JP2015088397A - Wire harness for vehicle and production method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate the need of lap winding of tapes different in function, e.g. a protective tape and a sound deadening tape, around the outer periphery of a wire group so as to reduce work trouble.SOLUTION: An exterior sheet consisting of a reinforcing fiber layer and a foam layer, laminated together is wound in a sushi-maki(roll) form around the outer periphery of a wire group with the reinforcing fiber layer on the inner peripheral side and the foam layer on the outer peripheral side, and the winding start part and the winding end part of the exterior sheet at both ends in the width direction have a laminating surface formed by peeling the foam layer to make the reinforcing fiber layer exposed and are fused together, with the laminating surfaces superimposed mutually.

Description

  The present invention relates to a wire harness for a vehicle and a method for manufacturing the wire harness, and more particularly to a novel method without winding an adhesive tape or sheet around the outer periphery of a group of wires constituting the wire harness and without penetrating a corrugated tube or the like. The wire group is focused and protected with a simple exterior material.

  2. Description of the Related Art Conventionally, a large number of wire harnesses each having a group of electric wires are routed inside a vehicle such as an automobile in order to supply power to mounted electrical components. The wire harness focuses and protects a group of separated wires using an exterior material such as an adhesive tape, a resin sheet, and a corrugated tube.

In addition, recently, silence in automobiles is required, and in order to prevent abnormal noise from being generated due to contact between the wire harness and the interior material, a silencer tape may be further attached to the outer surface of the exterior material. is there. For example, a sound-absorbing tape made of a foam material or the like is overlapped on the outer surface of an adhesive tape spirally wound around the outer periphery of the electric wire group.
However, as described above, when a sound deadening tape is wound around the outer surface of a tape, sheet, or corrugated tube that serves as a bundling protective material, there is a problem that the parts cost and the number of work are increased.

  Japanese Patent Application Laid-Open No. 2013-65561 (Patent Document 1) provides a wire harness that is sheathed with an exterior material that combines convergence protection and noise reduction of a group of wires. As shown in FIGS. 7 (A) to (C), the wire harness is made to have a different hardness in the thickness direction on the exterior sheet 100 made of a nonwoven fabric wound around the electric wire group 120, and the first portion 101 having a hard surface, A soft second portion 102 and an intermediate third portion 103 are provided. In the wound state around the wire group 120, the hard part first portion 101 is disposed on the surface to maintain the shape and protect it to function as a protector, and the second and third parts 102 and 103 function as a silencer and a buffer. I am letting.

  If it is set as the structure wound around the outer periphery sheet | seat 100 which consists of a nonwoven fabric on the outer periphery of the electric wire group 120 of the said wire harness of the said patent document 1, focusing protection and a noise reduction can be achieved only by attachment of the one exterior sheet | seat 100. FIG. However, in order to make the exterior sheet 100 made of non-woven fabric have different hardness in the thickness direction, the non-woven fabric is attached to the electric wire group 120 via the upper and lower jigs 112 in the cavity of the upper and lower mold 110 as shown in FIG. The exterior sheet 100 made of is loaded in a wound state, and pressed and heated in this state, the outer surface side of the exterior sheet 100 is hardened, the inner surface side is softened, and the hardness is made different in the thickness direction. And the edge part of the exterior sheet | seat 100 wound around the electric wire group is welded mutually, and the winding state is hold | maintained.

JP 2013-65561 A

  In Patent Document 1, it is possible to achieve bundling protection and noise reduction just by wrapping an outer sheet 100 made of a nonwoven fabric around an electric wire group. However, when the hardness is varied in the length direction, each region in the length direction is It is necessary to make adjustments by changing the pressurization and heating temperature into the mold through a jig. Further, in a region where the wire harness needs to be bent and routed, a bent mold and jig are required.

  Thus, a mold and a jig are required, and it is necessary to adjust the pressing force and the heating temperature during molding. Therefore, there is a problem that the production of the wire harness in which the non-woven fabric 100 having different hardness in the thickness direction is wound around the electric wire group cannot be easily performed, and the cost of equipment is increased. Moreover, there is no versatility and it cannot be easily used as an exterior material of a wire harness.

  The present invention has been made in view of the above problems, and it is possible to achieve bundling protection and silencing of the electric wire group by simply covering one electric sheet on the electric wire group, and without requiring a molding die or a jig, It is an object of the present invention to improve the workability of attaching an exterior material to a wire harness by eliminating the need for manually holding an adhesive using an adhesive tape, an adhesive sheet, or the like.

  In order to solve the above-mentioned problems, the present invention has a sushi roll shape in which an exterior sheet in which a reinforcing fiber layer and a foam layer are laminated has an outer periphery side of the electric wire group, the reinforcing fiber layer is an inner periphery side, and the foam layer is an outer periphery side. The winding start end and the winding end end of both ends in the width direction of the exterior sheet are used as the bonding surfaces in which the foam layer is peeled to expose the reinforcing fiber layer, and the bonding surfaces are overlapped. A wire harness characterized by being fused together is provided.

The reinforcing fiber layer of the exterior sheet is obtained by impregnating a woven fabric made of resin yarn with a resin or rubber adhesive. Therefore, when the foam layer is peeled off and heated in a state where the exposed reinforcing fiber layers are overlapped, the pressure-sensitive adhesive melts and the overlapped reinforcing fiber layers are fused and firmly integrated. it can. The foam layer to be laminated on the reinforcing fiber layer is made of polyurethane or foam rubber layer, and has the required thickness, as described above, having the function of silencing, buffering with other members, and vibration damping during running. Yes.
The reinforcing fiber layer is preferably a woven fabric from the viewpoint of wear resistance and strength, but may be a non-woven fabric, and in the case of the non-woven fabric, it is preferably formed of a resin yarn having strength.

In the present invention, no other noise-reducing tape is wound around the outer periphery of the wound portion of the outer sheet, and only one bonded surface continuous in the length direction of the outer sheet wound around the electric wire group is provided. Heated and fused.
That is, since the entire exterior sheet is not heated, it does not become hard during cooling, retains flexibility, and can be arbitrarily bent along the routing route when routing the wire harness to the vehicle.

  As described above, the exterior sheet used in the present invention has strength and wear resistance with a reinforcing fiber layer to protect the group of electric wires, while the foam layer has a composite function to mute, cushion, and absorb vibration. It is an exterior sheet. Therefore, it is only necessary to wrap the outer sheet around the outer periphery of the electric wire group, and it is not necessary to further wrap the sound-absorbing tape around the outer peripheral surface of the tape for bundling protection, and the wire harness forming operation can be greatly simplified.

  The bonding surface of the exterior sheet from which the reinforcing fiber layer is exposed may be provided with an uneven fitting portion, and the uneven fitting portions may be fused together.

Furthermore, the present invention provides a method for forming the wire harness,
The outer sheet is wound around the electric wire group with sushi rolls, and the overlapping of the winding start end and the winding end end at both ends in the width direction of the outer sheet,
At both ends in the length direction of the exterior sheet, the overlapped portion is pushed into a U-shaped jig and temporarily held in a wound state,
Or, the concave and convex fitting portions provided on the bonding surface of the winding start end and the winding end end of the exterior sheet are fitted to each other and temporarily held in a wound state,
There is provided a method of forming a wire harness in which the overlapped portion is heated and fused by a heat gun from the outside in the temporary holding state.

As described above, in the wire harness of the present invention, the outer sheet wound around the electric wire group is a laminate of the reinforcing fiber layer and the foam layer, and the reinforcing fiber layer has strength and wear resistance to protect the electric wire group. On the other hand, the foam layer is designed to mute, cushion, and absorb vibration. Thus, since it is set as the exterior sheet | seat which has a composite function, it only has to wind this exterior sheet | seat around the outer periphery of an electric wire group. As a result, it is not necessary to further wrap the muffler tape on the outer peripheral surface of the tape to be bundled and protected, and the wire harness forming operation can be greatly simplified. When the overlapping part is continuously heated with a heat gun, etc., the overlapping part is continuously fused in the length direction by the adhesive compounded in the reinforcing fiber layer, and it is externally attached to the electric wire group. It can be easily held while the sheet is wound. Further, since the portion to be heated and fused is a narrow region of the overlapped portion, the portion that becomes hard by cooling after heating is limited, and the flexibility of the wire harness covered with the exterior material is not impaired.

The wire harness of this invention is shown, (A) is a perspective view, (B) is a principal part expansion perspective view. It is a perspective view of the exterior sheet wound around the wire harness. (A)-(E) are drawings which show the process of armoring an electric wire group with the said exterior sheet | seat. The modification of 1st Embodiment is shown, (A) is a perspective view which shows the jig | tool used at the temporary holding process of an exterior sheet, (B) is sectional drawing of the temporary holding process using the said jig | tool. It is drawing which shows the exterior sheet | seat of 2nd Embodiment. (A) is sectional drawing which shows the state which fitted the uneven | corrugated fitting part of the exterior sheet | seat of 2nd Embodiment, (B) is a principal part enlarged view. (A)-(C) are drawings which show a prior art example.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1 to 3 show a first embodiment.

  As shown in FIG. 1, the wire harness 1 routed in the automobile of the present invention covers the outer periphery of a plurality of electric wire groups 2 by winding a single exterior sheet 3 with a composite function in a sushi roll shape. . As shown in FIG. 2, the exterior sheet 3 is made of a sheet in which a reinforcing fiber layer 10 made of a woven fabric made of reinforcing fibers and a foam layer 11 made of polyurethane, foam rubber, or the like are bonded and laminated.

  The reinforcing fiber layer 10 is made of a fluorine resin such as PET (polyethylene terephthalate) or PTFE (polytetrafluoroethylene), a polyolefin resin such as PP (polypropylene) or PE (polyethylene), or a polyimide resin such as nylon. A woven fabric impregnated with a rubber-based, acrylic-based, or silicone-based adhesive is preferably used. Among these, a PET woven fabric is preferably used because of its high rigidity.

  The reinforcing fiber layer 10 can be fused to each other by heating at a relatively low temperature, and also functions as a fused layer, as will be described later. Therefore, in a state where the foam layer 11 is laminated on the reinforcing fiber layer 10, the reinforcing fiber layer 10 and the foam layer 11 are thermally welded and integrated by heating at a temperature at which the surface of the pressure-sensitive adhesive melts. The packaged outer sheet 3 can be easily provided.

  The exterior sheet 3 in which the reinforcing fiber layer 10 and the foam layer 11 are laminated has a thickness of 0.20 mm or more and can be set to a thickness according to the application. The reinforcing fiber layer 10 has an adhesive strength of 1 to 10 N / 10 mm, a tensile strength of 10 to 200 N / 10 mm, an elongation of 10 to 500%, and a heat resistance of 100 ° C. or higher. However, physical property values such as adhesive strength are not limited to the above numerical range.

  The exterior sheet 3 has a function as a protective material for the electric wire group because the reinforcing fiber layer 10 is excellent in wear resistance, and the foam layer 11 has a silencing function, a buffering function with an external member, and a vibration damping function. Take on. Thus, since the exterior sheet 3 has multiple functions, it is possible to wrap the exterior sheet 3 around the electric wire group, without wrapping another sheet or the like, and to protect the electric wire group from focusing, silencing, buffering, vibration damping, etc. Has various effects.

As shown in FIG. 2, the exterior sheet 3 has a length X corresponding to the length of the exterior region of the exterior sheet 3 to the wire harness 1, and the width Y of the exterior sheet 13 is the outer peripheral length of the wire group 2. The dimensions are slightly longer.
The exterior sheet 3 is arranged in a required region of the wire harness with the length direction X of the exterior sheet 3 being added to the length direction of the electric wire group 2, the reinforcing fiber layer 10 being the inner surface side, and the foam layer 11 being the outer surface. As a side, the outer sheet 1 is wound around the outer peripheral surface of the electric wire group 2 only once with sushi rolls. Before this winding, the exterior sheet 3 peels the foam layer 11 along the entire length in the length direction X at both ends in the width direction Y and peels the required size (2 to 5 cm in this embodiment), and the reinforcing fiber layer 10 is peeled off. Exposed bonding surfaces 10r1 and 10r2 are provided. One end in the width direction where the bonding surface 10r1 is provided is a winding start end 3s, and the bonding surface 10r2 is a winding end 3e.

A method of wrapping and holding the exterior sheet 3 around the wire group 2 of the wire harness will be described with reference to FIG.
The length X of the exterior sheet 3 corresponds to the length of the exterior region of the exterior sheet 3 to the wire harness 1. As shown in FIG. 3 (A), the exterior sheet 3 is arranged in a required region of the wire harness with the length direction X of the exterior sheet 3 aligned with the length direction of the electric wire group 2, and the reinforcing fiber layer 10. The outer sheet 3 is wound around the outer peripheral surface of the electric wire group 2 by sushi winding for one turn with the inner surface side and the foam layer 11 as the outer surface side.

  As shown in FIG. 3B, when the wire group 2 is wound once around the outer periphery of the wire group 2, the bonding surface 10r2 of the winding end 3e of the exterior sheet 3 overlaps the outer surface of the exposed surface 10r1 of the winding start end 3s. That is, the exposed bonding surfaces 10r1 and 10r2 of the reinforcing fiber layer 10 functioning as a fusion layer are overlapped over the entire length in the length direction.

  As described above, the outer sheet 3 is wound around the outer periphery of the electric wire group 2 and, as shown in FIGS. 3C and 3D, the overlapping surfaces 10r1 and 10r2 on both ends in the length direction are overlapped. The portion 3d is temporarily held in a superposed state using a pair of U-shaped jigs 20 (20A, 20B). The U-shaped jig 20 connects upper and lower plate portions 21 and 22 with a connecting plate portion 23, and an insertion opening 20 a is provided at a position facing the connecting plate portion 23. The dimension H of the space 20c between the upper and lower plate portions 21 and 22 is set to be twice or less the thickness of the reinforcing fiber layer 10 and is slightly smaller than the thickness of the overlapping portion 3d of the bonding surfaces 10r1 and 10r2.

  The overlapping portion 3d of the winding start end 3s and the winding end end 3e at both ends in the length direction of the exterior sheet 3 wound around the electric wire group 2 is passed through the openings 20a of the U-shaped jigs 20A and 20B. It attaches so that it may push in in the space 20c between the parts 21 and 22. FIG. As a result, the overlapping portions 3d of the bonding surfaces 10r1 and 10r2 at both ends in the length direction of the exterior sheet 3 wound around the wire group 2 are sandwiched between the upper and lower plate portions 21 and 22 of the U-shaped jigs 20A and 20B. The exterior sheet 3 is temporarily held in a wound state.

  In this way, with both ends in the length direction temporarily held by the U-shaped jigs 20A and 20B, the bonding surface 10r1 of the winding start end 3s of the entire length of the exterior sheet 3 wound around the wire group 2 and the winding end As shown in FIG. 3E, the overlapping portion 3d of the end 3e with the bonding surface 10e2 is heated from the outside using a heat gun 30. The heating temperature by the heat gun 30 is set to about 110 to 140 ° C., and does not adversely affect the internal wire group 2. By heating the overlapping portion 3d of the bonding surfaces 10r1 and 10r2 made of the reinforcing fiber layer 10 with the heat gun 30, the adhesive contained in the reinforcing fiber layer 10 is melted, and the overlapping portion is fused and integrated. Turn into. By providing the fusion part 3k in a line shape over substantially the entire length in the length direction of the exterior sheet 3, the exterior sheet 3 can be held in a state of being wound around the outer periphery of the electric wire group 2. It is preferable that the U-shaped jigs 20A and 20B at both ends in the length direction are removed after fusion with a heat gun, and the removed part is heated and fused with the heat gun 30 and integrated.

  Conventionally, in a state where the sheet is wound around the electric wire group, an operator manually adheres the winding end end of the sheet to the first winding portion with the adhesive previously applied to the sheet and maintains the wound state. On the other hand, in the present invention, it is only necessary to heat the exterior sheet 3 by causing the heat gun to scan linearly in the covering region of the exterior sheet 3. In this way, the holding operation in the winding state can be simplified very much and the winding holding strength can be increased by reliably fusing and integrating.

Moreover, the exterior sheet 3 wound around the electric wire group 2 of the wire harness 1 of the present invention aims to protect the electric wire group with the reinforcing fiber layer 10 having excellent wear resistance, and is silenced with the foam layer 11, Buffering and vibration damping can be achieved. Thus, since the exterior sheet 3 has a composite function, it is only necessary to wind one exterior sheet 3 around the electric wire group 2, and there is no need to wrap the sound deadening tape around the outer peripheral surface of the protective tape as in the related art.
Furthermore, since the exterior sheet only heats the overlapped portion 3d with a heat gun and the other portions are not hardened by heating and cooling, the exterior sheet 3 retains flexibility as a whole. Therefore, the wire harness around which the exterior sheet 3 is wound can be easily bent along the routing route.

FIG. 4 shows a modification of the first embodiment.
In the first embodiment, the overlapping portion 3d of the exposed bonding surfaces 10r1 and 10r2 made of the reinforcing fiber layer 10 is heated by the heat gun 30 in a state where the exterior sheet 3 is wound around the wire group 2. During this heating, the electric wire on the inner surface side of the overlapped portion 3d is affected by heat by the heat gun 30. However, since the heat effect is instantaneous heating of about 140 ° C., it is not adversely affected. However, it is preferable that a heat-resistant inclusion exists between the overlapping portion 3d and the wire group 12.
Therefore, in the first modified example, a connecting plate portion 25 protruding from the tip of the lower plate portion 22 of one U-shaped jig 20A toward the other U-shaped jig 20B is provided so as to protrude from the other U-shape. A connecting frame 26 is provided on the lower surface of the mold jig 20B to allow the connecting plate portion 25 to pass therethrough. Thereby, the dimension between the U-shaped jigs 20 </ b> A and 20 </ b> B at both ends can be adjusted according to the length of the exterior sheet 3.

Specifically, the connecting plate portion 25 is inserted into the gap between the inner surface of the overlapping portion 3d and the electric wire 2, and one end of the overlapping portion 3d is pushed into the U-shaped jig 20A and temporarily held.
Next, while passing the connecting plate portion 25 from the tip through the connecting frame 26 of the other U-shaped jig 20B, the other end of the overlapping portion 3d is pushed into the U-shaped jig 20B and temporarily held.
Accordingly, the U-shaped jigs 20 </ b> A and 20 </ b> B can be connected and held at both ends in the length direction of the exterior sheet 3 via the connecting plate part 25, and the overlapping portion 3 d and the electric wire 2 heated by the heat gun 30 can be connected. By interposing the heat-resistant connecting plate part 25 therebetween, the influence of heating on the electric wire 2 can be reliably eliminated.

5 and 6 show a second embodiment.
In the second embodiment, temporary holding in a state where the exterior sheet 3 is wound around the wire group 2 can be performed without using a jig. The configuration of the exterior sheet 3 and the configuration in which the exterior sheet 3 is wound around the electric wire group 2 substantially once, temporarily held in the wound state, and then fused by scanning the heat gun over the overlapping portion are the same as in the first embodiment.

  The exterior sheet 3 in which the reinforcing fiber layer 10 and the foam layer 11 are laminated and integrated has a length corresponding to the winding region of the exterior sheet 3 around the power supply group 2 as in the first embodiment. The width is slightly longer than the outer peripheral length of the group 2. And the both ends of the width direction of the foam layer 11 of this exterior sheet 3 are peeled only by a required dimension over the full length of the length direction, and the bonding surfaces 10r1 and 10r2 which the reinforcement fiber layer 10 exposed are provided.

  The uneven fitting portion 50 is press-formed on one bonding surface 10r1, while the uneven fitting portion 51 is press-formed on the opposite surface of the other reinforcing fiber layer 10 to the bonding surface 10r2.

  The outer sheet 3 is wound around the outer periphery of the electric wire group 2 by sushi winding around the bonding surface 10r1 provided with the uneven fitting part 50, and the uneven fitting part 51 at the winding end is wound around the winding start end. The overlapping portion 3d is provided that is fitted to the concave-convex fitting portion 50 and temporarily holds the outer sheet 3 in a wound state around the wire group 2. Since the concave and convex fitting portions 50 and 51 provided at both ends in the width direction Y of the outer sheet 3 are provided in the entire length in the length direction X, the outer sheet 3 wound around the electric wire group 2 has the concave and convex fitting portions 50 and 51 over the entire length. As shown in FIG. 6, it can be temporarily held.

  In this state, similarly to the first embodiment, the overlapping portion 3d in which the concave and convex fitting portions 50 and 51 are fitted is scanned from the outside along the length direction and heated from the outside. . Thereby, the fusion | fusion part 3k by which the uneven | corrugated fitting parts 50 and 51 which consist of the reinforced fiber layer 10 were fuse | melted can be formed in the full length of a length direction, and it can fix in a winding state.

  In the second embodiment, a temporary holding jig is not required, and the concavo-convex fitting portions 50 and 51 are fitted over the entire length in a state in which the outer sheet 3 is wound around the electric wire group 2, and the wound state Therefore, the temporary holding function has a high advantage.

DESCRIPTION OF SYMBOLS 1 Wire harness 2 Electric wire group 3 Exterior sheet 3d Overlapping part
3k Fusion part 3s Winding end 3e Winding end 10 Reinforcing fiber layer 10r1, 10r2 Bonding surface
11 Foam layer 20 (20A, 20B) Jig 30 Heat gun 50, 51 Concavity and convexity fitting part

Claims (5)

  An outer sheet in which the reinforcing fiber layer and the foam layer are laminated is wound around the outer periphery of the electric wire group in a sushi roll with the reinforcing fiber layer on the inner peripheral side and the foam layer on the outer peripheral side. The winding start end and winding end end portions at both ends are bonded surfaces in which the foam layer is peeled to expose the reinforcing fiber layer, and the bonded surfaces are overlapped and fused. Wire harness.   The wire harness according to claim 1, wherein the reinforcing fiber layer of the outer sheet is impregnated with a resin or rubber adhesive in a woven fabric made of resin yarn, and the foam layer is formed of polyurethane or foam rubber.   No other silencing tape is wound around the outer periphery of the wound portion of the outer sheet, and only one bonded surface that is continuous in the length direction of the outer sheet wound around the wire group is heated. The wire harness according to claim 1 or 2, wherein the wire harness is fused.   The uneven | corrugated fitting part is each provided in the bonding surface which exposed the said reinforced fiber layer of the said exterior sheet | seat, It fuse | melts in the state which these uneven | corrugated fitting parts were mutually fitted. The wire harness of any one of Claims. A method of forming a wire harness according to any one of claims 1 to 4,
The outer sheet is wound around the electric wire group with sushi rolls, and the overlapping of the winding start end and the winding end end at both ends in the width direction of the outer sheet,
At both ends in the length direction of the exterior sheet, the overlapped portion is pushed into a U-shaped jig and temporarily held in a wound state,
Or, temporarily hold in a wound state by fitting the uneven fitting portion provided on the bonding surface of the winding start end and winding end of the exterior sheet,
A method of forming a wire harness in which the overlapped portion is heated and fused with a heat gun from the outside in the temporary holding state.

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