JP2017168468A - Electric wire structure, electric connection structure, and method of producing electric wire structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric wire structure that allows a first covered electric wire and a second covered electric wire to be readily and accurately disposed at an electric wire group intersection to achieve a desired wiring pattern without any dedicated jig.SOLUTION: An electric wire structure is composed of a first covered electric wire 31A and a second covered electric wire 31B. The first covered electric wire 31A is composed of a covered electric wire 31 that is formed of an electric conductor 32 and an insulating cover 33 covering the electric conductor 32 and disposed in a first direction X. The second covered electric wire 31B is disposed in a second direction Y intersecting with the first direction X. An electric wire intersection 34 where the first covered electric wire 31A and the second covered electric wire 31B intersect has an intersecting electric wire set 30 where electric conductors 32 of the first and second covered electric wires are conductively joined. At an electric wire group intersection 20 where a plurality of first covered electric wires 31A disposed in parallel and a plurality of second covered electric wires 31B disposed in parallel intersect in the same plane, a plurality of intersecting electric wire sets 30 are disposed such that the first covered electric wires 31A are disposed in parallel and the second covered electric wires 31B are disposed in parallel.SELECTED DRAWING: Figure 2

Description

  According to the present invention, in the electric wire group crossing portion in which a plurality of electric wire crossing portions where the first covered electric wire and the second covered electric wire cross each other are arranged, the first covered electric wire and the second covered electric wire according to a desired wiring pattern The present invention relates to an electric wire structure, an electric connection structure, and a method for manufacturing the electric wire structure, in which the wire is electrically connected at a predetermined electric wire intersection (hereinafter also referred to as “conductive state”).

  In recent years, a lot of various electric devices such as a lamp, an audio, an ABS, and a rear camera are mounted on a vehicle. Wire harnesses for supplying electric power and control signals to these various electric devices are routed in the vehicle. When a common signal is input between the plurality of electric devices, it can be expected to reduce the cost by sharing the connector connected to the wire harness.

  However, since the number of pins of the connector of the wire harness is different for each grade or specification even in the difference in the vehicle type or in the same vehicle type, it has not been possible to share the connector correspondingly. For this reason, it is necessary to prepare a connector for each vehicle type, grade, and specification, and the cost cannot be reduced.

  Under such a background, by selecting and configuring the number of pins and pin positions according to the type of signals exchanged between electrical devices, regardless of differences in connection points, vehicle grades and specifications A connector that can be shared has been proposed.

The branch connector disclosed in Patent Document 1 below is one of them.
In the following branch connector, a plurality of press contact terminals 14 and 17 are arranged at predetermined positions of the connector main body 11, and a plurality of electric wires 18 and 18 ′ are crossed with each other in the horizontal and vertical directions of the connector main body 11. In this way, a branch circuit is constituted by arranging a plurality of electric wires 18, 18 'to a plurality of press contact terminals 14, 17 appropriately arranged on the front and back surfaces.

  However, the branch connector holds the electric wires in an arrayed state at a predetermined pitch by a dedicated jig such as a connector main body or a pressure contact terminal. Therefore, the electric wires cannot be held in the arrayed state. When such a dedicated jig is provided at a connection portion of a plurality of wire harnesses existing in a vehicle, there are problems that the cost is increased and that it is difficult to save space.

  Further, the press contact terminal can be arranged by press-contacting the press contact terminal at a predetermined position of the connector main body 11, but when the press contact terminal is press-contacted in this way, the press contact terminal is caused by vibration of the vehicle or the like. There is a risk of coming off. As described above, when the press contact terminal comes off, the connection state between the electric wire arranged on the front surface side and the electric wire arranged on the back surface side cannot be maintained, and there arises a problem that the conductive state between the electric wires cannot be secured.

JP 2001-0776779 A

  Therefore, the present invention easily and accurately arranges the first covered wire and the second covered wire so that a desired wiring pattern can be obtained without requiring a dedicated jig at the crossing portion of the wire group. It aims at provision of the electric wire structure which can do.

The present invention comprises a covered electric wire in which a conductor is covered with an insulating coating, the first covered electric wire arranged in a first direction and the second covered electric wire arranged in a second direction intersecting the first direction, A plurality of first covered electric wires provided with a crossed electric wire set in which the first covered electric wires and the second covered electric wires are connected to each other at the electric wire crossing portions and connected to each other in a conductive state, and arranged in parallel. And a plurality of second covered wires that are arranged in parallel with each other in the same plane, the plurality of first covered wires and the second covered wires are parallel to each other. The crossing electric wire set is arranged and configured , and includes a holding and holding unit that holds and holds the crossing portion of the electric wire group, and the holding and holding unit is arranged to be stacked in the thickness direction in the same plane. The covered wire and the second covered wire are abbreviated Wherein the holding groove for fitting holding the child shape is formed.

  According to the present invention, the first covered electric wire and the second covered electric wire can be easily and accurately arranged so as to have a desired wiring pattern without requiring a dedicated jig at the electric wire group intersection. Can be arranged.

In addition, the wire connection structure can be configured in an appropriate form according to various functions and installation locations by appropriately changing the number of crossed wire sets and the arrangement form thereof. Can be used in common.
Thereby, the cost reduction and space saving of an electric wire structure can be achieved.

  Further, by arranging a plurality of crossed wire sets that are integrated in advance in the wire group crossing group, a crossed wire structure that is more electrically reliable can be configured.

  Moreover, according to the structure mentioned above, the outstanding integrity in the cross | intersection part of the said 1st covered electric wire and the said 2nd covered electric wire can be acquired, and a more electrically reliable crossing electric wire structure is comprised. I can do it.

  Moreover, according to the structure mentioned above, while the some edge part of the covered electric wire located in the edge part side of the said electric wire crossing part can be formed as a connection terminal, these several connection terminals are made to 1st direction or 2nd. Since it can arrange | position in planar shape instead of the linear form along a direction, an electric wire structure can be comprised as a branch connection means provided with many connection terminals, without requiring installation space.

  Here, the conductor may be formed of a single wire made of a single wire, or may be formed of a stranded wire obtained by twisting a plurality of strands. In addition, the twisted wire includes a twisted pair wire (twisted pair cable) obtained by twisting two covered electric wires. The conductor may be covered with a shield member such as a net-like metal member or metal foil and formed as a core wire.

  In addition, in a state where a plurality of crossed wire sets are arranged, a wire crossing portion where a covered wire constituting a predetermined crossed wire set and a covered wire constituting another crossed wire set cross is in a conductive state or a non-conductive state. Any of these may be used.

In addition, bending in a zigzag shape means bending in a zigzag shape.
In addition, the first covered electric wire is not limited to bend in a zigzag shape, and a plurality of the first covered electric wires are formed for each length corresponding to one side of the electric wire group intersecting portion, and the plural electric wire group intersecting portions are stacked. For example, a configuration in which the electric wire group intersections are stacked is not particularly limited.

In addition, by accommodating and holding the wire group intersection in the housing and holding means, the plurality of first covered wires arranged in parallel and the plurality of second covered wires arranged in parallel have a predetermined pitch and angle. Can be held to keep.

By storing and holding the electric wire group intersection in the holding and holding means, it is possible to ensure insulation between the conductors at the electric wire crossing portion where the conductors are joined to each other, which is superior to the case where no holding and holding means is provided. Electrical characteristics can be obtained.

  As an aspect of this invention, the said covered electric wire can be equipped with one conductor per one.

According to the above-described configuration, the first cross section is formed by arranging a plurality of crossed electric wire sets so as to obtain a desired wiring pattern without arranging a plurality of flat cables so as to cross each other at the electric wire group crossing portion. It is possible to easily and accurately arrange the covered electric wire and the second covered electric wire in a state where they are arranged in parallel.
Therefore, since the electric wire structure can be configured by using the covered electric wire whose unit price is lower than that of the flat cable with the same number of conductors, a significant cost reduction can be achieved.

  Further, as an aspect of the present invention, the plurality of second covered electric wires are crossed with the crossed electric wire set being spaced apart in the longitudinal direction with respect to the first covered electric wire, and the crossing portions are connected to a conductive state. Can be configured.

  According to the above-described configuration, it is possible to configure a plurality of electric wire group crossing portions at intervals along the longitudinal direction of the first covered electric wire, that is, the first direction, and wiring with more variations. An electric wire structure having a pattern can be configured.

  As an aspect of the present invention, the first covered electric wire can be cut at one place or a plurality of places in the longitudinal direction.

  As described above, the first covered electric wire is cut at one or more places in the longitudinal direction, so that the conductive state of the first covered electric wire can be made non-conductive at the cut place. Depending on which part in the longitudinal direction of the covered electric wire is to be cut, an electric wire structure having a complicated wiring pattern rich in variations can be constructed.

  Moreover, as an aspect of the present invention, a harness can be connected to the end portion of the second covered electric wire in the electric wire structure described above.

  According to the above-described configuration, by storing and holding the wire group intersection in the holding and holding means, it is possible to obtain a wire structure that realizes cost reduction and space saving of the wire structure, and is electrically reliable. High electrical connection structure can be configured.

According to the present invention, a covered electric wire in which a conductor is covered with an insulating coating is composed of a first covered electric wire arranged in a first direction and a second covered electric wire arranged in a second direction intersecting the first direction, While peeling off the insulation coating at the intersection with the second covered wire in the longitudinal direction of the first covered wire, peeling off the insulation coating at the intersection with the first covered wire in the longitudinal direction of the second covered wire An insulation coating peeling step that constitutes a conductor exposed portion where the conductor is exposed, and a cross placement step of crossing the first covered electric wire and the second covered electric wire so that the exposed portions of the conductors are in contact with each other. The conductor exposed portions of the first covered electric wire and the second covered electric wire are joined to each other, and the conductors of the first covered electric wire and the second covered electric wire are electrically connected to each other at the intersecting portion. Conductive intersection And a conductor joining step for forming a crossed wire set in which the first covered wire and the second covered wire are connected in a conductive state by the conductive crossing portion, and a plurality of first covered wires arranged in parallel. In the wire group intersection where the plurality of second covered wires arranged in parallel intersect in the same plane, the plurality of the intersections so that the first covered wires and the second covered wires are parallel to each other. The first covered electric wire and the second electric wire in the electric wire crossing portion are formed in the holding groove portion formed in a lattice shape in the crossing electric wire set arrangement step of arranging the electric wire set and the holding holding means for receiving and holding the electric wire group crossing portion. It is a manufacturing method of the electric wire structure which carries out the holding | maintenance holding | maintenance process which makes a holding | maintenance means accommodate and hold | maintain the said electric wire group cross | intersection part by fittingly holding a covered electric wire in this order .

  In the above-described crossed wire set arrangement step, only the crossed wire sets are arranged so that the first covered wires and the second covered wires are parallel to each other at the wire group crossing portion. Well, there is no need to perform an insulation coating peeling step or a conductor joining step in the crossed wire assembly arrangement step.

  For this reason, in the crossed wire assembly arrangement process, there is a possibility that the arrangement pitch and the arrangement angle of the plurality of covered wires arranged in parallel are shifted as in the conventional manufacturing method such as joining the conductors of the covered wires crossing each other. Therefore, the electric wire structure can be manufactured accurately and easily.

  As an aspect of the present invention, in the conductor joining step, laser irradiation is performed from the gap between the insulation coating of the first covered wire and the insulation coating of the second covered wire toward the contact portion where the conductor exposed portions are in contact with each other. Can do.

  According to the structure mentioned above, the contact part which the said conductor exposed parts contact can be joined to a conduction | electrical_connection state by laser irradiation. Since laser irradiation can be firmly joined with high energy at a pinpoint, when joining the conductors of the first covered electric wire and the second covered electric wire, the insulation coating of each covered electric wire is circumferentially and longitudinally. In this case, it is not necessary to peel and remove in a wide range, and it is possible to perform spot welding with a laser through at least a minimum gap between the insulating coatings of the covered electric wire where laser irradiation is possible.

  This enables strong bonding with a laser and prevents moisture from adhering to the exposed conductor and intruding into the coated wire between the conductor and the insulation coating. Characteristics can be obtained.

  Further, as an aspect of the present invention, in the conductor joining step, either one of the positive electrode and the negative electrode is brought into contact with the conductor exposed portion of the first covered electric wire, and the conductor exposed of the second covered electric wire The other electrode is brought into contact with the portion, and a current capable of welding the exposed conductors can be passed between the one electrode and the other electrode.

  According to the configuration described above, one electrode is brought into contact with the conductor exposed portion of the first covered electric wire, and the other electrode is brought into contact with the conductor exposed portion of the second covered electric wire. By energizing between the exposed portions, the conductor exposed portions can be strongly resistance-welded using heat generated by the resistance of the conductor exposed portions.

  Here, the bonding between the conductors is not limited to resistance welding using a laser or an electrode as described above, but a conductive adhesive is applied, ultrasonic connection, soldering, or a combination of these is performed. It can be joined by means.

  Further, as an aspect of the present invention, after the crossing wire assembly arrangement step, a zigzag folding step of bending the first covered wires in a zigzag shape in the longitudinal direction so that the plurality of wire group crossing portions are stacked in the thickness direction It can be performed.

  According to the manufacturing method described above, by performing the zigzag folding step, a plurality of ends of the covered electric wire positioned on the end side of the electric wire intersection can be formed as connection terminals, and the plurality of connection terminals are It is possible to manufacture a wire structure arranged in a planar shape instead of a linear shape along one direction or the second direction, and this wire structure is provided with a large number of connection terminals without requiring installation space. It can be configured as a branch connection means.

  As an aspect of the present invention, after the crossed wire group arrangement step, a wire holding means housing step for housing the parallel wire group intersecting portion can be performed on the housing holding means for housing and holding the wire group intersecting portion.

  By performing the above-described electric wire accommodating means accommodating step, the electric wire group intersecting portion can be accommodated and held in the accommodating holding means, and thereby the plurality of first covered electric wires arranged in parallel and the plurality of the arranged electric wires arranged in parallel. The second covered electric wire can be held so as to maintain a predetermined pitch and angle.

  Furthermore, by accommodating and holding the electric wire group intersection in the accommodating and holding means, it is possible to prevent moisture from adhering at the electric wire intersection where the conductors are joined to each other, and to ensure insulation between the conductors. Excellent electrical characteristics can be obtained as compared with the case where no is provided.

  According to the present invention, the first covered electric wire and the second covered electric wire can be easily and accurately arranged so as to have a desired wiring pattern without requiring a dedicated jig at the electric wire group crossing portion. The electric wire structure which can be arrange | positioned can be provided.

The top view of the harness connection structure which wired the some wire harness. The perspective view of a branch connector. The disassembled perspective view of a branch connector. Structure explanatory drawing of the electric wire group crossing part which has arrange | positioned several crossed electric wire groups. The top view of a branch connector. Structure explanatory drawing of an electric wire group crossing part. Explanatory drawing of the conductor joining process which joins conductors using a pair of electrode. Explanatory drawing of the cross arrangement process which cross | intersects a 1st covered electric wire and a 2nd covered electric wire. Explanatory drawing which showed the mode of the conductor joining process by laser irradiation by the cross section. Explanatory drawing which showed the mode of the conductor joining process with the top view. The top view of the branch connector which comprised the some electric wire group crossing part along the X direction. The side view of the branch connector which bent the 1st covered electric wire in the shape of a spell for every electric wire group crossing part.

An embodiment of the present invention will be described below with reference to the drawings.
(First embodiment)
In a vehicle such as an automobile, a harness connection structure 1 that establishes an electrical connection by mutually connecting a power source, a control device such as an ECU (Electronic Control Unit), and an electrical device such as an audio device or a direction indicator, As shown in FIG. 1, it comprises a wire harness W and a branch connector 10 that connects these wire harnesses W.

  The wire harness W is constituted by a main harness Wm connected to a power source or a control device, and a branch harness Ws that branches from the main harness Wm and has a connector C connected to each electric device at the end, and a branch connector 10 is configured to be connected to at least one of the backbone harness Wm and the branch harness Ws.

  The branch connector 10 in such a harness connection structure 1 is demonstrated in detail using FIG. 2 thru | or FIG.

  As shown in FIGS. 2 to 4, the branch connector 10 includes a wire group crossing portion 20 in which a plurality of covered wires 31 are arranged in a substantially lattice shape, and a holder 50 that holds the wire group crossing portion 20. Yes.

  As shown in FIG. 4, the wire group crossing portion 20 includes a crossed wire set 30 that is integrally formed so that the first covered wire 31 </ b> A and the second covered wire 31 </ b> B that are substantially orthogonal to each other in plan view can be made conductive. It is configured by superimposing a plurality.

  In the following description, the X direction indicates the longitudinal direction of the first covered electric wires 31A arranged in parallel, and the Y direction indicates the longitudinal direction of the second covered electric wires 31B arranged in parallel.

  More specifically, the first covered electric wire 31A and the second covered electric wire 31B are composed of a conductive core wire 32 (32A, 32B) and an insulating insulating coating 33 (33A, 33B) covering the core wires 32A, 32B. It is composed. Further, in the first covered electric wire 31A and the second covered electric wire 31B, the conductor exposed portions 32A1 and 32B1 that expose the core wires 32A and 32B, respectively, are removed from the predetermined range in the insulating coatings 33A and 33B over the entire circumference. Formed.

  In addition, as shown in FIG. 1, as for the 1st covered electric wire 31A, while the one end side derived | led-out from the branch connector 10 can connect the branch harness Ws, the other end side can connect the backbone harness Wm. On the other hand, as for the 2nd covered electric wire 31B, the both ends derived | led-out from the branch connector 10 can connect the branch harness Ws.

  One set of crossed electric wires 30 is arranged so that the longitudinal direction of the second covered electric wire 31B is substantially orthogonal to the longitudinal direction of the first covered electric wire 31A, and the conductor exposed portion 32A1 of the first covered electric wire 31A; The conductor exposed portion 32B1 of the second covered electric wire 31B is welded. In addition, the welding part 60 which welded conductor exposed part 32A1, 32B1 mutually is formed in the electric wire crossing part 34 (welding location) of the core wire 32A of the 1st covered electric wire 31A, and the core wire 32B of the 2nd covered electric wire 31B. ing.

  As shown in FIGS. 4 and 5, the wire group crossing portion 20 is configured by overlapping a plurality of crossed wire sets 30 such that the first covered wires 31 </ b> A are arranged in parallel and the second covered wires 31 </ b> B are arranged in parallel. doing. At this time, the electric wire group crossing portion 20 is arranged so that the welding portion 60 is arranged at a predetermined interval in the order in which the crossing electric wire sets 30 are superimposed on a diagonal line in a substantially lattice shape. The crossed wire set 30 is overlapped from one side with respect to the surface to be configured.

  Moreover, while setting the crossing part of 31 A of 1st covered electric wires and the 2nd covered electric wire 31B in the crossed electric wire set 30 to the electric wire crossing part in the same set, the covered electric wire 31 in the predetermined crossed electric wire set 30 and other The crossing portion of the crossing wire set 30 with the covered wire 31 is set as the crossing portion between the other sets of wires, and the wire crossing portion 34 in the crossing portion 20 of the wire group is composed of a plurality of crossing wires within the same set and crossing portions of the crossing wires. It consists of.

  Specifically, as shown in FIGS. 5 and 6, the second group of covered wires 31 </ b> B in five rows are arranged from the right to the left in the state shown in FIGS. In addition, five rows of first covered electric wires 31A are arranged from the top to the bottom, and a plurality of electric wire intersections 34 are arranged in a state of five rows and five columns accordingly.

  Here, as shown in FIG. 6, each of the plurality of electric wire intersections 34 is made to correspond to the covered electric wires 31 arranged in a 5 × 5 grid, and each of them is R11 to R15, R21 to R25, R311. R35, R41 to R45, R51 to R55 are set.

  At this time, among the plurality of electric wire crossing portions 34 (R11 to R15, R21 to R25, R31 to R35, R41 to R45, R51 to R55), It is a wire conduction state intersection where the first covered wire 31A and the second covered wire 31B are connected in a conductive state.

  On the other hand, among the plurality of electric wire crossing portions 34 (R11 to R15, R21 to R25, R31 to R35, R41 to R45, R51 to R55), the inter-set wire crossing portions R12 to R15, R21, R23 to R25, R31, R32, R34, R35, R41 to R43, R45, R51 to R54 are wire non-conductive state intersections where the first covered wire 31A and the second covered wire 31B are connected in a non-conductive state.

  The holder 50 is formed in a size capable of accommodating and holding the wire group intersection 20 with an insulating synthetic resin or the like. In the holder 50, holding groove portions 51 for fitting and holding the first covered wire 31A and the second covered wire 31B at the wire group crossing portion 20 are formed in a substantially lattice shape.

Next, a method of forming the crossed wire set 30 by welding the first covered wire 31A and the second covered wire 31B described above will be described in detail with reference to FIG.
[Production Method Example 1]
First, as the insulation coating peeling step, the core wire 32A is exposed from the conductor exposed portion 32A1 in which a predetermined portion of the first covered electric wire 31A is irradiated with, for example, a laser L to remove the entire circumference of the insulation coating 33A in a predetermined range in the longitudinal direction. Let Similarly, with respect to the second covered electric wire 31B, the insulation coating 33B is removed to expose the core wire 32B from the conductor exposed portion 32B1.

  And as a crossing arrangement | positioning process, while making conductor exposed part 32B1 of 2nd covered electric wire 31B contact conductor exposed part 32A1 of 1st covered electric wire 31A, the longitudinal direction of 31 A of 1st covered electric wires and 2nd covered electric wire 31B Overlapping is performed so that the longitudinal direction is perpendicular to each other.

  Then, as a conductor joining step, as shown in FIG. 7, the conductor exposed portion 32A1 in the first covered electric wire 31A and the conductor exposed portion 32B1 in the second covered electric wire 31B are cored with a pair of probes 200a and 200b (200). The core wire 32A of the first covered electric wire 31A and the core wire 32B of the second covered electric wire 31B are bonded by resistance welding in which a current flows between the pair of probes 200a and 200b while being crimped in the lateral direction (short direction) of 32A and 32B. Weld.

  A cross-shaped crossed wire set 30 formed by welding the first covered wire 31A and the second covered wire 31B in this way is used as a constituent element, and a plurality of these crossed wire sets 30 are provided as a crossed wire set placement step. The electric wire group crossing portion 20 is configured by overlapping.

  Then, as a holder accommodation process, after the electric wire group intersection part 20 is accommodated and held in the holder 50, an insulating synthetic resin (not shown) is poured into the holder 50 to fix the electric wire group intersection part 20 to the holder 50. The branch connector 10 is configured by covering the core wire 32A of the first covered electric wire 31A and the core wire 32B of the second covered electric wire 31B.

  The branch connector 10 having the above-described configuration can provide the following operations and effects.

  According to the branch connector 10 of the first embodiment, the covered electric wire 31 in which the core wire 32 is covered with the insulating coating 33 is arranged in the first covered electric wire 31A arranged in the X direction and in the Y direction intersecting the X direction. In the electric wire crossing part 34 which is composed of the two covered electric wires 31B and is an intersection of the first covered electric wire 31A and the second covered electric wire 31B, the conductor exposed portions 32A1 and 32B1 are joined to each other and connected to the conductive state. The crossed electric wire set 30 configured as described above is provided.

  Further, the branch connector 10 includes the first covered electric wires 31A at the electric wire group intersection portion 20 where the plurality of first covered electric wires 31A arranged in parallel and the plurality of second covered electric wires 31B arranged in parallel intersect in the same plane. And the 2nd covered electric wire 31B is the structure which has arrange | positioned and comprised the some crossed electric wire set 30 so that it might mutually become parallel.

  With such a configuration, the branch connector 10 has the first covered electric wire 31A and the second covered electric wire 31B so as to have a desired wiring pattern at the electric wire group intersection 20 without requiring a dedicated jig. Can be arranged easily and accurately.

Further, the branch connector 10 can be configured in an appropriate form according to various functions and installation locations by appropriately changing the number of the crossed wire sets 30 and the arrangement form thereof. The parts as the connector 10 can be shared.
Thereby, cost reduction and space saving of the branch connector 10 can be achieved.

  Furthermore, it is possible to configure the branch connector 10 that is electrically more reliable by arranging a plurality of crossed wire sets 30 that are integrally configured in advance at the wire group crossing portion 20.

  Specifically, as in the prior art, a plurality of first covered wires 31A are arranged in parallel in the X direction and a plurality of second covered wires 31B are arranged in parallel in the Y direction, and then the first covered wires 31A and the second Of the plurality of wire intersections 34 with the covered wire 31B, when it is attempted to connect the covered wires 31 in a conductive state for each appropriate wire crossing portion 34, the arrangement direction and pitch of the covered wire 31 are determined at that time. There is a problem that it becomes easy to shift, and it becomes difficult to maintain a predetermined arrangement state.

  In addition, for such a problem, it may be possible to provide a dedicated jig capable of holding the plurality of first covered wires 31A and the second covered wires 31B in a predetermined arrangement state. It is necessary to change the size and shape of the jig in accordance with the diameter and the number of the covered electric wires 31 to be arranged at the intersection, and in order to cope with this, it is necessary to provide jigs of various sizes and shapes. The problem of increased costs arises.

  That is, in the case of a configuration in which a plurality of covered electric wires 31 are held by a jig, it cannot cope with the difference in wire diameter for each of the plurality of covered electric wires 31, and the covered electric wires 31 cannot be held firmly, resulting in vibration of the vehicle. In connection with the problem that the conductive state between the covered wires 31 cannot be secured due to rattling or the jig cannot be configured with an appropriate size according to the installation location, space saving and cost reduction cannot be achieved. There was a risk of problems.

  On the other hand, according to the branch connector 10 of the present embodiment, the first covered electric wire 31A and the second covered electric wire 31B are electrically connected by joining the exposed conductor portions 32A1 and 32B1 to each other at the intersection. A plurality of crossed electric wire sets 30 connected in a state are configured in advance, and the plurality of crossed electric wire sets 30 are arranged so that the first covered electric wires 31A and the second covered electric wires 31B are mutually in the same plane. An electric wire structure can be comprised in the electric wire group crossing part 20 by arrange | positioning so that it may become parallel.

  For this reason, the branch connector 10 can be comprised only by arrange | positioning the some crossing electric wire set 30 comprised previously in the electric wire group crossing part 20. FIG.

  Accordingly, the branch connector 10 in which the plurality of first covered electric wires 31A arranged in the X direction and the plurality of second covered electric wires 31B arranged in the Y direction intersecting with the X direction intersect with each other in a conductive state is used. Can be configured accurately and easily without the need for a special jig for holding the components in a parallel array.

Moreover, since the branch connector 10 can be configured in an appropriate form according to various functions and installation locations by appropriately changing the number of arrangements of the crossed wire sets 30 and their arrangement form, The parts as the electric wire set 30 can be shared.
Thereby, cost reduction and space saving of the crossed wire assembly 30 can be achieved.

  Moreover, according to the structure mentioned above, the outstanding integration in the cross | intersection part of 31 A of 1st covered electric wires and the 2nd covered electric wires 31B can be obtained, and the more highly reliable branch connector 10 is comprised. I can do it.

  More specifically, the branch connector 10 of the present embodiment has the first covered electric wire 31A and the second covered electric wire 31B before arranging each of the plurality of first covered electric wires 31A and the second covered electric wires 31B at the intersections. Are configured in advance, and these crossed wire sets 30 are appropriately arranged at the crossing portions.

  For this reason, since it is the structure which arrange | positions the crossing electric wire set 30 integrated previously beforehand, each of several 1st covering electric wire 31A and 2nd covering electric wire 31B is arrange | positioned independently in an intersection part, and after that, 1st Compared to the case where the covered electric wire 31A and the second covered electric wire 31B are joined to each other at the electric wire intersection 34, the covered electric wire 31 is feared that the arrangement state of the first covered electric wire 31A and the second covered electric wire 31B may be destroyed. There is no need to join each other.

  And the branch connector 10 of 1st Embodiment is not the structure which inserts a pressure-contact terminal in a crossing part, and press-connects and connects with the covered electric wire 31 like the past, for example, but the 1st covered electric wire 31A Since the conductor-exposed portions 32A1 and 32B1 of the second covered electric wire 31B are joined to each other so that the covered electric wires 31 are connected to each other, the crossed electric wire set 30 having strong integrity can be obtained.

  Therefore, for example, it is possible to prevent a situation in which the pressure contact portion of the pressure contact terminal is loosened and gradually comes off with the vibration of the vehicle.

  For the reasons described above, it is possible to obtain excellent integrity at the intersection between the first covered electric wire 31A and the second covered electric wire 31B, and it is possible to configure the branch connector 10 that is more electrically reliable.

  Furthermore, the covered electric wire 31 provided in the branch connector 10 of the first embodiment has a configuration including one core wire 32 per one.

  According to the configuration described above, in the electric wire group intersecting portion 20, it is possible to obtain a desired wiring pattern only by arranging a plurality of crossed electric wire sets 30 without arranging a plurality of flat cables so as to cross each other. The first covered electric wire 31A and the second covered electric wire 31B can be easily and accurately arranged in a state where the first covered electric wire 31A and the second covered electric wire 31B are arranged in parallel.

  Therefore, since the electric wire structure can be configured at the electric wire group crossing portion 20 using the covered electric wires 31 having the same number of core wires 32 and having a unit price lower than that of the flat cable, a significant cost reduction can be achieved.

  Furthermore, according to the branch connector 10 of the first embodiment, the intersecting wire set 30 intersects the first covered wire 31A with a plurality of second covered wires 31B at intervals in the longitudinal direction, Since the wire crossing portion 34 is configured to be connected in a conductive state, a plurality of wire group crossing portions 20 can be formed at intervals along the longitudinal direction of the first covered wire 31A, that is, along the X direction. Thus, an electric wire structure having a wiring pattern rich in variations can be configured.

  Moreover, according to the branch connector 10 of 1st Embodiment, by providing the holder 50 which accommodates and hold | maintains the electric wire group crossing part 20, several 1st covering electric wire 31A arrange | positioned in parallel and several 2nd arranged in parallel. The covered electric wire 31B can be held so as to maintain a predetermined pitch and angle.

  By accommodating and holding the wire group intersection 20 in the holder 50, moisture is prevented from adhering at the wire intersection 34 where the conductor exposed portions 32A1 and 32B1 are joined to each other, and the insulation between the conductor exposed portions 32A1 and 32B1 is prevented. Therefore, superior electrical characteristics can be obtained as compared with the case where the holder 50 is not provided.

Moreover, the manufacturing method of the branch connector 10 of 1st Embodiment can have the following effects | actions and effects.
In the method of manufacturing the branch connector 10 according to the first embodiment, in the crossed wire assembly arrangement step, the first covered wires 31A and the second covered wires 31B are parallel to each other at the wire group crossing portion 20. Thus, it is only necessary to arrange a plurality of crossed wire sets 30, and there is a merit that it is not necessary to perform an insulating coating peeling step and a conductor joining step in the crossed wire set arranging step.

  For this reason, in the crossed electric wire assembly arrangement step, the arrangement pitch and arrangement of the plurality of covered electric wires 31 arranged in parallel as in the conventional manufacturing method such as joining conductor exposed portions 32A1 and 32B1 of the covered electric wires 31 intersecting each other. The electric wire structure can be manufactured accurately and easily without the risk of an angle shift.

In particular, in the conductor joining step, the positive electrode probe 200a is brought into contact with the conductor exposed portion 32A1 of the first covered electric wire 31A, and the negative electrode probe 200b is brought into contact with the conductor exposed portion 32B1 of the second covered electric wire 31B. Between the two probes 200 (200a and 200b), a current that can weld the conductor exposed portions 32A1 and 32B1 is energized, thereby utilizing the heat generated by the resistance of the conductor exposed portions 32A1 and 32B1 to expose the conductor exposed portions 32A1. , 32B1 can be strongly resistance welded together.
Further, in the crossing wire assembly arrangement step, when the crossing wire assembly 30 is superposed in a substantially lattice shape, as described above, the crossing wire assembly 30 is already arranged from one side in the thickness direction of the wire group crossing portion 20. Are arranged so as to overlap another cross electric wire set 30.

  Thereby, conductor exposed part 32A1, 32B1 can be maintained in the joining state which was excellent in the electric wire crossing part 34 of 31 A of 1st covered electric wires and the 2nd covered electric wire 31B which comprise the crossed electric wire set 30. FIG.

  Specifically, when the crossed wire set 30 is superimposed in a substantially lattice shape, the second covered wire 31B in the crossed wire set 30 to be newly placed with respect to the first covered wire 31A in the already placed crossed wire set 30. It is necessary to make you speak like If it does so, since load will be applied to the electric wire crossing part 34 which conductor exposed part 32A1, 32B1 in the already arranged crossed electric wire set 30 has joined, there exists a possibility that joining of conductor exposed part 32A1, 32B1 may space apart.

  On the other hand, in the manufacturing method of the branch connector 10 according to the first embodiment, when the crossed wire sets 30 are overlapped in a substantially lattice shape in the crossed wire set arranging step, as described above, When the crossed wire set 30 is superposed in a substantially lattice shape by arranging the crossed wire set 30 so as to overlap with the crossed wire set 30 already arranged from one side in the thickness direction, the wire crossing portion Since no load is applied to 34, the conductor exposed portions 32 </ b> A <b> 1 and 32 </ b> B <b> 1 in the electric wire group intersecting portion 20 can be kept in an excellent joined state.

[Production Method Example 2]
Next, an example in which the method of forming the crossed wire set 30 by welding the first covered wire 31A and the second covered wire 31B in the conductor joining step is different from the manufacturing method example 1 in FIGS. 8 to 10. Will be described in detail.
In addition, the same structure as the above-mentioned manufacturing method example 1 attaches | subjects the same code | symbol, and abbreviate | omits the detailed description. Here, FIG. 8 shows an explanatory view of a conductor joining step in which one of the covered electric wires 31 crossed with each other is shown in a state of joining the conductor exposed portions 32A1 and 32B1 by laser irradiation. FIG. 9 is an explanatory diagram of the conductor joining process showing a state where the conductor exposed portions 32A1 and 32B1 are joined together by laser irradiation in a plan view.

  First, the crossed wire set 30 in the manufacturing method example 2 forms the conductor exposed portions 32A1 and 32B1 by removing half of the peripheral surface of the insulating coating 33A of the first covered wire 31A and the insulating coating 33B of the second covered wire 31B. After that, the conductor exposed portions 32A1 and 32B1 are welded together by laser spot welding.

  Specifically, a predetermined portion of the first covered electric wire 31A is irradiated with a laser L, for example, and as shown in FIG. 8A, the insulating coating 33A in a predetermined range in the longitudinal direction is removed by a half circumference to expose the core wire 32A. The exposed conductor exposed portion 32A1 is formed. Similarly, with respect to the second covered electric wire 31B, the conductor covering portion 32B1 is formed by removing the insulating coating and exposing the core wire 32B.

  And as shown in FIG.8 (b), while making conductor exposed part 32B1 of 2nd covered electric wire 31B contact conductor exposed part 32A1 of 1st covered electric wire 31A, the longitudinal direction of 31 A of 1st covered electric wires and They are overlapped so that the longitudinal direction of the second covered electric wire 31B is orthogonal.

  Thereafter, as shown in FIG. 9, the first covered electric wire 31A and the second covered electric wire 32A1 are in contact with the conductor exposed portion 32A1 in the first covered electric wire 31A and the conductor exposed portion 32B1 in the second covered electric wire 31B. Laser L is irradiated from a laser irradiation unit 210a of a laser welding machine (not shown) as a laser welding means from the gap between the insulation coatings 33A and 33B to the covered wire 31B toward the contact portion between the conductor exposed portions 32A1 and 32B1. .

  At this time, as shown in FIG. 10, the core wire 32A of the first covered electric wire 31A and the core wire 32B of the second covered electric wire 31B are separated by a laser irradiation unit 210a, for example, along the longitudinal direction of the second covered electric wire 31B. The core wires 32A and 32B are welded together while forming the welded portion 60.

  The plurality of crossed wire sets 30 formed by welding the first covered wire 31 </ b> A and the second covered wire 31 </ b> B in this way are overlapped to constitute the wire group crossing portion 20. After that, the branch connector 10 is configured by accommodating and holding the wire group intersection 20 in the holder 50.

  The manufacturing method example 2 using the laser welding machine mentioned above can have the following operations and effects.

  In the manufacturing method example 2, as described above, in the conductor joining step, the conductor exposed portions 32A1 and 32B1 are in contact with each other through the gap between the insulating coating 33A of the first covered electric wire 31A and the insulating coating 33B of the second covered electric wire 31B. This is a manufacturing method in which laser irradiation is performed toward a portion.

  According to the structure mentioned above, the contact part which conductor exposed part 32A1, 32B1 contacts can be joined to a conduction | electrical_connection state by laser irradiation. Since laser irradiation can be firmly joined with high energy at a pinpoint, when joining the exposed conductor portions 32A1 and 32B1 between the first covered electric wire 31A and the second covered electric wire 31B, the insulation coatings 33A, 33B does not need to be peeled and removed in a wide range in the circumferential direction and the longitudinal direction, and can be spot-welded with the laser L through at least the minimum gap between the insulating coatings 33 of the covered electric wire 31 that can be irradiated with laser. .

  As a result, strong bonding by the laser L is possible, and moisture adheres to the conductor exposed portions 32A1 and 32B1 and prevents moisture from entering the covered electric wire 31 between the core wire 32 and the insulating coating 33. Therefore, excellent electrical characteristics can be obtained.

Subsequently, a branch connector 10P2 in another embodiment will be described.
However, in the configuration of the branch connector 10P2 described below, the same components as those of the branch connector 10 in the first embodiment described above are denoted by the same reference numerals, and the description thereof is omitted.

(Second Embodiment)
The configuration of the branch connector 10P2 in the second embodiment will be described with reference to FIG.
The branch connector 10P2 in the second embodiment includes a plurality of holders 50 and a plurality of electric wire group intersections 20.
More specifically, the branch connector 10P2 forms the first covered electric wire 31A constituting the crossed wire set 30 to be longer than the length corresponding to the electric wire group crossing portion 20, and the first covered electric wire 31A. The plurality of second covered electric wires 31B are crossed at a constant interval in the X direction (longitudinal direction), and the crossing portions are connected to a conductive state.

  That is, the branch connector 10P2 arranges the plurality of wire group intersecting portions 20 at regular intervals along the longitudinal direction of the first covered wire 31A, and holds and holds each wire group intersecting portion 20 in the holder 50. It is a configuration.

  According to the above-described configuration, it is possible to configure a plurality of wire group crossing portions 20 at regular intervals along the longitudinal direction of the first covered wire 31 </ b> A, that is, the X direction. Even complicated wiring patterns can be constructed.

  As described above, the first covered wire 31A is cut at one or more places in the longitudinal direction, so that the conductive state of the first covered wire 31A can be made non-conductive at the cut portion. Depending on which part in the longitudinal direction of the electric wire 31A is to be cut, a complicated wiring pattern rich in variations can be constructed.

(Third embodiment)
The configuration of the branch connector 10P3 in the third embodiment will be described with reference to FIG.
The branch connector 10P3 in the third embodiment has a plurality of wire group intersections 20 arranged at predetermined intervals along the longitudinal direction of the first covered wire 31A, that is, the branch connector 10P2 in the second embodiment. As shown in FIG. 12, the branch connector 10P2 in the second embodiment having the configuration in which the respective wire group intersecting portions 20 are accommodated and held in the holder 50 is spaced apart by a predetermined distance in the longitudinal direction of the first covered wire 31A. The plurality of arranged holders 50 are configured to overlap each other.

  In other words, the branch connector 10P3 includes a plurality of electric wire group intersections 20 formed at predetermined intervals in the longitudinal direction of the first covered electric wire 31A, and a plurality of holders 50 for accommodating and holding the electric wire group intersections 20; In the longitudinal direction of the first covered electric wire 31A, the first covered electric wire 31A on which the holder 50 is laminated is spelled and configured.

  The branch connector 10P3 performs a zigzag folding process of bending the first covered wires 31A in a zigzag shape in the longitudinal direction so that the plurality of wire group crossing portions 20 are stacked in the thickness direction after the crossing wire assembly arranging step. Can be manufactured.

  According to the configuration described above, the end portions 31Ba of the plurality of second covered wires 31B constituting the wire group crossing portion 20 can be formed as connection terminals, and the plurality of connection terminals are linear in the X direction. Therefore, the branch connector 10P3 can be configured as a branch connection means having a large number of connection terminals without requiring an installation space.

  And by connecting the wire harness W to the end portion 31Ba of the second covered electric wire 31B in the branch connector 10, 10P2, 10P3 in the first to third embodiments described above, for example, as shown in FIG. A desired harness connection structure 1 can be configured.

In the correspondence between the configuration of the present invention and the embodiment,
The electric wire structure of the present invention corresponds to the branch connector 10, 10P2, 10P3 of the embodiment,
Similarly,
The conductor corresponds to the conductive core wire 32 (32A, 32B),
The accommodation holding means corresponds to the holder 50,
One electrode corresponds to the positive electrode probe 200a,
The other electrode corresponds to the negative electrode probe 200b,
The laser irradiation means corresponds to the laser irradiation unit 210a,
The harness corresponds to the backbone harness Wm and the branch harness Ws,
The first direction corresponds to the X direction,
The second direction corresponds to the Y direction,
The electrical connection structure corresponds to the harness connection structure 1,
The wire accommodating means accommodating process corresponds to the holder accommodating process,
The present invention is not limited to the configuration of the above-described embodiment, but can be applied based on the technical idea shown in the claims, and many embodiments can be obtained.

  For example, the wire crossing portion 34 is not limited to a case where the wire crossing portion 34 crosses at right angles, and includes a configuration where the wire crossing portion 34 crosses at a predetermined angle other than 90 degrees. Further, the first direction may be set in the Y direction and the second direction may be set in the X direction.

  In Example 1 and Example 2 described above, the first covered electric wire 31A and the second covered electric wire 31B are configured by the core wire 32 and the insulating coating 33. However, the present invention is not limited to this. The core wire 32 may be covered with a shield member such as an aluminum member, and then covered with an insulating coating 33.

Moreover, you may comprise 31 A of 1st covered electric wires, and the 2nd covered electric wire 31B with the twisted pair cable which twisted the some covered electric wire 31, for example. □
Further, the core wire 32A of the first covered electric wire 31A and the core wire 32B of the second covered electric wire 31B may be a single conductive wire or a twisted wire obtained by twisting a plurality of strands.

  As shown in FIG. 5, the electric wire group crossing portion 20 is arranged such that the welded portions 60 are arranged at predetermined intervals in the order in which the crossing electric wire sets 30 are superimposed on a diagonal line in a substantially lattice shape. However, the present invention is not limited to the arrangement of the crossed wire sets 30 so as to have such an arrangement form. For example, the electric wire group crossing portion 20 may be arranged such that the welded portion 60 is not on a diagonal line in a substantially lattice shape, and can be configured in an arbitrary arrangement form according to the wiring pattern of the branch connector 10.

Moreover, in the electric wire group crossing part 20, it was set as the structure by which the overlapping crossed electric wire groups 30 become non-conducting, However, It is not limited to this, As the structure in which the overlapping crossed electric wire groups 30 in the electric wire group crossing part 20 become conductive. Good. □
Specifically, among the plurality of electric wire intersections 34, not only the electric wire intersections R11, R22, R33, R44, R55 in the same group, but also the electric wire intersections R12 to R15, R21, R23 to R25 between the other groups. At least one of R31, R32, R34, R35, R41 to R43, R45, R51 to R54 may be configured as a wire conduction state intersection where the conductor exposed portions 32A1 and 32B1 are connected to each other in a conduction state.

  In addition, a connecting terminal such as a crimp terminal and a connector housing are attached to the first covered electric wire 31A or the second covered electric wire 31B derived from the branch connector 10 to form the connector-attached branch connector 10, and the main harness Wm or branch The connector provided in the harness Ws may be configured to be male and female.

  Moreover, although the electric wire group crossing part 20 was accommodated and held in the holder 50, it is not limited to this, What is necessary is just a structure which can accommodate and hold the electric wire group crossing part 20. FIG. For example, a cover that covers the holder 50 may be provided to hold the wire group intersection 20 in cooperation with the holder 50.

  Further, for example, after the crossed wire sets 30 are superposed in a substantially lattice shape, the wire group crossing portion 20 may be held by being sandwiched from both sides in the thickness direction with an insulating sheet.

  Furthermore, the wire group crossing portion 20 does not need to be housed and held in the holder 50 as long as the wire group crossing portion 20 as a whole has shape retention. For example, only the wire crossing portion 34 is insulated. Insulation may be ensured by coating with a synthetic resin.

  Further, in the crossing wire assembly arrangement step, when the crossing wire assembly 30 is superposed in a substantially lattice shape, as described above, the crossing wire assembly 30 is already arranged from one side in the thickness direction of the wire group crossing portion 20. However, the present invention is not limited to such an arrangement form.

For example, in the crossed wire set arrangement step, when the crossed wire sets 30 are superposed in a substantially lattice shape, the first covered wires 31A constituting the plurality of crossed wire sets 30 are respectively at the same height level with respect to the second covered wires 31B. That is, while being arrange | positioned in the same surface, the 2nd covered electric wire 31B which comprises the some crossed electric wire set 30 is arrange | positioned in the same height level, ie, the same surface, respectively with respect to the 2nd covered electric wire 31B. A plurality of crossed wire sets 30 may be arranged as described above.
Thereby, it can be set as a compact form including the holder 50, without the thickness of the electric wire group intersection part 20 being bulky.

  Further, the branch connector 10P2 of the second embodiment has a configuration in which the plurality of wire group intersections 20 are arranged at regular intervals along the longitudinal direction of the first covered wire 31A, but is not limited to this configuration. Moreover, the space | interval of the adjacent electric wire group intersection part 20 of the some electric wire group intersection part 20 can each be set arbitrarily.

  In the crossed electric wire set arrangement step, not only the crossed electric wire set 30 is arranged, or at least one of the first covered electric wire 31A and the second covered electric wire 31B that do not constitute the electric wire group intersecting portion 20 may be arranged.

  In the crossed wire set arrangement step, not only the crossed wire set 30 is arranged, but in addition to the crossed wire set 30, at least one of the first covered wire 31A and the second covered wire 31B that does not constitute the crossed wire set 30. You may comprise the electric wire group crossing part 20 by arrange | positioning the covered electric wire 31 of.

  Further, in the conductor joining step in Manufacturing Method Example 1, the positive electrode probe 200a is brought into contact with the conductor exposed portion 32A1 of the first covered electric wire 31A, and the negative electrode probe 200b is applied to the conductor exposed portion 32B1 of the second covered electric wire 31B. The positive electrode probe 200a is brought into contact with the conductor exposed portion 32B1 of the second covered electric wire 31B, and the negative electrode probe 200b is brought into contact with the conductor exposed portion 32A1 of the first covered electric wire 31A, thereby exposing the conductor exposed portion 32A1. , 32B1 may be welded together.

  In the conductor joining step, the conductor exposed portions 32A1 and 32B1 are joined not only by welding using a laser or an electrode, but also by ultrasonic connection, applying a conductive adhesive, or soldering. Alternatively, they may be joined by a combination of these means.

DESCRIPTION OF SYMBOLS 1 ... Electrical connection structure 10, 10P2, 10P3 ... Branch connector 20 ... Electric wire group crossing part 30 ... Cross electric wire group 31 ... Covered electric wire 31A (31) ... 1st covered electric wire 31B (31) ... 2nd covered electric wire 31Ba ... 1st 2 End portions of covered wires 32A, 32B ... Conductive core wires 32A1, 32B1 ... Conductor exposed portions 33A, 33B ... Insulation coating 34 ... Wire crossing portion 50 ... Holder 200a ... Positive electrode probe 200b ... Negative electrode probe 210a ... Laser irradiation portion Wm ... Core harness Ws ... Branch harness

Claims (8)

A covered electric wire in which a conductor is covered with an insulating coating is composed of a first covered electric wire arranged in a first direction and a second covered electric wire arranged in a second direction intersecting the first direction,
In the crossing portion of each of the first covered electric wire and the second covered electric wire, each of the conductors is joined to each other and connected to the conductive state to provide a crossed wire set,
In the electric wire group intersection where the plurality of first covered wires arranged in parallel and the plurality of second covered wires arranged in parallel intersect in the same plane, the first covered wires and the second covered wires are A plurality of crossed wire sets are arranged and configured to be parallel to each other,
Comprising an accommodation holding means for accommodating and holding the wire group intersection;
The housing and holding means
An electric wire structure in which a holding groove portion that fits and holds the first covered electric wire and the second covered electric wire in a substantially lattice shape arranged so as to be laminated in the thickness direction in the same plane . The covered electric wire is wire structure according to claim 1 comprising a single conductor per one. The crossed wire set is
The electric wire structure according to claim 1 or 2, wherein a plurality of the second covered electric wires are crossed at intervals in the longitudinal direction with respect to the first covered electric wires, and the intersecting portions are connected to a conductive state. body. The electric wire structure according to claim 3 , wherein the first covered electric wire is cut at one place or a plurality of places in the longitudinal direction. The electrical connection structure which connects a harness to the edge part of the said 2nd covered electric wire in the electric wire structure in any one of Claims 1 thru | or 4 . The covered electric wire in which the conductor is covered with the insulating coating is composed of a first covered electric wire arranged in the first direction and a second covered electric wire arranged in the second direction intersecting the first direction,
The insulation coating at the intersection with the second covered electric wire in the longitudinal direction of the first covered electric wire is peeled off, and the insulation coating at the intersection with the first covered electric wire in the longitudinal direction of the second covered electric wire is peeled off Insulating coating stripping process that constitutes a conductor exposed portion where the conductor is exposed,
An intersection arrangement step of crossing the first covered electric wire and the second covered electric wire so that the exposed portions of the conductors are in contact with each other;
Conductors in which the conductor exposed portions of the first covered electric wire and the second covered electric wire are joined to each other so that the conductors of the first covered electric wire and the second covered electric wire are electrically connected to each other. A conductor joining step that constitutes a crossed wire set in which the first covered wire and the second covered wire are connected to each other in a conductive state by the conductive crossing portion.
In the electric wire group intersection where the plurality of first covered electric wires arranged in parallel and the plurality of second covered electric wires arranged in parallel intersect in the same plane, the first covered electric wires and the second covered electric wires are respectively Crossing electric wire set arrangement step of arranging a plurality of the crossing electric wire sets so as to be parallel to each other;
The electric wire group is formed by fitting and holding the first covered electric wire and the second covered electric wire in the electric wire intersecting portion in the holding groove portion formed in a lattice shape in the holding and holding means for accommodating and holding the electric wire group intersecting portion. A method of manufacturing an electric wire structure, wherein an accommodation holding step of accommodating and holding the intersecting portion in an accommodation holding means is performed in this order . In the conductor joining step,
The manufacturing method of the electric wire structure of Claim 6 which irradiates a laser toward the contact part which the said conductor exposed parts contact from the clearance gap between the insulation coating of the said 1st covered electric wire, and the insulation coating of the said 2nd covered electric wire. In the conductor joining step,
One of the positive electrode and the negative electrode is brought into contact with the conductor exposed portion of the first covered electric wire, and the other electrode is brought into contact with the conductor exposed portion of the second covered electric wire. The manufacturing method of the electric wire structure of Claim 7 which supplies the electric current which can weld the said conductor exposed parts between the said electrode and said other electrode.

Images