JP2015116109A - Method of manufacturing wire harness and wire harness - Google Patents

Abstract

PROBLEM TO BE SOLVED: To attach a protector, capable of regulating the route of a wire harness three-dimensionally, easily to a wire.SOLUTION: A method of manufacturing a wire harness 10 includes a step (a) of processing a sheet material, by bending, into a temporary protector capable of housing at least a part of a wire group 12, and disposing the temporary protector along a plane, a step (b) of attaching the temporary protector to the wire group 12 so as to cover the protected part of the wire group 12 disposed along the plane, and a step (c) of maintaining the temporary protector in bent state, so that at least a part thereof crosses the plane. Consequently, the wire 12 can be maintained in a state bent by means of the protector 20.

Description

  The present invention relates to a technique for attaching a protective member to a wire harness used as a wiring material in a vehicle or the like.

  A protective member for protecting a wire harness used in a vehicle or the like while regulating the path of the electric wire may be attached.

  Patent document 1 is disclosing the protector provided with a bowl-shaped protector main body and a cover body as the above protection members. This protector is formed of a synthetic resin or the like.

  Patent Document 2 discloses a technique for forming a protective member by covering the periphery of a wire harness main body with a nonwoven material and hot-pressing the nonwoven material in a mold. .

JP 2004-319141 A JP 2013-73896 A

  By the way, it may be necessary to restrict the route of the wire harness in three dimensions. However, the wire harness is usually assembled on a work plate that spreads in a plane. For this reason, it is difficult to incorporate a configuration that three-dimensionally regulates the wire harness in the work board.

  For example, if the wire harness is three-dimensionally restricted by the technique disclosed in Patent Document 1, it is necessary to attach a protector having a shape that restricts the wire harness three-dimensionally to the wire harness. However, it is difficult to attach a protector having a shape that restricts the path to a three-dimensional shape with respect to the wire harness that is arranged in a plane on the work plate.

  In this case, it is conceivable that a jig for mounting the protector is prepared on a work table different from the work plate for assembling the wire harness in a plane, and the protector is mounted on the wire harness on the jig. In that case, a wire harness transfer operation or the like is required, and the assembly work of the wire harness becomes complicated.

  Further, for example, according to the technique disclosed in Patent Document 2, it is necessary to introduce a hot press machine for forming a non-woven material into a shape that can accommodate the wire harness at the manufacturing site of the wire harness, There is a problem that the work load increases.

  Then, an object of this invention is to enable it to mount | wear easily with respect to an electric wire the protector which can route-control a wire harness in three dimensions.

  In order to solve the above-described problem, a manufacturing method of a wire harness according to a first aspect includes: (a) bending a sheet material to process a temporary protector capable of accommodating at least a part of an electric wire group; And (b) attaching the temporary protector to the wire group so as to cover a portion to be protected disposed along the plane of the wire group, and (c) the step And maintaining the temporary protector in a bent state so that at least a part of the temporary protector intersects the plane after the step (b).

  A 2nd aspect is a manufacturing method of the wire harness which concerns on a 1st aspect, Comprising: The said process (a) is a process which bends the said sheet | seat material and processes into the elongate main-body part extended in elongate shape. The step (b) includes a step of attaching the long main body portion to the electric wire group, and the step (c) includes at least a part of the long main body portion intersecting the plane. And a step of maintaining the elongated main body in a bent state.

  A 3rd aspect is a manufacturing method of the wire harness which concerns on a 2nd aspect, Comprising: With respect to the said elongate main-body part, the attachment part attached to the said electric wire group in the several place distant along the extension direction Is provided, and a length adjusting part that can be expanded and contracted along the extending direction of the long main body part is provided between the plurality of attaching parts. In the step (c), the length adjusting part The elongate main body is bent while stretching or contracting.

  A 4th aspect is a manufacturing method of the wire harness which concerns on a 3rd aspect, Comprising: A said some attachment part is provided in the both ends of the said elongate main-body part.

  A 5th aspect is a manufacturing method of the wire harness which concerns on a 4th aspect, Comprising: In the said process (b), the said electric wire group is the trunk part accommodated in the said elongate main-body part, and the said elongate main body. A branch guide portion that is arranged to include a branch portion that branches from the main line portion at an intermediate portion in the extending direction of the portion, and that guides the branch portion to the long main body portion so as to branch from the main line portion. In the step (c), a bent portion is formed between the branch guide portion and at least one end of the long main body portion, and the branch guide portion of the long main body portion is formed on the branch guide portion. On the other hand, the length adjusting part is provided on the part where the bent part is formed.

  A 6th aspect is a manufacturing method of the wire harness which concerns on any one aspect of the 2nd-5th, Comprising: The said length adjustment part can be expanded-contracted along the extension direction of the said elongate main-body part. It includes a folded bellows-like part.

  A 7th aspect is a manufacturing method of the wire harness which concerns on any one aspect of the 2nd-5th, Comprising: The said length adjustment part is extension of the said elongate main-body part, while two members slide The component part connected so that expansion-contraction along a direction is included is included.

  The wire harness which concerns on an 8th aspect is equipped with the electric wire group containing a protection object part, and the protector attached to the said electric wire group so that the said protection object part may be covered, The said protector bends a sheet | seat material. And a plurality of attachment portions provided with attachment portions attached to the wire group at a plurality of locations separated along the extending direction with respect to the long body portion. A length adjusting portion that can be expanded and contracted along the extending direction of the long main body portion is provided between the portions.

  A 9th aspect is a wire harness which concerns on an 8th aspect, Comprising: The said length adjustment part contains the bellows-shaped part folded so that expansion-contraction was possible along the extension direction of the said elongate main-body part.

  A 10th aspect is a wire harness which concerns on an 8th aspect, Comprising: The said length adjustment part contains the component part connected so that expansion and contraction is possible, while two members slide.

  According to the first aspect, since the temporary protector is attached to the wire group so as to cover the protection target portion disposed along the plane of the wire group, the temporary protector is easily attached to the wire group. it can. Further, in order to maintain the temporary protector in a bent state so that at least a part of the temporary protector intersects the plane, the wire harness is three-dimensionally formed by the protector formed from the sheet material through the temporary protector form. The route can be restricted.

  According to the second aspect, at least one sheet material is bent and processed into a long main body portion extending in a long shape along the plane, and the long main body portion is attached to the electric wire group. Therefore, the temporary protector can be easily attached to the electric wire group.

  According to the third aspect, the long main body portion is attached to the electric wire group so as to cover the portion to be protected disposed along the plane of the electric wire group, and then the long main body portion is bent. There is a possibility that an excess or insufficient dimension of the electric wire group may occur between the mounting portions. Therefore, an extendable length adjusting portion is provided between a plurality of attachment portions of the long main body portion, and in the step (c), the length adjusting portion is extended or contracted while the length adjusting portion is extended. By bending the main body portion, it is possible to eliminate the dimensional excess or shortage of the electric wire group. In addition, this makes it possible to design a fixed portion of the electric wire group with respect to the sheet material on a flat surface, thereby facilitating the design of the wire harness.

  According to the 4th aspect, the attaching part of the both ends of a elongate main-body part can be attached easily and firmly with respect to an electric wire group.

  According to the 5th aspect, when the branched part has branched from the middle of the elongate main-body part, the part from which the said branched part branches is hard to move with respect to the extension direction of a long main-body part. Therefore, the length adjustment portion is provided in a portion of the long main body portion on the side where the bent portion is formed with respect to the branch guide portion, so that the size of the electric wire group is insufficient or insufficient. Can be eliminated.

  According to the sixth aspect, the length can be adjusted with a simple configuration.

  According to the 7th aspect, an unevenness | corrugation can be reduced as much as possible in the external appearance shape of a protector.

  According to the eighth aspect, the long main body portion is attached to the electric wire group so as to cover the portion to be protected disposed along the plane of the electric wire group, and then the long main body portion is bent. In some cases, the long body portion can be bent while the length adjusting portion is extended or contracted. Thereby, the excess dimension or shortage of the size of the electric wire group can be eliminated between the attachment portions.

  According to the ninth aspect, the length can be adjusted with a simple configuration.

  According to the 10th aspect, an unevenness | corrugation can be reduced as much as possible in the external appearance shape of a protector.

It is explanatory drawing which shows the relationship between a wire harness and an assembly drawing board. It is explanatory drawing which shows the relationship between a wire harness and an assembly drawing board. It is explanatory drawing which shows the example of a process of forming a sheet material from a non-woven member. It is a partially cutaway perspective view showing an example of a hollow sheet material used as a sheet material. It is a partially cutaway perspective view which shows the other example of the hollow sheet material used as a sheet material. It is a partially cutaway perspective view showing still another example of a hollow sheet material used as a sheet material. It is explanatory drawing which shows the operation | work which bends a sheet material in a process (a). It is explanatory drawing which shows the state which accommodated the electric wire group in the temporary protector processed by the process (a). It is explanatory drawing which shows the state which attached the temporary protector to the electric wire group in the process (b). It is explanatory drawing which shows the state which bent the temporary protector in the process (c). It is a figure for demonstrating that the excess dimension of an electric wire group arises when a bellows part is not provided. It is a figure for demonstrating that the excess dimension of an electric wire group arises when a bellows part is not provided. It is a figure for demonstrating that the excess dimension of an electric wire group is suppressed by providing a bellows part. It is a figure for demonstrating that the excess dimension of an electric wire group is suppressed by providing a bellows part. It is explanatory drawing which shows the length adjustment part which concerns on a modification.

  Hereinafter, the manufacturing method and wire harness of the wire harness which concern on embodiment are demonstrated.

<Relationship between wire harness design path and assembly drawing board>
In describing the wire harness manufacturing method and the wire harness according to the present embodiment, the relationship between the design path of the wire harness and the assembly drawing board will be described.

  1 and 2 are explanatory views showing the relationship between the wire harness 10 and its assembly drawing board 50. FIG. In FIG. 1 and FIG. 2, XYZ orthogonal coordinate axes are shown for convenience of explanation.

  The wire harness 10 is a wiring material including a plurality of electric wire groups 12. More specifically, the wire harness 10 is a wiring member that electrically connects various electric devices in a vehicle or the like, and a plurality of electric wires are bound while being appropriately branched along a wiring path in the vehicle or the like. A connector or the like is connected to the end of the wire harness 10, and the connector at the end is connected to various electric devices mounted on the vehicle or the like in a state where the wire harness 10 is incorporated in the vehicle. The various electric devices are electrically connected to each other through the wire harness 10. The wire harness 10 may include an optical fiber cord or the like.

  The wire harness 10 is disposed along a three-dimensional wiring path in the vehicle. However, when the wire harness 10 is assembled, in order to facilitate the design and manufacturing work of the wire harness 10, a route design in which a three-dimensional wiring route is developed two-dimensionally is performed. And the electric wire group 12 is arrange | positioned along the predetermined | prescribed two-dimensional path | route in the virtual work plane (XY plane in FIG.1 and FIG.2) parallel to the said assembly drawing board 50 on the assembly drawing board 50, In this state, bundling work of the electric wire group 12, and mounting work of exterior parts such as a protector and a vehicle fixture are performed. The electric wire group 12 is supported on the assembly drawing board 50 by a U-shaped jig 52 or the like.

  A protector 20 that covers at least a part of the wire harness 10 may be attached to the wire harness 10 in order to perform protection and path regulation. Further, depending on the wiring route of the wire harness 10 in the vehicle, as shown in FIG. 1, a part of the protector 20 may be skewed with respect to the work plane (in FIG. 1, tilted in the Z-axis direction). The protector 20 may have a bent shape.

  In order to attach the protector 20 to the electric wire group 12 on the assembly drawing board 50, it is necessary to arrange the electric wire group 12 so as to incline toward the Z-axis direction and attach the electric wire group 12 to the protector 20. . For this purpose, it is necessary to design the path for assembling the wire harness 10 in a three-dimensional manner, and to perform the assembly work, which makes the design and manufacturing work difficult.

  Moreover, after performing the bundling work of the electric wire group 12 etc. except the mounting work of the above protectors 20, the wire harness 10 before attaching the protector 20 is transferred to another work drawing board for mounting the protector, If the protector 20 is attached to the wire harness 10 on the work drawing board for attaching the protector, the work on the assembly drawing board 50 can be assembled based on a two-dimensional assembly path design. In this case, however, the wire harness 10 needs to be transferred.

  Therefore, as shown in FIG. 2, the electric wire group 12 is arranged along a predetermined two-dimensional path on a virtual work plane (XY plane in FIG. 2) parallel to the assembly drawing board 50, and in this state, A temporary protector 30 is attached to the wire group 12. Further, in the same state, a bundling operation of other portions of the electric wire group 12 and a fixing operation of exterior parts and the like are performed.

  Thereafter, if the temporary protector 30 is maintained in a bent state (an arrow in FIG. 2) so that a part of the temporary protector 30 is inclined with respect to the virtual work plane (inclined in the Z-axis direction in FIG. 2). As for the bundling work on the assembly drawing board 50 and the attaching work of the exterior parts, the work based on the two-dimensional assembly path design is possible, and the assembly work of the wire harness 10 is facilitated.

<About the structure of the sheet material for forming the protector>
The structure of the sheet material for forming the protector 20 will be described. In the present embodiment, the protector 20 is formed by bending the sheet material 40, in particular, bending.

  The protector 20 formed of the sheet material 40 can be processed into various shapes by appropriately changing the bending method and the folding method of the sheet material 40. For this reason, by using the protector 20 formed of the sheet material 40, it is possible to realize the regulation of the electric wire group 12 by various paths at a relatively low cost.

  As the sheet material 40 for forming the protector 20, the sheet material 40 has such a rigidity that it can be subjected to path regulation and protection of the electric wire group 12 in a state of covering the electric wire group 12 and bendable. Those having (preferably bendable properties) may be used.

  As the sheet material 40, a non-woven sheet obtained by hot pressing a non-woven member, a resin sheet, a paper sheet, or the like can be used.

  FIG. 3 is an explanatory view showing a process example of forming the sheet material 40 by hot pressing the non-woven member 78 and solidifying it.

  The non-woven member 78 is a fiber material in which a plurality of fibers are intertwined without being woven, and has flexibility. The non-woven member 78 becomes highly rigid by melting at least a part by heating and then curing. Further, when the melted portion of the non-woven member 78 is cured, it can be processed to exhibit a predetermined shape, for example, a thin sheet shape, by applying pressure.

  Specifically, as the non-woven member 78, a flexible member including intertwined basic fibers and an adhesive resin (also referred to as “binder”) can be used. The adhesive resin is a resin having a melting point lower than the melting point of the basic fiber. The non-woven member 78 is heated to a temperature lower than the melting point of the basic fiber and higher than the melting point of the adhesive resin, so that the adhesive resin melts and soaks between the basic fibers. Thereafter, when the nonwoven member 78 reaches a temperature lower than the melting point of the adhesive resin, the adhesive resin is solidified in a state where the basic fibers are bonded to each other. Thereby, the non-woven member is cured and becomes harder than the state before heating. Further, when the non-woven member 78 is compressed in a state where the adhesive resin is melted, the non-woven member 78 is maintained in a predetermined molding shape at the time of the compression.

  The adhesive resin may be granular or fibrous. An adhesive resin layer may be formed on the outer periphery of the core fiber to form a binder fiber, which may be entangled with the basic fiber. As the core fiber in this case, the same material as the basic fiber can be used.

  Thus, if the non-woven member 78 includes a basic fiber and an adhesive resin, the basic fiber can remain in a fiber state even after the hot pressing. For this reason, the sheet material 40 formed by hot pressing the non-woven member 78 has a certain degree of flexibility. For this reason, even if the protector 20 which formed the said sheet | seat material 40 hits the surrounding member, there exists an advantage that it is hard to generate a contact sound.

  The non-woven member 78 is formed in a long band shape and is wound up as a wound body 70. The non-woven member 78 is drawn out from the wound body 70 and guided between the pair of heat and pressure rollers 74 through the preheating device 72. The pair of heat and pressure rollers 74 are heated by a heater or the like and are rotationally driven in a direction to pull out the non-woven member 78 by a motor or the like (not shown). The non-woven member 78 is preheated below the temperature at which the adhesive resin melts by the preheating device 72 and then reaches between the pair of heating and pressure rollers 74. In the pair of heating and pressing rollers 74, the non-woven member 78 is pressed while being heated to a temperature higher than the temperature at which the adhesive resin melts. Thereby, the non-woven member 78 is processed into the sheet material 40 having a sheet shape with a certain degree of rigidity.

  A scraper 75 that is gradually thinner toward the upstream side in the pulling direction of the nonwoven member 78 is disposed on the downstream side of the pair of heat and pressure rollers 74. The tip portions of the pair of scrapers 75 are disposed between the pair of heating and pressing rollers 74 and the sheet material 40 led out from the pair of heating and pressing rollers 74. The sheet material 40 is removed.

  It should be noted that an uneven shape can be formed on the sheet material 40 by providing a groove shape or a protrusion shape on the surface of the pair of heat and pressure rollers 74. In particular, if a groove shape is formed on the surface of the pair of heat and pressure rollers 74, a portion that does not heat the sheet material 40 to the melting point of the adhesive resin or more can be provided. It can be formed as an eye.

  Further, as the sheet material 40, it is also preferable to use a hollow sheet material in which a hollow structure is formed between a plurality of plate-like portions. This is because such a hollow sheet material can provide a protector 20 that is lightweight and excellent in strength.

  4 to 6 are partially cutaway perspective views showing examples of the hollow sheet materials 40A, 40B, and 40C, respectively.

  A hollow sheet material 40A shown in FIG. 4 includes a plurality (two in this case) of plate-like members 42A and an interposition member 46A sandwiched between the plurality of plate-like members 42A.

  The material for forming the plurality of plate-like members 42A and the interposition member 46A is not particularly limited. The plurality of plate-like members 42 </ b> A and the interposition members 46 </ b> A may be formed of paper, may be formed of resin, or may be configured by a combination thereof. When at least one of the plurality of plate-like members 42A and the intervening member 46A is formed of paper, it is preferable to perform a water repellent treatment or the like on the surface.

  The plate member 42A is formed in a flat plate shape. A plurality of plate-like members 42 </ b> A are connected in a state of being spaced apart via an interposed member 46 </ b> A.

  The intervening member 46A is a member formed in a plate shape having an uneven shape. The interposition member 46A is joined to the inward surface of the plate member 42A while being sandwiched between the plurality of plate members 42A. The joining of the plate-like member 42A and the interposition member 46A is performed with, for example, an adhesive or a pressure-sensitive adhesive. Thereby, the hollow structure according to the uneven | corrugated shape which 46 A of interposition members exhibit is formed among some plate-shaped member 42A.

  Here, the interposition member 46A is formed in a shape in which a peak portion 46Aa and a valley portion 46Ab are continuous in a wave shape. The extending direction of the peak portions 46Aa and the extending direction of the valley portions 46Ab are in a parallel positional relationship. Therefore, when the interposed member 46A is viewed in plan, the plurality of peak portions 46Aa and the plurality of valley portions 46Ab are alternately arranged. It is set as the structure formed in parallel.

  The interposition member 46A is sandwiched between the plurality of plate-like members 42A, the lower surface of the bottom portion of the valley portion 46Ab and the lower plate-like member 42A are joined, and the upper surface and the upper side of the top portion of the peak portion 46Aa. The plate-like member 42A is joined.

  According to such a hollow sheet material 40A, since the plurality of plate-like members 42A are connected by the interposition member 46A at intervals, it is difficult to bend. Further, since the interposition member 46A is interposed between the plate-like members 42A, the interposition member 46A also reinforces the hollow sheet material 40A so that it is difficult to bend and dent.

  Further, since a hollow structure is formed between the plurality of plate-like members 42A of the hollow sheet material 40A, it is possible to reduce the weight and the material cost accordingly.

  The hollow sheet material 40A is cut into a predetermined shape or formed into a predetermined shape of a broken line L (described later) by providing a cutting blade and a projection or blade for forming the bent line L on the surface of the pair of rollers. Can be easily carried out continuously by sandwiching the hollow sheet material 40A.

  A manufacturing example of the hollow sheet material 40A will be described.

  The intervening member 46A can be formed, for example, by sandwiching a flat plate member between press dies having an uneven surface. For example, a flat plate-like member having a belt shape is continuously supplied along a predetermined conveyance path, and a pair of rollers is disposed along the conveyance path. An uneven shape is formed on the surface of the pair of rollers. And while interposing the flat plate-shaped member which makes | forms a strip | belt along a predetermined conveyance path, the said flat-plate member is continuously pinched | interposed with a pair of rollers, and the interposition member 46A is formed continuously. be able to.

  In addition, a pair of strip-shaped plate members 42A are continuously supplied along the predetermined conveying path to the downstream side of the pair of rollers, and an interposing member 46A is interposed between the pair of strip-shaped plate members 42A. Are sequentially inserted and joined with an adhesive or the like. Thereby, the hollow sheet material 40A can be manufactured continuously.

  The hollow sheet material 40B shown in FIG. 5 is different from the hollow sheet material 40A in that an interposed member 46B is used instead of the interposed member 46A.

  That is, the interposed member 46B is a member formed in a plate shape having an uneven shape, and more specifically, a configuration in which a plurality of protrusions 47B are formed so as to be scattered in a plan view of the interposed member 46B. Has been. Here, in a state in which the interposed member 46B is viewed in plan, the plurality of protrusions 47B are formed so as to be arranged at regular intervals in the vertical and horizontal directions. The protrusion 47B is formed so as to protrude toward the one main surface side from the board portion 48B extending in a flat plate shape in the interposition member 46B, and has a shape in which the upper end portion of the cylinder is closed. Here, the protrusion 47B is formed in a shape that gradually narrows upward, ie, a frustum shape. The protrusion 47B may be formed in a truncated cone shape, may be formed in a truncated pyramid shape, or may be formed in a shape obtained by rounding the corners of the truncated pyramid.

  Then, the interposition member 46B is sandwiched between the plurality of plate-like members 42B, the lower surface of the substrate portion 48B is joined to the lower plate-like member 42B, and the top of the projection 47B is joined to the upper plate-like member 42B. ing.

  According to such a hollow sheet material 40B, similarly to the hollow sheet material 40A, it is excellent in strength and can be reduced in weight.

  It should be noted that two interposition members 46B may be interposed between the two plate-like members 42B.

  The hollow sheet material 40C shown in FIG. 6 is a member formed of a resin material, and includes a plurality (here, two) of plate-like portions 42C and an interposition portion 46C interposed between the plate-like portions 42C. It is formed in a shape having a ladder-like cross section.

  More specifically, the plate-like portion 42C is formed in a flat plate shape. The plurality of plate-like portions 42C are connected with an interval therebetween via the interposition portion 46C.

  Between the plurality of plate-like portions 42C, a plurality of intervening portions 46C are provided in a parallel state with a space therebetween.

  Each interposition part 46C is formed in an elongated plate shape, and is integrally formed with the plate-like part 42C in a posture orthogonal to the plate-like parts 42C on both sides.

  For this reason, when the hollow sheet material 40C is cut along a plane orthogonal to the extending direction of the interposition part 46C, a ladder-like cross section in which a plurality of interposition parts 46C extend between the pair of plate-like parts 42C is shown.

  Such a hollow sheet material 40C can be continuously manufactured by, for example, an extrusion molding apparatus that extrudes a resin from an extrusion hole corresponding to the ladder-shaped cross section, whereby the hollow sheet material 40C can be easily reduced. Can be manufactured at cost.

  Even with such a hollow sheet material 40C, as in the case of the hollow sheet material 40A, the strength can be improved and the weight can be reduced. Further, such a hollow sheet material 40C has an advantage that it can be efficiently manufactured by extrusion molding of a resin material.

  In addition, the interposition part which interposes between several plate-shaped parts and forms a hollow structure may form another hollow shape. For example, between a plurality of plate-like portions, the intervening portion between them may form a polygonal hollow shape such as a triangular prism, and may form a honeycomb structure in particular.

  In addition, it is preferable that the thickness dimension of hollow sheet material 40A, 40B, 40C is about 1.5 mm-15.0 mm.

  In the following description, the sheet material 40 is used regardless of whether it is formed by the non-woven member 78 or the hollow sheet materials 40A, 40B, and 40C.

<About wire harness manufacturing method and wire harness>
The wire harness manufacturing method and the wire harness will be described in more detail. The method of manufacturing the wire harness includes: (a) bending a sheet material to process at least a part of the electric wire group into a temporary protector, and disposing the temporary protector along a plane; (b) Attaching the temporary protector to the electric wire group so as to cover a portion to be protected disposed along the plane of the electric wire group; and (c) after the step (b), at least of the temporary protector. Maintaining the temporary protector in a bent state so that a portion intersects the plane.

  FIG. 7 is an explanatory view showing an operation of bending the sheet material 40 in the step (a), and FIG. 8 is an explanatory view showing a state in which the electric wire group 12 is housed in the temporary protector 30 processed in the step (a). 9 is an explanatory view showing a state in which the temporary protector 30 is attached to the wire group 12 in the step (b), and FIG. 10 is an explanatory view showing a state in which the temporary protector 30 is bent in the step (c). It is.

<About the shape of the sheet material 40>
Here, the sheet material 40 used for processing will be described.

  Here, the temporary protector 30 is processed from one sheet material 40. The sheet material 40 has a configuration in which a first sheet portion 42 and a second sheet portion 44 are connected via a bellows portion 46 as a length adjusting portion (see FIG. 7).

  The first sheet portion 42 includes a long plate-like first bottom portion 42a, a pair of first side wall portions 42b provided on both sides of the first bottom portion 42a, and a pair of first side wall portions 42b. And a pair of first lid portions 42c provided on one side, and easy folding lines L are formed at the respective boundaries. In addition, the 1st side wall part 42b is formed in the strip | belt shape which becomes thin gradually here toward the outward edge part.

  A mounting portion 42ap that extends outward from the first side wall portion 42b is provided at the end of the first bottom portion 42a opposite to the second sheet portion 44.

  Moreover, the edge part by the side of the 2nd sheet | seat part 44 among a pair of 1st side wall parts 42b has a part extended so that it may incline toward the said 2nd sheet | seat part 44 side toward the outward.

  Further, a branch guide portion 42d is formed at the intermediate portion in the extending direction of the first side wall portion 42b on one side. Here, the branch guide portion 42d cuts the intermediate portion in the extending direction of the first side wall portion 42b into a square shape except for the portion on the first bottom portion 42a side, thereby forming a rectangular opening 42dh and the opening 42dh. Of these, it is formed by forming a branch fixing portion 42 bp that can extend outward from a portion on the first bottom portion 42 a side.

  And the branch part 12b branched from the trunk line part 12a among the electric wire groups 12 is guided to the outside through the opening 42dh and attached to the branch fixing part 42bp, so that the branch part 12b is separated from the trunk line part 12a. It is guided to branch (see FIGS. 8 to 10).

  By folding the pair of first side wall portions 42b to the same side with respect to the first bottom portion 42a, a bowl-shaped first temporary housing portion 32 that opens on the opposite side to the first bottom portion 42a is formed. In the final configuration, the pair of first lid portions 42c are folded and overlapped so as to close the opening, and fixed in the overlapped state, whereby the first accommodating portion 22 is formed. The 1st accommodating part 22 maintains the state along a fixed path | route (here straight line path | route), in the state which covered and protected the surrounding four directions of a part of electric wire group 12.

  In addition, although a pair of 1st cover part 42c is provided here, you may make it close opening by one cover part. Moreover, it is not essential that there is a lid. Furthermore, this 1st accommodating part 22 may be formed so that it may bend in a work plane.

  The second sheet portion 44 includes a rectangular plate-like second bottom portion 44a, a pair of second side wall portions 44b provided on both sides of the second bottom portion 44a, and a pair of second side wall portions 44b. And a second lid portion 44c provided on one side, and a fold line L that is easy to fold is formed at each of these boundaries.

  A mounting portion 44ap extending outward from the periphery of the second bottom portion 44a and one second side wall portion 44b on the opposite side of the second sheet portion 44 is extended.

  Moreover, the edge part by the side of the 2nd sheet | seat part 44 of the pair of 2nd side wall parts 44b is extended to the said 1st sheet | seat part 42 side, The edge part is said 2nd toward the outer side. It is formed to extend so as to incline toward the side away from the seat portion 44.

  By folding the pair of second side wall portions 44b to the same side with respect to the second bottom portion 44a, a bowl-shaped second temporary housing portion 34 that opens on the opposite side to the second bottom portion 44a is formed. In the final form, the pair of second lid portions 44c are folded and overlapped so as to close the opening, and fixed in the overlapped state, whereby the second accommodating portion 24 is formed. The second accommodating portion 24 covers and protects the other four sides of the other part of the electric wire group 12 and keeps the other part of the electric wire group 12 along a certain route (in this case, a straight route). maintain.

  Here, although a pair of 2nd cover parts 44c are provided, you may make it close opening by one cover part. Moreover, it is not essential that there is a lid. Further, the second housing portion 24 may be formed to bend in the work plane.

  The bellows portion 46 is configured to be foldable so as to extend and contract along a direction connecting the first temporary storage portion 32 and the second temporary storage portion 34. Here, the bellows portion 46 includes a plurality (here, two) of plate-like portions 46p. The plate-like portion 46p is formed to have the same width as the first bottom portion 42a and the second bottom portion 44a. Each plate-like portion 46p is folded so as to form a mountain fold when viewed from the inner surface side with respect to the first bottom portion 42a and the second bottom portion 44a. (See FIG. 8). Accordingly, the bellows portion 46 is folded so as to protrude outward in a V shape between the first bottom portion 42a and the second bottom portion 44a. The bellows part 46 can be expanded and contracted in the direction connecting the first bottom part 42a and the second bottom part 44a by adjusting the folding angle of each folding part. The bellows portion 46 may be configured to be folded more times.

  The first sheet portion 42 is bent and formed in the first temporary storage portion 32, and the second sheet portion 44 is bent and formed in the second temporary storage portion 34, whereby the sheet material 40 is processed into the temporary protector 30. Is done. In this state, the temporary protector 30 includes a long main body portion 31 in which the first temporary storage portion 32 and the second temporary storage portion 34 extend in a long shape via the bellows portion 46 (see FIG. 8).

  When the long main body 31 is observed, attachment portions 42ap and attachment portions 44ap that can be attached to the electric wire group 12 are provided at a plurality of locations separated along the extending direction. Here, the attachment part 42ap and the attachment part 44ap are provided in the both ends of the elongate main-body part 31, respectively. But the attachment part (for example, the hole or groove | channel which can penetrate a binding band) which can be attached to an electric wire group may be provided in the extension direction intermediate part of the elongate main-body part.

  In addition, the bellows part 46 is provided between the attachment part 42ap and the attachment part 44ap as the length adjusting part. Therefore, the path length between the long main body 31 and the wire group 12 between the mounting portion 42ap and the mounting portion 44ap in a state where the mounting portion 42ap and the mounting portion 44ap of the long main body portion 31 are attached to the wire group 12. When a difference occurs, the path length difference can be absorbed by the bellows portion 46 extending and contracting along the extending direction of the long main body portion 31.

  In addition, the long main body 31 is bent between the first temporary housing portion 32 and the second temporary housing portion 34 in the step (b). The bellows portion 46 as the length adjusting portion is provided on the side of the long main body portion 31 that is bent with respect to the branch guide portion 42d. For this reason, the bellows part 46 can be expanded / contracted between the branch guide part 42d and the attachment part 44ap, and the remainder or shortage of the dimension of the electric wire group 12 can be suppressed.

  Based on the above, each step (a), (b), (c) will be described.

<About step (a)>
In the step (a), as shown in FIG. 7, the sheet material 40 is bent and processed into a temporary protector 30 that can accommodate at least a part of the electric wire group 12. (See FIG. 2).

  In the example shown in FIG. 7, a bending jig 54 is disposed on the assembly drawing board 50. The jig 54 is formed on a long member made of resin or metal. A sheet bending groove 55 is formed in the bending jig 54 along the extending direction thereof. The sheet bending groove 55 is formed in the shape of a square groove that opens to both ends and upward of the bending jig 54, and is formed to have the same width as the first bottom portion 42a and the second bottom portion 44a. Further, a relief recess 56 is formed in the intermediate portion in the extending direction of the bottom of the sheet bending groove 55. In addition, an opening 57 is formed at a position on one side wall of the jig 54 that faces a branch portion 12b described later. The height position of the bottom of the sheet bending groove 55 is preferably approximately the same as the height position of the electric wire group 12 supported by the jig 52.

  Then, when the first bottom portion 42a, the second bottom portion 44a and the bellows portion 46 of the sheet material 40 are pushed into the sheet bending groove 55 (see arrow C in FIG. 7), the pair of first side wall portions 42b and the pair of The second side wall portion 44b is bent with respect to the first bottom portion 42a and the second bottom portion 44a so as to rise along the side wall of the sheet bending groove 55 (see arrow B in FIG. 7). Thereby, the 1st temporary accommodation part 32 and the 2nd temporary accommodation part 34 are formed. Thereby, the 1st temporary storage part 32 and the 2nd temporary storage part 34 are connected through the bellows part 46, and the elongate main-body part 31 extended in elongate shape is formed. At this time, the first temporary storage portion 32 and the second temporary storage portion 34 are brought close to each other, and the bellows portion 46 is bent so as to be stored in the escape recess 56. The portion 32 and the second temporary housing portion 34 are contracted.

  Note that the operation of folding the sheet material 40 is not necessarily performed using the jig 54. An operator may bend the sheet material 40 by hand in a state where the sheet material 40 is disposed on a plane on the assembly drawing board 50. Further, the operator may bend the sheet material 40 by holding the sheet material 40 by hand.

<About step (b)>
In the step (b), as shown in FIGS. 8 and 9, the temporary protector 30 is attached to the wire group 12 so as to cover the protection target portion disposed along the plane of the wire group 12.

  That is, the electric wire group 12 is disposed on the assembly drawing board 50 along a predetermined assembly plane along a predetermined work plane. At this time, the entire wire group 12 is preferably disposed along the work plane, but there may be a portion that is partially bent in a direction intersecting the work plane.

  Here, the part protected by the protector 20 in the electric wire group 12 is branched from the main line part 12a at the intermediate part in the extending direction of the main body part 31 and the main line part 12a accommodated in the long main body part 31. And a branched portion 12b.

  The trunk portion 12 a is accommodated in the first temporary accommodation portion 32 and the second temporary accommodation portion 34. Further, the branch portion 12b is guided outward so as to branch from the main line portion 12a through the opening 42dh of the branch guide portion 42d formed in the first side wall portion 42b.

  In this state, the binding member 18 such as an adhesive tape or a binding band is bound to the attachment portion 42ap and the wire group 12, and the same binding member 18 is bound to the attachment portion 44ap and the wire group 12. Thereby, both ends of the long main body 31 are attached to the electric wire group 12.

  Further, the same bundling member 18 is also bound to the branch fixing portion 42 bp of the branch guide portion 42 d and the branch portion 12 b of the wire group 12. Thereby, the trunk line portion 12a is positioned at a fixed position in the extending direction with respect to the long main body portion 31 at a position where the branch portion 12b branches.

  When the sheet material 40 is pushed into the sheet bending groove 55, the electric wire group 12 may be pushed against the first bottom portion 42a and the second bottom portion 44a of the sheet material 40. Thereby, the operation | work which bends the sheet | seat material 40 and the operation | work which covers the electric wire group 12 with the sheet | seat material 40 can be performed simultaneously. That is, step (a) and step (b) may be performed at the same time.

  The first lid portion 42c and the second lid portion 44c are configured to close the upper openings of the first temporary storage portion 32 and the second temporary storage portion 34 as appropriate in this step (b) or the next step (c). Closed. The first lid 42c and the second lid 44c are maintained in a closed state by overlapping the pair of first lids 42c and the pair of second lids 44c and joining them with an adhesive, a double-sided tape, a stapler, or the like. Alternatively, the insertion piece formed on the lid can be inserted into a slit formed on the other lid or the like and fixed.

<About step (c)>
In the step (c), as shown in FIG. 10, after the step (b), the temporary protector 30 (here, the long main body portion 31) is temporarily moved so that at least a part thereof intersects the work plane. The protector 30 is kept bent.

  That is, the first temporary storage portion 32 and the second temporary storage portion 34 are bent so that the second temporary storage portion 34 faces obliquely upward with respect to the first temporary storage portion 32 (arrow D in FIG. 10). reference). And in the state where the 1st temporary accommodation part 32 and the 2nd temporary accommodation part 34 make the predetermined angle according to the wiring route of wire harness 10, between the 1st temporary accommodation part 32 and the 2nd temporary accommodation part 34 Maintain the bending angle. Here, the first temporary storage portion 32 and the second temporary storage portion 34 are maintained by maintaining the overlapping portions of the pair of first side wall portions 42b and the pair of second side wall portions 44b in a predetermined overlapping state. And keep the bending angle constant. The superposition state of the pair of first side wall portions 42b and the pair of second side wall portions 44b can be maintained by, for example, bonding with an adhesive, a double-sided tape, a stapler, or the like, or the first side wall portion 42b and the second side wall portion 42b. The connecting portion 20q can be provided by inserting and fixing an insertion piece formed on one side of the side wall portion 44b into a slit formed on the other side. As a result, a bending portion 31 </ b> V is formed at the intermediate portion in the extending direction of the long main body portion 31.

  The bending operation of the long main body 31 may be performed while the first temporary housing portion 32 is disposed in the bending groove 55, or in a state where the long main body 31 is removed from the bending groove 55. You may go.

  When the second temporary storage portion 34 is bent with respect to the first temporary storage portion 32, the outer end portion of the first temporary storage portion 32 is attached to the wire group 12, and the outer end portion of the second temporary storage portion 34 is the wire group. 12 is attached. For this reason, according to a bending state, the dimension remainder of the electric wire group 12 may arise between the attachment locations. Here, in accordance with such a surplus or short dimension, the long main body 31 is bent while the bellows part 46 is stretched or contracted (stretched here). Occurrence of insufficient dimensions or excess dimensions is suppressed.

  Further, here, since the branch guide part 42 d is formed in the long body part 31, the electric wire group 12 is moved along the extending direction of the long body part 31 at the position of the branch guide part 42 d. I can't. Therefore, the position of the bending portion 31V is set between the branch guide portion 42d of the long main body portion 31 and the attachment portion 44ap at the end on one end side thereof, and the branch guide portion 42d of the long main body portion 31 is set. Thus, a bellows portion 46 as a length adjusting portion is formed on the side where the bent portion 31V is formed. Thereby, the excess or insufficient dimension of the electric wire group 12 caused by the bent portion 31V can be suppressed by the bellows portion 46 as the length adjusting portion.

  As described above, the wire harness 10 in which the protector 20 is attached to the electric wire group 12 can be manufactured by forming the bent portion 31V.

  FIGS. 11 and 12 are diagrams for explaining that an excess dimension of the electric wire group 12 occurs when the bellows portion 46 is not provided. FIGS. 13 and 14 are diagrams illustrating the electric wire group 12 provided with the bellows portion 46. It is a figure for demonstrating that the remainder of a dimension is suppressed.

  In the protector 120 shown in FIGS. 11 and 12, the first temporary storage portion 132 corresponding to the first temporary storage portion 32 and the second temporary storage portion 134 corresponding to the second temporary storage portion 34 are directly folded. It is connected to bendable. In this case, similarly to the above, it is assumed that both ends of the protector 120 are fixed to the wire group 12 and the first temporary storage portion 132 and the second temporary storage portion 134 are bent. Since the 1st temporary accommodation part 132 and the 2nd temporary accommodation part 134 are connected via the mutual bottom part, the 1st temporary accommodation part 132 and the 2nd temporary accommodation part 134 are attached so that the said bottom part may become an outer side. If it bends, the excess dimension will arise in the electric wire group 12 which passes the inner side of the bottom part, and the protrusion part 12p from the 1st temporary accommodation part 132 and the 2nd temporary accommodation part 34 will arise (refer FIG. 12).

  Therefore, as shown in FIGS. 13 and 14, the first temporary housing portion 32 and the second temporary housing portion 34 are connected via the bellows portion 46. Then, when the second temporary housing portion 34 is bent with respect to the first temporary housing portion 32, the bellows portion 46 is changed according to a change in the length connecting the attachment portions 42 ap and 44 ap at both ends of the long main body portion 31. Can be deformed to stretch. As a result, the dimensional surplus etc. of the electric wire group 12 are suppressed, and the electric wire group 12 is suppressed from protruding from the first temporary accommodation portion 32 and the second temporary accommodation portion 34. In addition, when the first bottom portion 42a and the second bottom portion 44a are bent outwardly, there is a possibility that the dimension of the electric wire group 12 may be insufficient. In this case, the long main body while the bellows portion 46 is contracted. If the portion 31 is bent, it is possible to suppress the shortage of the dimension of the electric wire group 12.

  In the above-described embodiment, the example in which the length adjusting unit is the bellows unit 46 has been described, but other configurations may be used.

  For example, as illustrated in FIG. 15, a configuration in which the two first slide portions 247 and the second slide portion 248 are slidably connected while being slidable may be employed as the length adjusting portion 246.

  More specifically, the length adjusting unit 246 includes a first slide unit 247 and a second slide unit 248. The first slide portion 247 has a configuration in which a pair of side wall portions 247b are erected on both sides of the bottom portion 247a. The second slide portion 248 has a configuration in which a pair of side wall portions 248b are erected on both sides of the bottom portion 248a. In addition, the outer width dimension of the second slide part 248 is approximately the same as the inner width dimension of the first slide part 247, and the second slide part 248 can slide within the first slide part 247. In addition, guide pieces 248c extending outward are formed on both sides of the bottom portion 248a of the second slide portion 248. Between the bottom portion 247a of the first slide portion 247 and the pair of side wall portions 247b, A guide slit 247s is formed in which the guide piece 248c can be slidably fitted. The second slide part 248 can slide within the first slide part 247 within a range in which the guide piece 248c can move within the guide slit 247s. The length adjusting unit 246 is realized by a structure in which the second slide unit 248 slides in the first slide unit 247.

  The length adjusting portion 246 is incorporated in the intermediate portion in the extending direction of the first temporary housing portion 32 or the second temporary housing portion 34 in the above-described embodiment, thereby eliminating the excess or short dimension of the wire group 12 with respect to bending. It can be stretched and deformed. However, when the branch guide portion 42d is provided as in the above-described embodiment, the length is adjusted to the side where the bent portion 31V is provided with respect to the branch guide portion 42d, that is, the second temporary housing portion 34. The part 246 may be incorporated. In this case, the bellows part 46 may be omitted, and the first temporary storage part 32 and the second temporary storage part 34 may be connected through one fold.

  According to this modification, the external shape of the protector can be made as small as possible.

<About the effects>
According to the method for manufacturing the wire harness 10 and the wire harness 10 configured as described above, the temporary protector 30 covers the protection target portion disposed along the work plane in the wire group 12. Therefore, the temporary protector 30 can be easily attached to the electric wire group 12.

  Moreover, in order to maintain the temporary protector 30 in a bent state so that at least a part of the temporary protector 30 intersects the work plane, the protector formed from the sheet material 40 through the form of the temporary protector 30. 20, the wire harness 10 can be three-dimensionally restricted.

  Also, here, at least one sheet material 40 is bent and processed into a long main body portion 31 extending along the work plane, and this is attached to the electric wire group 12, and then the long main body portion 31. Therefore, the temporary protector 30 can be easily attached to the electric wire group 12.

  Further, a bellows portion 46 is provided as a length adjusting portion that can be expanded and contracted between the plurality of attachment portions 42ap and 44ap in the long main body portion 31, and the bellows portion 46 is being stretched or contracted in the step (c). In order to bend the elongate main body 31, in the bent protector 20, it is possible to eliminate the dimensional excess or shortage of the wire group 12. Moreover, since the fixing location of the electric wire group 12 with respect to the sheet | seat material 40 etc. can be designed on a plane by this, design of the wire harness 10 becomes easy.

  Further, since the attachment portions 42ap and 44ap are provided at both end portions of the long main body portion 31, the attachment portions 42ap and 44ap at both ends of the long main body portion 31 are easily and firmly attached to the wire group 12. be able to.

  Further, when the branched portion 12 b is branched from the middle of the extending direction of the long main body portion 31, the portion of the trunk portion 12 a where the branched portion 12 b branches moves with respect to the extending direction of the long main body portion 31. hard. Therefore, by providing a bellows portion 46 as a length adjusting portion on the side of the long main body portion 31 where the bent portion 31V is formed with respect to the branch guide portion 42d, the dimensional remainder or size of the electric wire group 12 is provided. The shortage can be resolved.

  In addition, it is not essential that the branch part 12b branches in the middle of the extending direction of the elongate main-body part 31. FIG.

  Further, by providing the bellows portion 46 as the length adjusting portion, the length can be adjusted with a simple configuration in which the sheet material 40 is bent.

  In the present embodiment, the bellows portion 46 is provided at a position connecting the first bottom portion 42a and the second bottom portion 44a, but may be provided on a side wall portion or the like.

<Modification>
In the said embodiment, although the 1st temporary storage part 32 and the 2nd temporary storage part 34 demonstrated in the example connected via the bellows part 46 grade | etc., The 1st temporary storage part 32 and the 2nd temporary storage part 34, May be formed as a separate body. Even in this case, the first temporary storage portion and the second temporary storage portion constituting the temporary protector are mounted by the wire group so as to cover the portion to be protected arranged along the plane of the wire group. And, after that, by combining and connecting the first temporary storage portion and the second temporary storage portion in a state of forming a predetermined angle, the wire harness can be three-dimensionally regulated. be able to.

  As described above, the present invention has been described in detail. However, the above description is illustrative in all aspects, and the present invention is not limited thereto. It is understood that countless variations that are not illustrated can be envisaged without departing from the scope of the present invention.

DESCRIPTION OF SYMBOLS 10 Wire harness 12 Electric wire group 12a Trunk part 12b Branch part 18 Bundling member 20 Protector 20q Connection part 22 1st accommodating part 24 2nd accommodating part 30 Temporary protector 31 Long body part 31V Bending part 32 1st temporary accommodating part 34 2nd Temporary housing part 40 Sheet material 42ap, 44ap Mounting part 42d Branch guide part 46 Bellows part 50 Assembly drawing board 246 Length adjustment part 247 First slide part 248 Second slide member

Claims (10)

(A) bending the sheet material, processing it into a temporary protector capable of accommodating at least a part of the electric wire group, and disposing the temporary protector along a plane;
(B) attaching the temporary protector to the electric wire group so as to cover a portion to be protected disposed along the plane of the electric wire group;
(C) after the step (b), maintaining the temporary protector in a bent state so that at least a part of the temporary protector intersects the plane;
A method of manufacturing a wire harness comprising: It is a manufacturing method of the wire harness of Claim 1, Comprising:
The step (a) includes a step of bending the sheet material into a long main body extending in a long shape,
The step (b) includes a step of attaching the long body part to the wire group,
The step (c) includes a step of maintaining the elongated main body portion in a bent state so that at least a part of the elongated main body portion intersects the plane.
Manufacturing method of wire harness. It is a manufacturing method of the wire harness of Claim 2,
Attachment portions that are attached to the wire group are provided at a plurality of locations separated along the extending direction with respect to the elongated body portion, and the elongated body portion extends between the attachment portions. A length adjuster that can expand and contract along the direction is provided,
In the step (c), a method for manufacturing a wire harness, wherein the long main body portion is bent while the length adjusting portion is extended or contracted. It is a manufacturing method of the wire harness of Claim 3, Comprising:
The plurality of attachment portions are a method for manufacturing a wire harness, provided at both ends of the long main body portion. It is a manufacturing method of the wire harness of Claim 4, Comprising:
In the step (b), the electric wire group includes a main line portion accommodated in the long main body portion and a branch portion branched from the main line portion in an intermediate portion in the extending direction of the long main body portion. And a branch guide portion is formed to guide the branch portion to branch from the main line portion to the long main body portion,
In the step (c), a bent portion is formed between the branch guide portion and at least one end portion of the long main body portion,
The manufacturing method of the wire harness in which the said length adjustment part is provided in the part by which the said bending part is formed with respect to the said branch guide part among the said elongate main-body parts. It is a manufacturing method of the wire harness as described in any one of Claims 2-5,
The length adjusting unit is
The manufacturing method of a wire harness including the bellows-shaped part folded so that extension and contraction was possible along the extension direction of the said elongate main-body part. It is a manufacturing method of the wire harness as described in any one of Claims 2-5,
The length adjusting unit is
The manufacturing method of a wire harness including the structural part connected so that expansion and contraction is possible along the extension direction of the said elongate main-body part, while two members slide. A group of wires including a portion to be protected;
A protector attached to the wire group so as to cover the protection target part;
With
The protector includes a long main body formed by bending a sheet material, and is attached to the electric wire group at a plurality of locations separated along the extending direction with respect to the long main body. The wire harness is provided with a length adjusting portion that can be expanded and contracted along the extending direction of the long main body portion between the plurality of attachment portions. The wire harness according to claim 8,
The length adjusting unit is
A wire harness including a bellows-like portion folded in an extendable manner along the extending direction of the long main body. The wire harness according to claim 8,
The length adjusting unit is a wire harness including a component part in which two members are slidably connected while sliding.

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