した押付部材９０６（図１（ｂ）に示す）によって、図略の絶縁部材を介して押し付けられる。   A plurality of terminals (not shown) connected to the respective ends of the plurality of electric wires 91 are accommodated in the cylindrical portion 902. This terminal is electrically connected to the terminal 12 of the female connector 1 when the female connector 1 and the male connector 9 are fitted. The terminals of the female connector 1 and the terminals 12 of the female connector 1 are pressed through an insulating member (not shown) by a pressing member 906 (shown in FIG. 1B) screwed into the inner surface of the cylindrical portion 903.

図２に示すように、本体部材２は、複数の端子１２を雌側ハウジング１０の外部に臨ませる開口２１０を有する筒状部２１と、筒状部２１に連続して、複数の電線１１の配列方向（図２の上下方向）における幅が筒状部２１よりも小さく形成された小筒部２２と、小筒部２２の内部にて複数の電線１１の一端部を保持する電線保持部２３とを一体に有している。   As shown in FIG. 2, the main body member 2 includes a cylindrical portion 21 having openings 210 that allow the plurality of terminals 12 to face the outside of the female housing 10, and the cylindrical portion 21. A small tube portion 22 having a width in the arrangement direction (vertical direction in FIG. 2) smaller than that of the tubular portion 21, and an electric wire holding portion 23 that holds one end portion of the plurality of electric wires 11 inside the small tube portion 22. Are integrated.

小筒部２２と電線保持部２３との間には、雄側ハウジング９０の筒部９０２（図１（ａ）に示す）を収容する環状の空間が形成されている。小筒部２２と電線保持部２３とは、後述するリブ２４によって連結されている。また、電線保持部２３の外周には、雄側ハウジング９０の筒部９０２の内面との間をシールする環状のシール部材４１が配置されている。   Between the small cylinder part 22 and the electric wire holding | maintenance part 23, the cyclic | annular space which accommodates the cylinder part 902 (it shows to Fig.1 (a)) of the male side housing 90 is formed. The small tube portion 22 and the electric wire holding portion 23 are connected by a rib 24 described later. In addition, an annular seal member 41 that seals between the outer surface of the wire holding portion 23 and the inner surface of the cylindrical portion 902 of the male housing 90 is disposed.

筒状部２１には、押付部材９０６を雌側ハウジング１０の外部から回転操作可能とする丸孔２１１が形成されている。また、筒状部２１には、雄側ハウジング９０の係合突起９０４に係合して雄側ハウジング９０の雌側ハウジング１０からの不用意な離脱を抑止する係合部２１２が形成されている。   The cylindrical portion 21 is formed with a round hole 211 that allows the pressing member 906 to be rotated from the outside of the female housing 10. Further, the tubular portion 21 is formed with an engaging portion 212 that engages with the engaging protrusion 904 of the male housing 90 to prevent inadvertent detachment of the male housing 90 from the female housing 10. .

電線１１は、中心導体１１０と、中心導体１１０を被覆する絶縁体からなるシース１１１とを有している。端子１２は、加締め部１２０と、雄コネクタ９の端子に面接触する板状の接続部１２１とを一体に有している。電線１１の先端部では、シース１１１が除去されて中心導体１１０が露出し、この露出した中心導体１１０に加締め部１２０が加締められている。   The electric wire 11 includes a center conductor 110 and a sheath 111 made of an insulator that covers the center conductor 110. The terminal 12 integrally includes a caulking portion 120 and a plate-like connection portion 121 that is in surface contact with the terminal of the male connector 9. At the distal end portion of the electric wire 11, the sheath 111 is removed to expose the central conductor 110, and the crimped portion 120 is crimped to the exposed central conductor 110.

複数の電線１１の軸方向における電線保持部２３の一端部には、複数（３つ）の端子１２の接続部１２１を挿通させて各端子１２を支持する端子支持部材４０が固定されている。端子支持部材４０は、図略の係止機構によって電線保持部２３に固定されている。   A terminal support member 40 that supports the terminals 12 by inserting the connection portions 121 of the plurality of (three) terminals 12 is fixed to one end of the wire holding portion 23 in the axial direction of the plurality of wires 11. The terminal support member 40 is fixed to the electric wire holding part 23 by an unillustrated locking mechanism.

また、複数の電線１１の軸方向における電線保持部２３の他端部には、溶着部材３が溶着によって一体化されている。複数の電線１１は、この溶着部材３を介して雌側ハウジング１０の外部に導出されている。   Moreover, the welding member 3 is integrated with the other end part of the electric wire holding | maintenance part 23 in the axial direction of the some electric wire 11 by welding. The plurality of electric wires 11 are led out of the female housing 10 via the welding member 3.

図３は、溶着部材３が溶着される前の本体部材２を示し、（ａ）は外観斜視図、（ｂ）は（ａ）のＢ−Ｂ線断面における断面斜視図である。   3A and 3B show the main body member 2 before the welding member 3 is welded. FIG. 3A is an external perspective view, and FIG. 3B is a cross-sectional perspective view taken along line BB in FIG.

図３（ａ）に示すように、本体部材２の電線保持部２３及び小筒部２２は、電線保持部２３の外面と小筒部２２の内面との間に放射状に形成された複数のリブ２４（図３では１つのみ示す）によって連結されている。電線保持部２３には、３本の電線１１を挿通させる３つの挿通孔２３０が形成されている。本実施の形態では、挿通孔２３０が円筒状に形成されている。   As shown in FIG. 3A, the electric wire holding portion 23 and the small tube portion 22 of the main body member 2 are a plurality of ribs formed radially between the outer surface of the electric wire holding portion 23 and the inner surface of the small tube portion 22. 24 (only one is shown in FIG. 3). In the electric wire holding portion 23, three insertion holes 230 through which the three electric wires 11 are inserted are formed. In the present embodiment, the insertion hole 230 is formed in a cylindrical shape.

図３（ｂ）に示すように、挿通孔２３０は、電線１１の一端及び端子１２の加締め部１２０を収容する収容空間２３１と本体部材２の外部とを連通している。挿通孔２３０の内面は、収容空間２３１側に向かうにつれて内径が小さくなるテーパ面２３０ａと、電線１１の外径よりも僅かに大きな内径を有する円筒面２３０ｃと、テーパ面２３０ａ及び円筒面２３０ｃの間に形成され、挿通孔２３０の中心軸線に対して直交する面からなる環状の段差面２３０ｂとを含んでいる。円筒面２３０ｃは段差面２３０ｂの収容空間２３１側に、テーパ面２３０ａはその反対側（本体部材２の外部側）に、それぞれ形成されている。   As shown in FIG. 3B, the insertion hole 230 communicates the housing space 231 that houses one end of the electric wire 11 and the crimped portion 120 of the terminal 12 and the outside of the main body member 2. The inner surface of the insertion hole 230 has a tapered surface 230a whose inner diameter becomes smaller toward the accommodation space 231 side, a cylindrical surface 230c having an inner diameter slightly larger than the outer diameter of the electric wire 11, and the tapered surface 230a and the cylindrical surface 230c. And an annular step surface 230b formed of a surface orthogonal to the central axis of the insertion hole 230 is included. The cylindrical surface 230c is formed on the accommodation space 231 side of the step surface 230b, and the tapered surface 230a is formed on the opposite side (outside of the main body member 2).

図４は、本体部材２に溶着される前の溶着部材３を示し、（ａ）は外観斜視図、（ｂ）は（ａ）のＣ−Ｃ線断面図である。   4A and 4B show the welding member 3 before being welded to the main body member 2. FIG. 4A is an external perspective view, and FIG. 4B is a cross-sectional view taken along the line CC of FIG.

溶着部材３は、基部３０と、３つの筒部３１とを一体に有している。また、溶着部材３には、３つの挿入孔３１０が設けられている。挿入孔３１０は、筒部３１をその中心軸線に沿って貫通すると共に、基部３０を厚さ方向に貫通している。挿入孔３１０には電線１１が挿入される。   The welding member 3 integrally includes a base portion 30 and three cylindrical portions 31. The welding member 3 is provided with three insertion holes 310. The insertion hole 310 penetrates the cylindrical portion 31 along its central axis and penetrates the base portion 30 in the thickness direction. The electric wire 11 is inserted into the insertion hole 310.

基部３０は、周縁がトラック形状の板部３００と、板部３００の一方の平面３００ａの周縁に沿って形成された環状の外周突起部３０１と、外周突起部３０１に隣接して外周突起部３０１の内側に形成された環状の内周突起部３０２とを有している。外周突起部３０１及び内周突起部３０２は、挿入孔３１０の中心軸に沿って、すなわち電線１１の軸線方向に沿って突出し、その先端部ほど電線１１の軸線方向に直交する断面における断面積が小さくなるように形成されている。また、内周突起部３０２は、外周突起部３０１よりも平面３００ａからの高さ（挿入孔３１０の中心軸方向の高さ）が高く形成されている。   The base 30 includes a plate portion 300 having a track periphery, an annular outer peripheral protrusion 301 formed along the peripheral edge of one flat surface 300 a of the plate 300, and an outer peripheral protrusion 301 adjacent to the outer peripheral protrusion 301. And an annular inner peripheral projection 302 formed on the inner side of the inner periphery. The outer peripheral protrusion 301 and the inner peripheral protrusion 302 protrude along the central axis of the insertion hole 310, that is, along the axial direction of the electric wire 11, and the tip end portion has a cross-sectional area in a cross section orthogonal to the axial direction of the electric wire 11. It is formed to be smaller. Further, the inner peripheral protrusion 302 is formed to have a height higher than the outer peripheral protrusion 301 from the plane 300a (the height of the insertion hole 310 in the central axis direction).

３つの筒部３１は、板部３００の平面３００ａから、平面３００ａに対して直交する方向に延びるように形成されている。筒部３１は、その根元側（基部３０側）の円筒部３１１と、円筒部３１１に連続して形成された先端側の突起部３１２とを有して構成されている。突起部３１２は、挿入孔３１０の中心軸に沿って、すなわち電線１１の軸線方向に沿って突出し、その先端部ほど電線１１の軸線方向に直交する断面における断面積が小さくなるように形成されている。   The three cylindrical portions 31 are formed to extend from the plane 300a of the plate portion 300 in a direction orthogonal to the plane 300a. The cylindrical portion 31 includes a cylindrical portion 311 on the base side (base portion 30 side) and a protruding portion 312 on the distal end side formed continuously with the cylindrical portion 311. The protrusion 312 protrudes along the central axis of the insertion hole 310, that is, along the axial direction of the electric wire 11, and is formed so that a cross-sectional area in a cross section orthogonal to the axial direction of the electric wire 11 becomes smaller at the tip portion. Yes.

突起部３１２の先端面３１２ａは、溶着部材３と本体部材２とを電線１１に沿って配置したとき、本体部材２の挿通孔２３０における段差面２３０ｂに接触する。つまり、突起部３１２は、筒部３１の本体部材２側の一端部及び基部３０側の他端部のうち、本体部材２側の一端部に形成されている。   The distal end surface 312 a of the protruding portion 312 contacts the step surface 230 b in the insertion hole 230 of the main body member 2 when the welding member 3 and the main body member 2 are disposed along the electric wire 11. That is, the protruding portion 312 is formed at one end portion on the main body member 2 side among the one end portion on the main body member 2 side and the other end portion on the base portion 30 side of the cylindrical portion 31.

また、筒部３１における突起部３１２は、溶着部材３と本体部材２とを組み合わせたとき、本体部材２の挿通孔２３０に収容され、外周面３１２ｂが挿通孔２３０のテーパ面２３０ａに向かい合う。つまり、本体部材２の挿通孔２３０は、その一部が筒部３１の突起部３１２におけるテーパ面３１２ｂと向かい合うテーパ状に形成されている。   Further, when the welding member 3 and the main body member 2 are combined, the protruding portion 312 in the cylindrical portion 31 is accommodated in the insertion hole 230 of the main body member 2, and the outer peripheral surface 312 b faces the tapered surface 230 a of the insertion hole 230. That is, a part of the insertion hole 230 of the main body member 2 is formed in a tapered shape facing the tapered surface 312 b of the protruding portion 312 of the cylindrical portion 31.

また、基部３０は、筒部３１の他端部において筒部３１と一体に、筒部３１の外周側に張り出して形成されている。外周突起部３０１及び内周突起部３０２は、基部３０の本体部材２側に形成されている。   The base portion 30 is formed so as to protrude from the outer peripheral side of the cylindrical portion 31 integrally with the cylindrical portion 31 at the other end portion of the cylindrical portion 31. The outer peripheral protrusion 301 and the inner peripheral protrusion 302 are formed on the base member 2 side of the base 30.

外周突起部３０１及び内周突起部３０２ならびに突起部３１２は、本発明における「突起」の一例である。   The outer peripheral protrusion 301, the inner peripheral protrusion 302, and the protrusion 312 are examples of “protrusions” in the present invention.

（ワイヤハーネス１００の製造方法）
次に、ワイヤハーネス１００の製造方法について説明する。 (Method for manufacturing wire harness 100)
Next, a method for manufacturing the wire harness 100 will be described.

図５（ａ）及び（ｂ）は、ワイヤハーネス１００の製造工程を示す模式図である。図５（ｃ）は、ワイヤハーネス１００の製造工程において、支持台８０を表（おもて）面８０ａ側から見た状態を示す模式図である。   FIGS. 5A and 5B are schematic views showing a manufacturing process of the wire harness 100. FIG. FIG. 5C is a schematic diagram showing a state in which the support base 80 is viewed from the front (front) surface 80 a side in the manufacturing process of the wire harness 100.

ワイヤハーネス１００の製造工程は、本体部材２と溶着部材３とを電線１１の軸線方向に沿って向い合わせて配置する配置工程と、本体部材２に超音波ホーン８１を接触させる接触工程と、超音波ホーン８１による加振によって本体部材２と溶着部材３とを溶着させる溶着工程とを有している。以下、この各工程について、より詳細に説明する。なお、各工程における作業手順は一例として示すものであり、この作業手順に限定されることはない。   The manufacturing process of the wire harness 100 includes an arrangement process in which the main body member 2 and the welding member 3 are arranged to face each other along the axial direction of the electric wire 11, a contact process in which the ultrasonic horn 81 is brought into contact with the main body member 2, A welding step of welding the main body member 2 and the welding member 3 by vibration by the sonic horn 81. Hereinafter, each step will be described in more detail. In addition, the work procedure in each process is shown as an example, and is not limited to this work procedure.

（配置工程）
配置工程では、３本の電線１１を予め溶着部材３の挿通孔２３０に挿入し、かつ本体部材２の挿通孔２３０を挿通させ、その一端部に端子１２を接続する。次に、端子１２を電線保持部２３の一端部に固定された端子支持部材４０によって本体部材２内に支持する。次に、３本の電線１１を支持台８０に設けられたスリット部８０１（図５（ｃ）に示す）内に導入し、溶着部材３を基部３０が下側（支持台８０の表面８０ａ側）となるように支持台８０上に配置する。これにより、基部３０の板部３００における一方の平面３００ａの反対側の他方の平面３００ｂが支持台８０の表面８０ａに接触する。 (Arrangement process)
In the arrangement step, the three electric wires 11 are inserted into the insertion hole 230 of the welding member 3 in advance and the insertion hole 230 of the main body member 2 is inserted, and the terminal 12 is connected to one end thereof. Next, the terminal 12 is supported in the main body member 2 by a terminal support member 40 fixed to one end of the electric wire holding portion 23. Next, the three electric wires 11 are introduced into a slit portion 801 (shown in FIG. 5C) provided on the support base 80, and the welding member 3 is placed on the lower side (on the surface 80 a side of the support base 80 ) Is arranged on the support base 80. As a result, the other flat surface 300b of the base portion 30 opposite to the one flat surface 300a contacts the surface 80a of the support base 80.

次に、図５（ａ）に示すように、本体部材２と溶着部材３とを電線１１の軸線方向に沿って向い合わせ、本体部材２を図中の矢印のように溶着部材３に向けて移動させる。これにより、溶着部材３の筒部３１が本体部材２の挿通孔２３０に挿入され、筒部３１の突起部３１２における先端面３１２ａが挿通孔２３０における段差面２３０ｂに接触し、突起部３１２のテーパ状の外周面３１２ｂ（図４に示す）が挿通孔２３０におけるテーパ面２３０ａに向かい合う。また、溶着部材３の外周突起部３０１及び内周突起部３０２が本体部材２の電線保持部２３における挿通孔２３０の開口端面２３ａ（図４に示す）に向かい合う。   Next, as shown in FIG. 5A, the main body member 2 and the welding member 3 face each other along the axial direction of the electric wire 11, and the main body member 2 faces the welding member 3 as indicated by an arrow in the figure. Move. As a result, the cylindrical portion 31 of the welding member 3 is inserted into the insertion hole 230 of the main body member 2, the distal end surface 312 a of the protruding portion 312 of the cylindrical portion 31 comes into contact with the step surface 230 b of the inserting hole 230, and the tapered portion 312 is tapered. The outer peripheral surface 312 b (shown in FIG. 4) faces the tapered surface 230 a in the insertion hole 230. Further, the outer peripheral protrusion 301 and the inner peripheral protrusion 302 of the welding member 3 face the opening end surface 23 a (shown in FIG. 4) of the insertion hole 230 in the wire holding portion 23 of the main body member 2.

なお、内周突起部３０２の先端部を開口端面２３ａに接触させ、筒部３１の先端面３１２ａを挿通孔２３０における段差面２３０ｂに非接触で向い合せるようにしてもよい。また、内周突起部３０２と開口端面２３ａ、及び先端面３１２ａと段差面２３０ｂが共に接触するように各部の寸法を設定してもよい。   Note that the distal end portion of the inner peripheral projection 302 may be brought into contact with the opening end surface 23 a and the distal end surface 312 a of the cylindrical portion 31 may be opposed to the step surface 230 b in the insertion hole 230 without contact. In addition, the dimensions of each part may be set so that the inner peripheral protrusion 302 and the opening end surface 23a, and the tip end surface 312a and the stepped surface 230b come into contact with each other.

（接触工程）
接触工程では、超音波ホーン８１を本体部材２に向かって移動させ、超音波ホーン８１の端面８１ａを本体部材２における開口２１０の開口側端面２１ａに接触させる。本実施の形態では、端面８１ａが平面状に形成されている。超音波ホーン８１は、図略の超音波振動子に機械的に接続され、超音波振動子の振動（超音波振動）を本体部材２に伝達可能である。なお、超音波ホーン８１は、超音波振動しない状態で開口側端面２１ａに接触してもよく、超音波振動しながら開口側端面２１ａに接触してもよい。また、本実施の形態では、超音波ホーン８１が、端面８１ａの法線方向に、すなわち電線１１の軸線方向に沿って往復運動するように微振動する。 (Contact process)
In the contact step, the ultrasonic horn 81 is moved toward the main body member 2, and the end face 81 a of the ultrasonic horn 81 is brought into contact with the opening-side end face 21 a of the opening 210 in the main body member 2. In the present embodiment, the end surface 81a is formed in a planar shape. The ultrasonic horn 81 is mechanically connected to an ultrasonic transducer (not shown) and can transmit vibration (ultrasonic vibration) of the ultrasonic transducer to the main body member 2. In addition, the ultrasonic horn 81 may contact the opening side end surface 21a without ultrasonic vibration, or may contact the opening side end surface 21a while ultrasonically vibrating. Further, in the present embodiment, the ultrasonic horn 81 slightly vibrates so as to reciprocate in the normal direction of the end surface 81a, that is, along the axial direction of the electric wire 11.

（溶着工程）
溶着工程では、超音波ホーン８１を振動させながら支持台８０に向かって移動させ、本体部材２を押圧しながら加振する。この加振により、溶着部材３と本体部材２との接触部において樹脂材料が過熱されて溶融する。突起部３１２が溶融した液状の溶融樹脂の一部は、突起部３１２の外周面３１２ｂと挿通孔２３０のテーパ面２３０ａとの間に流れ込み、他の一部は挿入孔３１０の内面と電線１１の外周面との間に流れ込む。また、外周突起部３０１及び内周突起部３０２が溶融した液状の溶融樹脂の一部は、基部３０の平面３００ａと電線保持部２３の開口端面２３ａとの間に流れ込み、他の一部は挿入孔３１０の内面と電線１１の外周面との間に流れ込む。 (Welding process)
In the welding step, the ultrasonic horn 81 is moved toward the support base 80 while being vibrated, and the main body member 2 is vibrated while being pressed. By this vibration, the resin material is heated and melted at the contact portion between the welding member 3 and the main body member 2. Part of the liquid molten resin in which the protrusion 312 is melted flows between the outer peripheral surface 312 b of the protrusion 312 and the tapered surface 230 a of the insertion hole 230, and the other part of the inner surface of the insertion hole 310 and the wire 11. It flows between the outer peripheral surface. Further, a part of the liquid molten resin in which the outer peripheral protrusion 301 and the inner peripheral protrusion 302 are melted flows between the flat surface 300a of the base 30 and the opening end surface 23a of the electric wire holding part 23, and the other part is inserted. It flows between the inner surface of the hole 310 and the outer peripheral surface of the electric wire 11.

これら各部に流れ込んだ溶融樹脂は自然冷却によって固化し、本体部材２と溶着部材３とが溶着されると共に、挿入孔３１０の内面と電線１１の外周面との間が気密に封止される。これによって図１及び図２に示すワイヤハーネス１００が得られる。   The molten resin that has flowed into these parts is solidified by natural cooling, whereby the main body member 2 and the welding member 3 are welded, and the space between the inner surface of the insertion hole 310 and the outer peripheral surface of the electric wire 11 is hermetically sealed. As a result, the wire harness 100 shown in FIGS. 1 and 2 is obtained.

（第１の実施の形態の作用及び効果）
以上説明した第１の実施の形態によれば、以下に述べる作用及び効果が得られる。 (Operation and effect of the first embodiment)
According to the first embodiment described above, the following operations and effects can be obtained.

（１）超音波ホーン８１の平面状の端面８１ａを本体部材２における開口２１０の開口側端面２１ａに接触させるので、例えば特許文献１に記載の製造方法のように、ホーンに電線を挿通させる必要がない。また、電線が導出された側から溶着部材を加振するためにホーンを分割する必要もない。これにより、超音波ホーンの形状が単純なものとなり、超音波ホーンの製造コストを抑えられると共に、ワイヤハーネス１００の製造工程における作業工数を抑えることができる。 (1) Since the planar end surface 81a of the ultrasonic horn 81 is brought into contact with the opening-side end surface 21a of the opening 210 in the main body member 2, it is necessary to insert an electric wire through the horn as in the manufacturing method described in Patent Document 1, for example. There is no. Further, it is not necessary to divide the horn in order to vibrate the welding member from the side where the electric wire is led out. Thereby, the shape of the ultrasonic horn becomes simple, the manufacturing cost of the ultrasonic horn can be suppressed, and the number of work steps in the manufacturing process of the wire harness 100 can be suppressed.

（２）超音波ホーン８１の平面状の端面８１ａを本体部材２における開口２１０の開口側端面２１ａに接触させるので、電線１１の太さや本体部材２及び溶着部材３の大きさがワイヤハーネス１００の機種によって異っても、共通の超音波ホーン８１を用いて本体部材２を加振することが可能となる。つまり、本体部材２の筒状部２１の形状や大きさが変わると、開口側端面２１ａが超音波ホーン８１の端面８１ａに接触する箇所及び範囲が変化し得るが、その場合でも、本体部材２の開口側端面２１ａと超音波ホーン８１の端面８１ａとを面接触させ、本体部材２を加振することが可能である。これにより、一つの超音波ホーン８１によって複数の機種のワイヤハーネス１００を製造することが可能である。 (2) Since the planar end surface 81 a of the ultrasonic horn 81 is brought into contact with the opening-side end surface 21 a of the opening 210 in the main body member 2, the thickness of the electric wire 11 and the sizes of the main body member 2 and the welding member 3 are Even if it differs depending on the model, the main body member 2 can be vibrated using the common ultrasonic horn 81. That is, when the shape and size of the cylindrical portion 21 of the main body member 2 change, the location and range where the opening-side end surface 21a contacts the end surface 81a of the ultrasonic horn 81 can change. The opening-side end face 21a and the end face 81a of the ultrasonic horn 81 can be brought into surface contact with each other, and the main body member 2 can be vibrated. Thereby, it is possible to manufacture a plurality of types of wire harnesses 100 with one ultrasonic horn 81.

（３）本体部材２と溶着部材３とは、内周突起部３０２の先端部と開口端面２３ａ、及び突起部３１２の先端面３１２ａと段差面２３０ｂにおいて接触し、加振によって樹脂材料が溶融する。また、内周突起部３０２の溶融の進行に伴って、外周突起部３０１の先端部が開口端面２３ａに接触し、樹脂材料が溶融する。つまり、これら各部の接触面積は、溶着工程の初期には狭く、樹脂材料の溶融に伴って徐々に拡大する。これにより、加振による発熱をこれらの接触部位に集中させて他の部位における本体部材２又は溶着部材３の損傷を抑制すると共に、加振によって発生する溶融樹脂の量を確保して封止を確実にすることが可能となる。 (3) The main body member 2 and the welding member 3 are in contact with each other at the front end portion of the inner peripheral projection 302 and the opening end surface 23a, and the front end surface 312a of the projection 312 and the step surface 230b, and the resin material is melted by vibration. . In addition, as the inner peripheral protrusion 302 is melted, the distal end of the outer peripheral protrusion 301 comes into contact with the opening end surface 23a, and the resin material is melted. That is, the contact area of each part is narrow at the beginning of the welding process and gradually increases as the resin material melts. As a result, heat generated by vibration is concentrated on these contact parts to prevent damage to the main body member 2 or the welding member 3 in other parts, and the amount of molten resin generated by vibration is secured and sealed. It is possible to ensure.

（４）突起部３１２は、筒部３１の先端側に形成されているので、突起部３１２が溶融した溶融樹脂が挿入孔３１０の内面に流動し、電線１１の外周面と挿入孔３１０の内面との間が封止される。これにより、電線１１に沿って雌側ハウジング１０内に水分等が浸入することを防ぐことが可能となる。また、突起部３１２が溶融した溶融樹脂は、突起部３１２の外周面３１２ｂと挿通孔２３０のテーパ面２３０ａとの間にも流れ込み、本体部材２と溶着部材３とが、外周面３１２ｂ及びテーパ面２３０ａの広い面積で溶着する。これにより、本体部材２と溶着部材３とを強固に溶着させることが可能となる。 (4) Since the protruding portion 312 is formed on the distal end side of the cylindrical portion 31, the molten resin melted by the protruding portion 312 flows into the inner surface of the insertion hole 310, and the outer peripheral surface of the electric wire 11 and the inner surface of the insertion hole 310. Is sealed. This makes it possible to prevent moisture and the like from entering the female housing 10 along the electric wires 11. In addition, the molten resin in which the protruding portion 312 is melted also flows between the outer peripheral surface 312b of the protruding portion 312 and the tapered surface 230a of the insertion hole 230, and the main body member 2 and the welding member 3 are connected to the outer peripheral surface 312b and the tapered surface. Welds over a wide area of 230a. Thereby, the main body member 2 and the welding member 3 can be firmly welded.

（５）溶着部材３は、本体部材２の開口端面２３ａに向かい合う基部３０の平面３００ａに、外周突起部３０１及び内周突起部３０２が形成されているので、これら外周突起部３０１及び内周突起部３０２の溶融によって、これら両突起部を有しない場合に比較して、本体部材２と溶着部材３とがより強固に溶着する。 (5) Since the outer peripheral projection 301 and the inner peripheral projection 302 are formed on the flat surface 300a of the base 30 facing the opening end surface 23a of the main body member 2, the welding member 3 has the outer peripheral projection 301 and the inner peripheral projection. Due to the melting of the portion 302, the main body member 2 and the welding member 3 are more firmly welded than in the case where both the protrusions are not provided.

（６）内周突起部３０２は外周突起部３０１よりも高く形成されているので、配置工程において、内周突起部３０２が本体部材２の開口端面２３ａに接触し、外周突起部３０１は開口端面２３ａに接触しない。このため、溶着工程では、まず内周突起部３０２の先端部が溶融し、この溶融樹脂が外周突起部３０１にせき止められる。これにより、溶融樹脂が外周突起部３０１の外側に流れ出ることが抑制され、溶融樹脂をより確実に本体部材２側に流し込むことが可能となる。 (6) Since the inner peripheral protrusion 302 is formed higher than the outer peripheral protrusion 301, the inner peripheral protrusion 302 comes into contact with the opening end surface 23 a of the main body member 2, and the outer peripheral protrusion 301 is the opening end surface. 23a is not touched. For this reason, in the welding process, first, the tip end portion of the inner peripheral projection 302 is melted, and the molten resin is dammed to the outer peripheral projection 301. Thereby, it is possible to suppress the molten resin from flowing out of the outer peripheral projection 301, and it is possible to flow the molten resin more reliably to the main body member 2 side.

（７）本体部材２の挿通孔２３０は、その一部が筒部３１の突起部３１２におけるテーパ面３１２ｂと向かい合うテーパ状に形成されているので、突起部３１２を挿通孔２３０に容易に挿入することが可能であると共に、突起部３１２の外周面３１２ｂと挿通孔２３０における本体部材２との溶融を良好に行うことができる。すなわち、突起部３１２の先端面３１２ａと挿通孔２３０の段差面２３０ｂとの接触により溶融した溶融樹脂が突起部３１２におけるテーパ面３１２ｂと挿通孔２３０のテーパ面２３０ａとの間に流れ込み、本体部材２と溶着部材３とが広い面積で溶着される。 (7) Since a part of the insertion hole 230 of the main body member 2 is formed in a tapered shape facing the tapered surface 312b of the projection 312 of the cylindrical portion 31, the projection 312 can be easily inserted into the insertion hole 230. In addition, the outer peripheral surface 312b of the protrusion 312 and the main body member 2 in the insertion hole 230 can be melted satisfactorily. That is, the molten resin melted by the contact between the tip surface 312a of the protruding portion 312 and the stepped surface 230b of the insertion hole 230 flows between the tapered surface 312b of the protruding portion 312 and the tapered surface 230a of the insertion hole 230. And the welding member 3 are welded in a wide area.

（第１の実施の形態の変形例）
図６は、第１の実施の形態の変形例に係る溶着部材３を示す上面図である。 (Modification of the first embodiment)
FIG. 6 is a top view showing the welding member 3 according to a modification of the first embodiment.

この溶着部材３は、第１部材３Ａと第２部材３Ｂとからなり、第１部材３Ａと第２部材３Ｂとを結合すると、第１の実施の形態に係る溶着部材３と同一の形状となるように構成されている。第１部材３Ａと第２部材３Ｂとが結合された溶着部材３において、第１の実施の形態について説明したものと共通する機能を有する構成要素については、同一の符号を付してその重複した説明を省略する。   The welding member 3 includes a first member 3A and a second member 3B. When the first member 3A and the second member 3B are joined, the welding member 3 has the same shape as the welding member 3 according to the first embodiment. It is configured as follows. In the welding member 3 in which the first member 3A and the second member 3B are combined, the constituent elements having the same functions as those described in the first embodiment are denoted by the same reference numerals and duplicated. Description is omitted.

第１部材３Ａと第２部材３Ｂとは、３本の電線１１の中心軸線を含む仮想面に対して面対称に形成されている。第１部材３Ａには、３本の電線１１の外径に対応する内径を有する３つの円弧状の溝部３１０Ａが形成され、第２部材３Ｂには、溝部３１０Ａと同一の内径を有する３つの円弧状の溝部３１０Ｂが形成されている。溝部３１０Ａ及び溝部３１０Ｂの内径は、電線１１の外径よりもわずかに大きい寸法に設定されている。   The first member 3 </ b> A and the second member 3 </ b> B are formed symmetrically with respect to a virtual plane including the central axis of the three electric wires 11. Three arc-shaped grooves 310A having an inner diameter corresponding to the outer diameter of the three electric wires 11 are formed in the first member 3A, and three circles having the same inner diameter as the groove 310A are formed in the second member 3B. An arcuate groove 310B is formed. The inner diameters of the groove portions 310 </ b> A and 310 </ b> B are set to be slightly larger than the outer diameter of the electric wire 11.

この溶着部材３を用いたワイヤハーネス１００の製造工程では、配置工程において、第１部材３Ａ及び第２部材３Ｂによって３本の電線１１を挟持する。この際、溝部３１０Ａ及び溝部３１０Ｂは、電線１１の一部を収容する。この他は、第１の実施の形態について説明したものと共通の製造工程によってワイヤハーネス１００を製造する。   In the manufacturing process of the wire harness 100 using the welding member 3, the three electric wires 11 are sandwiched between the first member 3 </ b> A and the second member 3 </ b> B in the arrangement process. At this time, the groove portion 310 </ b> A and the groove portion 310 </ b> B accommodate a part of the electric wire 11. Other than this, the wire harness 100 is manufactured by a manufacturing process common to that described for the first embodiment.

この変形例によれば、第１部材３Ａ及び第２部材３Ｂによって３本の電線１１を挟持するので、第１の実施の形態に係る製造方法における挿入孔３１０に電線１１を挿入する作業が不要となる。これにより、ワイヤハーネス１００の製造工程をさらに簡略化することが可能となる。   According to this modification, since the three electric wires 11 are sandwiched between the first member 3A and the second member 3B, the operation of inserting the electric wires 11 into the insertion hole 310 in the manufacturing method according to the first embodiment is unnecessary. It becomes. Thereby, the manufacturing process of the wire harness 100 can be further simplified.

なお、第１部材３Ａ及び第２部材３Ｂは、溶着工程における溶融樹脂が第１部材３Ａと第２部材３Ｂとの対向面間に流入することにより溶着され、一体化される。   The first member 3A and the second member 3B are welded and integrated when the molten resin in the welding process flows between the facing surfaces of the first member 3A and the second member 3B.

（第２の実施の形態）
次に、本発明の第２の実施の形態について、図７から図１１を参照して説明する。これらの図において、第１の実施の形態について説明したものと共通する機能を有する構成要素については、同一の符号を付してその重複した説明を省略する。 (Second Embodiment)
Next, a second embodiment of the present invention will be described with reference to FIGS. In these drawings, components having the same functions as those described in the first embodiment are denoted by the same reference numerals, and redundant description thereof is omitted.

図７は、本実施の形態に係る雌コネクタ１を示し、（ａ）は開口側端面２１ａ側から見た正面図、（ｂ）は複数の電線１１の軸線を含む断面における断面図である。図８は、本実施の形態に係る本体部材２を示し、（ａ）は外観斜視図、（ｂ）は（ａ）のＤ−Ｄ線断面における断面斜視図、（ｃ）は（ａ）のＥ矢視図である。なお、図７（ａ）では、端子支持部材４０の図示を省略してその奥側を示している。   7A and 7B show the female connector 1 according to the present embodiment, in which FIG. 7A is a front view seen from the opening-side end face 21a side, and FIG. 7B is a cross-sectional view in a cross section including the axes of a plurality of electric wires 11. 8A and 8B show the main body member 2 according to the present embodiment, wherein FIG. 8A is an external perspective view, FIG. 8B is a cross-sectional perspective view taken along the line DD of FIG. FIG. In FIG. 7 (a), the terminal support member 40 is not shown and its inner side is shown.

本実施の形態に係る雌側ハウジング１０は、第１の実施の形態に係る溶着部材３に替えて、本体部材２に第１溶着部材５及び第２溶着部材６が溶着されている。つまり、本実施の形態では、雌側ハウジング１０が、本体部材２と、第１溶着部材５及び第２溶着部材６とを一体化して構成されている。本体部材２、第１溶着部材５、及び第２溶着部材６は、同一の樹脂材料からなる。   In the female housing 10 according to the present embodiment, the first welding member 5 and the second welding member 6 are welded to the main body member 2 in place of the welding member 3 according to the first embodiment. That is, in the present embodiment, the female housing 10 is configured by integrating the main body member 2, the first welding member 5, and the second welding member 6. The main body member 2, the first welding member 5, and the second welding member 6 are made of the same resin material.

本実施の形態に係る本体部材２は、電線１１を挿通させる挿通孔２３２が、端子１２の加締め部１２０及び接続部１２１を挿通させることが可能な大きさに形成されている。この挿通孔２３２は、長方形状の角孔として形成されている。また、電線保持部２３には、開口端面２３ａに対して直交する方向に突出する環状の鍔部２３３が形成されている。   In the main body member 2 according to the present embodiment, the insertion hole 232 through which the electric wire 11 is inserted is formed in a size that allows the crimping portion 120 and the connection portion 121 of the terminal 12 to be inserted. The insertion hole 232 is formed as a rectangular square hole. In addition, the wire holding portion 23 is formed with an annular flange portion 233 that protrudes in a direction orthogonal to the opening end surface 23a.

図９は、第２溶着部材６を示し、（ａ）は斜視図、（ｂ）は（ａ）と異なる方向から見た斜視図、（ｃ）は（ａ）のＦ−Ｆ線断面図である。   FIG. 9 shows the second welding member 6, (a) is a perspective view, (b) is a perspective view seen from a direction different from (a), and (c) is a sectional view taken along line FF in (a). is there.

第２溶着部材６は、周縁がトラック形状の板部６０と、板部６０の一方の平面６０ａの周縁に沿って形成された環状の突起部６１とを一体に有している。板部６０には、平面６０ａからその裏側における他方の平面６０ｂに至る３つの挿通孔６０１が互いに平行に形成されている。平面６０ａは、挿通孔６０１の開口の周辺部が、板部６０の厚さ方向に窪んでいる。   The second welding member 6 integrally includes a plate portion 60 whose peripheral edge is a track shape and an annular protrusion 61 formed along the peripheral edge of one flat surface 60 a of the plate portion 60. In the plate part 60, three insertion holes 601 extending from the flat surface 60a to the other flat surface 60b on the back side are formed in parallel to each other. In the flat surface 60 a, the peripheral portion of the opening of the insertion hole 601 is recessed in the thickness direction of the plate portion 60.

挿通孔６０１の内面は、大径の円筒面６０１ａと、円筒面６０１ａよりも内径が小さい小径の円筒面６０１ｄと、円筒面６０１ａに連続して形成され、円筒面６０１ｄ側に向かうにつれて内径が小さくなるテーパ面６０１ｂと、テーパ面６０１ｂにおける円筒面６０１ｄ側の端部と円筒面６０１ｄとの間に形成された段差面６０１ｃとを含んでいる。円筒面６０１ａは平面６０ｂ側に、円筒面６０１ｄは平面６０ａ側に、それぞれ形成されている。段差面６０１ｃは、挿通孔６０１の径方向に平行な円環状の面として形成されている。   The inner surface of the insertion hole 601 is formed continuously with the large-diameter cylindrical surface 601a, the small-diameter cylindrical surface 601d having a smaller inner diameter than the cylindrical surface 601a, and the cylindrical surface 601a, and the inner diameter decreases toward the cylindrical surface 601d side. A tapered surface 601b, and a stepped surface 601c formed between the end of the tapered surface 601b on the cylindrical surface 601d side and the cylindrical surface 601d. The cylindrical surface 601a is formed on the flat surface 60b side, and the cylindrical surface 601d is formed on the flat surface 60a side. The step surface 601 c is formed as an annular surface parallel to the radial direction of the insertion hole 601.

図１０は、第１溶着部材５を示し、（ａ）は斜視図、（ｂ）は（ａ）のＧ−Ｇ線断面図である。   10A and 10B show the first welding member 5, where FIG. 10A is a perspective view and FIG. 10B is a cross-sectional view taken along line GG in FIG.

第１溶着部材５は、基部５０と、３つの筒部５１とを一体に有している。第１溶着部材５には、３つの筒部５１をその中心軸線に沿って貫通すると共に基部５０を厚さ方向に貫通し、３本の電線１１がそれぞれ挿入される３つの挿入孔５１０が設けられている。   The first welding member 5 integrally includes a base portion 50 and three cylindrical portions 51. The first welding member 5 is provided with three insertion holes 510 that penetrate the three cylindrical portions 51 along the central axis thereof and penetrate the base portion 50 in the thickness direction and into which the three electric wires 11 are respectively inserted. It has been.

基部５０は、周縁がトラック形状の板部５００と、板部５００の一方の平面５００ａの周縁に沿って形成された環状の外周突起部５０１と、外周突起部５０１に隣接して外周突起部５０１の内側に形成された環状の内周突起部５０２とを有している。   The base portion 50 includes a plate portion 500 having a track shape on the periphery, an annular outer peripheral protrusion portion 501 formed along the peripheral edge of one flat surface 500 a of the plate portion 500, and an outer peripheral protrusion portion 501 adjacent to the outer peripheral protrusion portion 501. And an annular inner peripheral projection 502 formed on the inner side.

外周突起部５０１及び内周突起部５０２は、挿入孔５１０の中心軸に沿って、すなわち電線１１の軸線方向に沿って突出し、その先端部ほど電線１１の軸線方向に直交する断面における断面積が小さくなるように形成されている。また、内周突起部５０２は、外周突起部５０１よりも平面５００ａからの高さが高く形成されている。   The outer peripheral protrusion 501 and the inner peripheral protrusion 502 protrude along the central axis of the insertion hole 510, that is, along the axial direction of the electric wire 11, and the tip end portion has a cross-sectional area in a cross section orthogonal to the axial direction of the electric wire 11. It is formed to be smaller. In addition, the inner circumferential protrusion 502 is formed to be higher than the outer circumferential protrusion 501 from the plane 500a.

３つの筒部５１は、板部５００の平面５００ａから、平面５００ａに対して直交する方向に延びるように形成されている。筒部５１は、その根元側（基部５０側）の第１円筒部５１１と、第１円筒部５１１の一端に形成され、筒部５１の先端側に向かうに連れて外径が小さくなるテーパ部５１２と、テーパ部５１２の小径側の一端に形成され、テーパ部５１２よりも薄肉に形成された第２円筒部５１３と、第２円筒部５１３の外周面に形成され、第２円筒部５１３の外周方向に突出する環板状の鍔部５１４とを一体に有して構成されている。   The three cylinder portions 51 are formed so as to extend from the plane 500a of the plate portion 500 in a direction orthogonal to the plane 500a. The cylindrical portion 51 is formed at the base side (base 50 side) of the first cylindrical portion 511 and one end of the first cylindrical portion 511, and a tapered portion whose outer diameter decreases toward the distal end side of the cylindrical portion 51. 512, a second cylindrical portion 513 formed at one end on the small diameter side of the tapered portion 512 and formed thinner than the tapered portion 512, and an outer peripheral surface of the second cylindrical portion 513. An annular plate-like flange portion 514 protruding in the outer peripheral direction is integrally formed.

挿入孔５１０は、基部５０側の大径部５１０ａ、及び筒部５１側の小径部５１０ｂからなる。小径部５１０ｂの内径は、電線１１の外径よりもわずかに大きく形成されている。大径部５１０ａの内径は、小径部５１０ｂよりも大きく形成されている。大径部５１０ａと小径部５１０ｂとの境界は、第１円筒部５１１の内側に位置している。   The insertion hole 510 includes a large diameter portion 510a on the base portion 50 side and a small diameter portion 510b on the cylinder portion 51 side. The inner diameter of the small diameter portion 510 b is formed slightly larger than the outer diameter of the electric wire 11. The inner diameter of the large diameter portion 510a is formed larger than that of the small diameter portion 510b. The boundary between the large diameter portion 510 a and the small diameter portion 510 b is located inside the first cylindrical portion 511.

外周突起部５０１及び内周突起部５０２は、本発明における「突起」の一例である。   The outer peripheral protrusion 501 and the inner peripheral protrusion 502 are examples of “protrusions” in the present invention.

図１１（ａ）及び（ｂ）は、本実施の形態に係るワイヤハーネス１００の製造工程を示す模式図である。   FIGS. 11A and 11B are schematic views showing a manufacturing process of the wire harness 100 according to the present embodiment.

本実施の形態に係るワイヤハーネス１００の製造工程は、第１の実施の形態と同様に、配置工程、接触工程、及び溶着工程を有するが、配置工程の作業内容が第１の実施の形態とは異なっている。即ち、本実施の形態に係る配置工程では、本体部材２と、第１溶着部材５と、第２溶着部材６とを電線１１の軸線方向に沿って向い合わせて配置する。また、本体部材２は、挿通孔２３２が端子１２を挿通させることが可能な大きさに形成されているので、電線１１の端部に端子１２を接続した後に、端子１２を挿通孔２３２に開口端面２３ａ側から挿通させることが可能である。   The manufacturing process of the wire harness 100 according to the present embodiment includes an arrangement process, a contact process, and a welding process as in the first embodiment, but the work content of the arrangement process is the same as that of the first embodiment. Is different. That is, in the arrangement step according to the present embodiment, the main body member 2, the first welding member 5, and the second welding member 6 are arranged facing each other along the axial direction of the electric wire 11. Moreover, since the main body member 2 is formed in such a size that the insertion hole 232 can be inserted into the terminal 12, the terminal 12 is opened to the insertion hole 232 after the terminal 12 is connected to the end of the electric wire 11. It can be inserted from the end face 23a side.

この配置工程において、第２溶着部材６は、本体部材２の鍔部２３３の内面２３３ａ及び電線保持部２３の開口端面２３ａによって形成される収容空間に収容される。第２溶着部材６は、平面６０ａが開口端面２３ａに向かい合うように収容空間内に配置され、第２溶着部材６の突起部６１は、その先端部が開口端面２３ａに接触する。   In this arrangement step, the second welding member 6 is accommodated in an accommodation space formed by the inner surface 233 a of the flange portion 233 of the main body member 2 and the opening end surface 23 a of the electric wire holding portion 23. The second welding member 6 is disposed in the accommodation space so that the flat surface 60a faces the opening end surface 23a, and the tip of the protrusion 61 of the second welding member 6 is in contact with the opening end surface 23a.

また、第１溶着部材５は、筒部５１が第２溶着部材６の挿通孔６０１に収容され、平面５００ａが第２溶着部材６の平面６０ｂに向かい合うように配置される。筒部５１の鍔部５１４は段差面６０１ｃに接触し、第２円筒部５１３の先端側の一部は円筒面６０１ｄを通過して平面６０ａ側に突出する。外周突起部５０１及び内周突起部５０２は、第２溶着部材６の板部６０における平面６０ｂに向かい合う。   Further, the first welding member 5 is disposed such that the cylinder portion 51 is accommodated in the insertion hole 601 of the second welding member 6 and the plane 500 a faces the plane 60 b of the second welding member 6. The flange portion 514 of the cylindrical portion 51 contacts the stepped surface 601c, and a part of the distal end side of the second cylindrical portion 513 passes through the cylindrical surface 601d and protrudes toward the flat surface 60a. The outer peripheral protrusion 501 and the inner peripheral protrusion 502 face the flat surface 60 b of the plate part 60 of the second welding member 6.

接触工程では、第１の実施の形態と同様に、本体部材２の開口側端面２１ａに超音波ホーン８１の端面８１ａを接触させる。   In the contact step, the end surface 81a of the ultrasonic horn 81 is brought into contact with the opening-side end surface 21a of the main body member 2 as in the first embodiment.

溶着工程では、筒部５１の鍔部５１４及び第２円筒部５１３の一部が溶融して溶融樹脂となり、この溶融樹脂の一部が電線１１の外周面と小径部５１０ｂの内面との間に流入し、他の一部がテーパ部５１２の外周面とテーパ面６０１ｂとの間に流入する。これにより、電線１１の外周面と第１溶着部材５の挿入孔５１０との間、及び第１溶着部材５の筒部５１の外周面と第２溶着部材６の挿通孔６０１の内面との間が気密に封止される。   In the welding step, a part of the flange part 514 and the second cylindrical part 513 of the cylindrical part 51 is melted to become a molten resin, and a part of the molten resin is between the outer peripheral surface of the electric wire 11 and the inner surface of the small diameter part 510b. The other part flows in between the outer peripheral surface of the tapered portion 512 and the tapered surface 601b. Thereby, between the outer peripheral surface of the electric wire 11 and the insertion hole 510 of the 1st welding member 5, and between the outer peripheral surface of the cylinder part 51 of the 1st welding member 5, and the inner surface of the insertion hole 601 of the 2nd welding member 6. Is hermetically sealed.

また、溶着工程では、第２溶着部材６の突起部６１が溶融して溶融樹脂となり、この溶融樹脂が平面６０ａと開口端面２３ａとの間に拡がって、本体部材２と第２溶着部材６とが溶着される。また、この溶融樹脂は板部６０の周面と鍔部２２３の内面２３３ａとの間にも流入し、本体部材２と第２溶着部材６との間が気密に封止される。   In the welding process, the protrusion 61 of the second welding member 6 is melted to become a molten resin, and the molten resin spreads between the flat surface 60a and the opening end surface 23a, and the main body member 2 and the second welding member 6 Is welded. The molten resin also flows between the peripheral surface of the plate portion 60 and the inner surface 233a of the flange portion 223, and the space between the main body member 2 and the second welding member 6 is hermetically sealed.

本実施の形態によれば、本体部材２に端子１２を挿通可能な挿通孔２３２を形成しても、この挿通孔２３２が第２溶着部材６によって塞がれるため、雌側ハウジング１０の気密性を保つことが可能となる。   According to the present embodiment, even if the insertion hole 232 into which the terminal 12 can be inserted is formed in the main body member 2, the insertion hole 232 is blocked by the second welding member 6, so that the airtightness of the female housing 10 is achieved. Can be maintained.

また、例えば挿通孔２３２と電線１１との間に溶融樹脂を流し込むことによって挿通孔２３２を塞ぐ場合には、多くの溶融樹脂が必要となるため、溶着工程における加振時間が長くなり、本体部材２と超音波ホーン８１との接触部や筒状部２１と小筒部２２との境界部等において意図しない溶融が発生しやすくなる。しかし、本実施の形態によれば、突起部６１を溶融させて第２溶着部材６を本体部材２に溶着することによって挿通孔２３２を塞ぐので、必要な溶融樹脂の量を低減することができ、溶着工程における加振時間を削減し、本体部材２の破損を回避することが可能となる。また、この加振時間の削減により、ワイヤハーネス１００の製造に要する時間を短縮することが可能となる。   In addition, for example, when the insertion hole 232 is blocked by pouring molten resin between the insertion hole 232 and the electric wire 11, a lot of molten resin is required, so that the vibration time in the welding process becomes long, and the main body member 2 and the ultrasonic horn 81 and the boundary between the tubular portion 21 and the small tubular portion 22 are likely to cause unintended melting. However, according to the present embodiment, the insertion hole 232 is closed by melting the protrusion 61 and welding the second welding member 6 to the main body member 2, so that the amount of necessary molten resin can be reduced. The vibration time in the welding process can be reduced, and the main body member 2 can be prevented from being damaged. Further, the time required for manufacturing the wire harness 100 can be shortened by reducing the vibration time.

（第２の実施の形態の変形例）
図１２（ａ）は、第２の実施の形態の変形例に係る第２溶着部材６を示す上面図である。図１２（ｂ）は、第２の実施の形態の変形例に係る第１溶着部材５を示す上面図である。 (Modification of the second embodiment)
FIG. 12A is a top view showing a second welding member 6 according to a modification of the second embodiment. FIG. 12B is a top view showing the first welding member 5 according to a modification of the second embodiment.

この変形例に係る第２溶着部材６は、第１部材６Ａと第２部材６Ｂとからなり、第１部材６Ａと第２部材６Ｂとを結合すると、第１の実施の形態に係る第２溶着部材６と同一の形状となるように構成されている。第１部材６Ａと第２部材６Ｂとが結合された状態において、第１の実施の形態について説明したものと共通する機能を有する構成要素については、同一の符号を付してその重複した説明を省略する。   The second welding member 6 according to this modification includes a first member 6A and a second member 6B. When the first member 6A and the second member 6B are joined, the second welding member according to the first embodiment is used. It is comprised so that it may become the same shape as the member 6. FIG. In the state in which the first member 6A and the second member 6B are coupled, the constituent elements having the same functions as those described in the first embodiment are denoted by the same reference numerals, and duplicate descriptions thereof are given. Omitted.

第１部材６Ａと第２部材６Ｂとは、３本の電線１１の中心軸線を含む仮想面に対して面対称に形成されている。第１部材６Ａには、３本の電線１１の外径に対応する内径を有する３つの円弧状の溝部６０１Ａが形成され、第２部材６Ｂには、溝部６０１Ａと同一の内径を有する３つの円弧状の溝部６０１Ｂが形成されている。溝部６０１Ａ及び溝部６０１Ｂの内径は、電線１１の外径よりもわずかに大きい寸法に設定されている。   The first member 6 </ b> A and the second member 6 </ b> B are formed symmetrically with respect to a virtual plane including the central axis of the three electric wires 11. Three arc-shaped grooves 601A having an inner diameter corresponding to the outer diameter of the three electric wires 11 are formed in the first member 6A, and three circles having the same inner diameter as the groove 601A are formed in the second member 6B. An arc-shaped groove 601B is formed. The inner diameters of the groove 601A and the groove 601B are set to be slightly larger than the outer diameter of the electric wire 11.

また、この変形例に係る第１溶着部材５は、第１部材５Ａと第２部材５Ｂとからなり、第１部材５Ａと第２部材５Ｂとを結合すると、第１の実施の形態に係る第１溶着部材５と同一の形状となるように構成されている。第１部材５Ａと第２部材５Ｂとが結合された状態において、第１の実施の形態について説明したものと共通する機能を有する構成要素については、同一の符号を付してその重複した説明を省略する。   Moreover, the 1st welding member 5 which concerns on this modification consists of the 1st member 5A and the 2nd member 5B, and if the 1st member 5A and the 2nd member 5B are couple | bonded, the 1st Embodiment which concerns on 1st Embodiment will be described. 1 It is comprised so that it may become the same shape as the welding member 5. FIG. In the state in which the first member 5A and the second member 5B are coupled, the same reference numerals are given to the constituent elements having the same functions as those described in the first embodiment, and the duplicate description is given. Omitted.

第１部材５Ａと第２部材５Ｂとは、３本の電線１１の中心軸線を含む仮想面に対して面対称に形成されている。第１部材５Ａには、３本の電線１１の外径に対応する内径を有する３つの円弧状の溝部５１０Ａが形成され、第２部材５Ｂには、溝部５１０Ａと同一の内径を有する３つの円弧状の溝部５１０Ｂが形成されている。溝部５１０Ａ及び溝部５１０Ｂの内径は、電線１１の外径よりもわずかに大きい寸法に設定されている。   The first member 5 </ b> A and the second member 5 </ b> B are formed symmetrically with respect to a virtual plane including the central axis of the three electric wires 11. Three arc-shaped grooves 510A having an inner diameter corresponding to the outer diameter of the three electric wires 11 are formed in the first member 5A, and three circles having the same inner diameter as the groove 510A are formed in the second member 5B. An arcuate groove 510B is formed. The inner diameters of the groove 510A and the groove 510B are set to be slightly larger than the outer diameter of the electric wire 11.

この変形例に係るワイヤハーネス１００の製造工程では、配置工程において、第１部材５Ａ及び第２部材５Ｂによって３本の電線１１を挟持すると共に、第１部材６Ａ及び第２部材６Ｂによって３本の電線１１を挟持する。この他は、第２の実施の形態について説明したものと共通の製造工程によってワイヤハーネス１００を製造する。   In the manufacturing process of the wire harness 100 according to this modification, in the arrangement process, the three electric wires 11 are sandwiched between the first member 5A and the second member 5B, and the three members are clamped by the first member 6A and the second member 6B. The electric wire 11 is clamped. Other than this, the wire harness 100 is manufactured by the same manufacturing process as that described for the second embodiment.

この変形例によれば、第１部材５Ａ及び第２部材５Ｂ、ならびに第１部材６Ａ及び第２部材６Ｂによって３本の電線１１を挟持するので、挿通孔６０１及び挿入孔５１０に電線１１を挿入する作業が不要となる。これにより、ワイヤハーネス１００の製造工程をさらに簡略化することが可能となる。   According to this modification, since the three electric wires 11 are clamped by the first member 5A and the second member 5B, and the first member 6A and the second member 6B, the electric wire 11 is inserted into the insertion hole 601 and the insertion hole 510. The work to do becomes unnecessary. Thereby, the manufacturing process of the wire harness 100 can be further simplified.

以上、本発明の実施の形態を説明したが、上記に記載した実施の形態は特許請求の範囲に係る発明を限定するものではない。また、実施の形態の中で説明した特徴の組合せの全てが発明の課題を解決するための手段に必須であるとは限らない点に留意すべきである。   While the embodiments of the present invention have been described above, the embodiments described above do not limit the invention according to the claims. In addition, it should be noted that not all the combinations of features described in the embodiments are essential to the means for solving the problems of the invention.

また、本発明は、その趣旨を逸脱しない範囲で適宜変形して実施することが可能である。例えば、上記第１及び第２の実施の形態では、溶着部材３、第１溶着部材５、及び第２溶着部材６に突起を設けたが、これに限らず、本体部材２に溶着部材３、第１溶着部材５、又は第２溶着部材６に向かって突出する突起を設け、この突起の先端部を溶着部材３、第１溶着部材５、及び第２溶着部材６に接触させてもよい。   Further, the present invention can be appropriately modified and implemented without departing from the spirit of the present invention. For example, in the said 1st and 2nd embodiment, although the welding member 3, the 1st welding member 5, and the 2nd welding member 6 provided the processus | protrusion, not only this but the welding member 3, A protrusion that protrudes toward the first welding member 5 or the second welding member 6 may be provided, and the tip of the protrusion may be brought into contact with the welding member 3, the first welding member 5, and the second welding member 6.

また、上記第１及び第２の実施の形態では、本体部材２と溶着部材３の樹脂材料、及び本体部材２と第１溶着部材５ならびに第２溶着部材６の樹脂材料が同一である場合について説明したが、それぞれの部材の樹脂材料は異なっていてもよい。またさらに、ワイヤハーネス１００の用途や電線１１の本数等についても特に制限はない。   Moreover, in the said 1st and 2nd embodiment, about the resin material of the main body member 2 and the welding member 3, and the resin material of the main body member 2, the 1st welding member 5, and the 2nd welding member 6 are the same. Although described, the resin material of each member may be different. Furthermore, there is no restriction | limiting in particular also about the use of the wire harness 100, the number of the electric wires 11, etc.

１…雌コネクタ、２…本体部材、３…溶着部材、３Ａ…第１部材、３Ｂ…第２部材、５…第１溶着部材、５Ａ…第１部材、５Ｂ…第２部材、６…第２溶着部材、６Ａ…第１部材、６Ｂ…第２部材、９…雄コネクタ、１０…雌側ハウジング、１１…電線、１２…端子、２１…筒状部、２１ａ…開口側端面、２２…小筒部、２３…電線保持部、２３ａ…開口端面、２４…リブ、３０…基部、３１…筒部、４０…端子支持部材、４１…シール部材、５０…基部、５１…筒部、６０…板部、６０ａ，６０ｂ…平面、６１…突起部、８０…支持台、８０ａ…表面、８１…超音波ホーン、８１ａ…端面、９０…雄側ハウジング、９１…電線、１００…ワイヤハーネス、１１０…中心導体、１１１…シース、１２０…加締め部、１２１…接続部、２１０…開口、２１１…丸孔、２１２…係合部、２２３…鍔部、２３０…挿通孔、２３０ａ…テーパ面、２３０ｂ…段差面、２３０ｃ…円筒面、２３１…収容空間、２３２…挿通孔、２３３…鍔部、２３３ａ…内面、３００…板部、３００ａ，３００ｂ…平面、３０１…外周突起部、３０２…内周突起部、３１０…挿入孔、３１０Ａ，３１０Ｂ…溝部、３１１…円筒部、３１２…突起部、３１２ａ…先端面、３１２ｂ…外周面、５００…板部、５００ａ…平面、５０１…外周突起部、５０２…内周突起部、５１０…挿入孔、５１０Ａ，５１０Ｂ…溝部、５１０ａ…大径部、５１０ｂ…小径部、５１１…第１円筒部、５１２…テーパ部、５１３…第２円筒部、５１４…鍔部、６０１…挿通孔、６０１Ａ，６０１Ｂ…溝部、６０１ａ…円筒面、６０１ｂ…テーパ面、６０１ｃ…段差面、６０１ｄ…円筒面、８０１…スリット部、９０１…フランジ部、９０２…筒部、９０３…円筒部、９０４…係合突起、９０５…導出部、９０６…押付部材 DESCRIPTION OF SYMBOLS 1 ... Female connector, 2 ... Main body member, 3 ... Welding member, 3A ... 1st member, 3B ... 2nd member, 5 ... 1st welding member, 5A ... 1st member, 5B ... 2nd member, 6 ... 2nd Welding member, 6A ... first member, 6B ... second member, 9 ... male connector, 10 ... female housing, 11 ... electric wire, 12 ... terminal, 21 ... cylindrical part, 21a ... opening end face, 22 ... small tube 23: Electric wire holding portion, 23a: Open end face, 24 ... Rib, 30 ... Base, 31 ... Tube, 40 ... Terminal support member, 41 ... Seal member, 50 ... Base, 51 ... Tube, 60 ... Plate , 60a, 60b ... plane, 61 ... projection, 80 ... support base, 80a ... surface, 81 ... ultrasonic horn, 81a ... end face, 90 ... male housing, 91 ... electric wire, 100 ... wire harness, 110 ... central conductor , 111 ... sheath, 120 ... caulking part, 121 ... connection part, 210 ... open , 211 ... round hole, 212 ... engagement part, 223 ... collar part, 230 ... insertion hole, 230a ... taper surface, 230b ... step surface, 230c ... cylindrical surface, 231 ... accommodation space, 232 ... insertion hole, 233 ... collar Part, 233a ... inner surface, 300 ... plate part, 300a, 300b ... plane, 301 ... outer peripheral projection part, 302 ... inner peripheral projection part, 310 ... insertion hole, 310A, 310B ... groove part, 311 ... cylindrical part, 312 ... projection part 312a ... tip surface, 312b ... outer peripheral surface, 500 ... plate portion, 500a ... flat surface, 501 ... outer peripheral projection portion, 502 ... inner peripheral projection portion, 510 ... insertion hole, 510A, 510B ... groove portion, 510a ... large diameter portion, 510b ... small diameter portion, 511 ... first cylindrical portion, 512 ... tapered portion, 513 ... second cylindrical portion, 514 ... collar portion, 601 ... insertion hole, 601A, 601B ... groove, 601a ... cylindrical surface, 601b ... te Tapered surface, 601c ... stepped surface, 601d ... cylindrical surface, 801 ... slits, 901 ... flange portion, 902 ... cylindrical portion, 903 ... cylindrical portion, 904 ... engaging projection, 905 ... lead-out portion, 906 ... pressing member

Claims (7)

電線、前記電線の端部に接続された端子、及び前記端子を収容する樹脂からなるハウジングを有するワイヤハーネスの製造方法であって、
前記ハウジングは、前記端子を外部に臨ませる開口を有する筒状部を含む本体部材と、前記本体部材に溶着され、前記電線が導出される溶着部材とを一体化してなり、
前記本体部材と前記溶着部材とを前記電線の軸線方向に沿って向い合わせて配置する配置工程と、
前記本体部材に超音波ホーンを接触させる接触工程と、
前記超音波ホーンによる加振によって前記本体部材と前記溶着部材とを溶着させる溶着工程とを有し、
前記接触工程は、前記超音波ホーンを前記開口における前記本体部材の開口側端面に接触させる工程である
ワイヤハーネスの製造方法。 An electric wire, a terminal connected to an end of the electric wire, and a method of manufacturing a wire harness having a housing made of a resin that accommodates the terminal,
The housing is formed by integrating a main body member including a cylindrical portion having an opening that exposes the terminal to the outside, and a welding member that is welded to the main body member and from which the electric wire is led out,
An arrangement step of arranging the main body member and the welding member so as to face each other along the axial direction of the electric wire;
Contacting the ultrasonic horn with the body member; and
A welding step of welding the main body member and the welding member by vibration with the ultrasonic horn,
The said contact process is a process of making the said ultrasonic horn contact the opening side end surface of the said main body member in the said opening. The manufacturing method of a wire harness. 前記本体部材及び前記溶着部材のうち少なくとも一方の部材は、前記電線の軸線方向に沿って突出し、その先端部ほど前記軸線方向に直交する断面における断面積が小さくなる突起を有し、
前記配置工程は、前記突起の先端部を前記一方の部材に向かい合う他方の部材に接触させて前記本体部材と前記溶着部材とを配置する工程である、
請求項１に記載のワイヤハーネスの製造方法。 At least one member of the main body member and the welding member protrudes along the axial direction of the electric wire, and has a protrusion with a smaller cross-sectional area in a cross section orthogonal to the axial direction at the tip portion thereof,
The placement step is a step of placing the main body member and the welding member by bringing the tip of the protrusion into contact with the other member facing the one member.
The manufacturing method of the wire harness of Claim 1. 前記溶着部材は、前記電線を挿通させる挿通孔が形成された筒状の筒部を有し、
前記突起は、前記筒部の一端部及び他端部のうち前記本体部材側の一端部に形成されている、
請求項２に記載のワイヤハーネスの製造方法。 The welding member has a cylindrical tube portion in which an insertion hole for inserting the electric wire is formed,
The protrusion is formed at one end of the cylinder portion on the main body member side among the one end and the other end.
The manufacturing method of the wire harness of Claim 2. 前記溶着部材は、前記筒部の前記他端部に前記筒部と一体に形成され、前記筒部の外周側に張り出した基部を有し、
前記突起は、前記筒部の前記一端部、及び前記基部の前記本体部材側に形成されている、
請求項３に記載のワイヤハーネスの製造方法。 The welding member is formed integrally with the cylindrical portion at the other end portion of the cylindrical portion, and has a base portion that protrudes to the outer peripheral side of the cylindrical portion,
The protrusion is formed on the one end portion of the cylindrical portion and the main body member side of the base portion,
The manufacturing method of the wire harness of Claim 3. 前記溶着部材の前記基部には、前記突起として、前記本体部材側に突出する環状の外周突起部、及び前記外周突起部の内側に形成された環状の内周突起部が形成され、前記外周突起部は、前記内周突起部よりも前記基部からの高さが高く形成された、
請求項４に記載のワイヤハーネスの製造方法。 The base part of the welding member is formed with an annular outer peripheral protrusion part protruding toward the main body member and an annular inner peripheral protrusion part formed on the inner side of the outer peripheral protrusion part as the protrusions. The part is formed to have a height higher than the base part than the inner peripheral protrusion part,
The manufacturing method of the wire harness of Claim 4. 前記筒部の前記一端部は、その外周面がテーパ面として形成され、
前記本体部材には、前記筒部を収容すると共に前記電線を挿通させる挿通孔が形成され、
前記本体部材の前記挿通孔は、その少なくとも一部が前記筒部の前記一端部における前記テーパ面と向かい合うテーパ状に形成されている、
請求項３乃至５の何れか１項に記載のワイヤハーネスの製造方法。 The one end portion of the cylindrical portion has an outer peripheral surface formed as a tapered surface,
The body member is formed with an insertion hole for accommodating the cylindrical portion and inserting the electric wire,
The insertion hole of the main body member is formed in a tapered shape so that at least a part thereof faces the tapered surface at the one end of the cylindrical portion.
The manufacturing method of the wire harness of any one of Claim 3 thru | or 5. 前記溶着部材は、互いに溶着される複数の部材からなり、
前記溶着工程は、前記本体部材及び前記溶着部材を構成する前記複数の部材を共に溶着させて一体化する工程である、
請求項１乃至６の何れか１項に記載のワイヤハーネスの製造方法。 The welding member is composed of a plurality of members welded to each other,
The welding step is a step of welding and integrating the plurality of members constituting the main body member and the welding member.
The manufacturing method of the wire harness of any one of Claims 1 thru | or 6.
JP2012116513A 2012-05-22 2012-05-22 Manufacturing method of wire harness Pending JP2013243078A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPWO2021106946A1 (en) * 2019-11-25 2021-06-03

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPWO2021106946A1 (en) * 2019-11-25 2021-06-03
WO2021106946A1 (en) * 2019-11-25 2021-06-03 株式会社フジクラ Power feed connector with cable attached thereto
JP7337191B2 (en) 2019-11-25 2023-09-01 株式会社フジクラ Power connector with cable

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