JP2019140104A - Flat wire connection structure and wire harness including the same - Google Patents

Abstract

To provide a flat wire connection structure that can be easily handled during manufacture or assembly to a vehicle while maintaining electrical connection reliability.SOLUTION: A flat wire connection structure Y1 includes a recessed portion 12 provided on a first flat conductor 11 of a flat wire 10B-1, and a projecting portion 22 provided on a second flat conductor 21 of a flat wire 10B-2 and locking the recessed portion 12, and the first flat conductor 11 and the second flat conductor 21 are electrically connected when the convex portion 12 is locked to the projecting portion 22.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a connection structure for flat electric wires, and particularly relates to a connection structure for flat electric wires arranged in a moving body such as a vehicle and a wire harness including the connection structure.

The wire harness is electrically connected between each element such as a power generation unit, a power supply unit, a power distribution box, a ground unit, and a communication control unit and each auxiliary machine such as an actuator, a sensor, and a control ECU mounted on the vehicle. By connecting, power supply, grounding, communication, etc. are performed in the vehicle.
In recent years, with the electrification of vehicles (hybrid vehicles, electric vehicles, etc.), multi-functionality / high functionality (automated driving systems, connected cars, etc.), etc., wire harnesses become enlarged and the routing route becomes complicated. Therefore, it may be difficult to secure a routing route.

  Conventionally, each auxiliary machine mounted on the entire vehicle is electrically connected to, for example, a power distribution box mounted in the engine room or a power supply box mounted on the left and right of the instrument panel via a wire harness. Supplying power to auxiliary equipment. In the case of such a configuration and arrangement, the length of the power circuit connected to the auxiliary device mounted on the rear side of the vehicle is longer than the length of the power circuit connected to the auxiliary device mounted on the front side of the vehicle. As the number of auxiliary machines connected to the terminal increases, the wire harness becomes enlarged and complicated. Similarly, since communication circuits such as actuators and sensors are electrically connected to a control ECU that controls them via a wire harness, the reason why the wire harness becomes enlarged and complicated as the number of communication circuits increases. It has become.

  In order to solve the above problems, for example, power distribution boxes are arranged at various locations such as the center of the instrument panel and the left and right sides of the vehicle, and each auxiliary machine supplies power from a closer power distribution box according to the mounting position. Thus, there is a configuration for shortening the power supply circuit. Similarly, the communication control unit is arranged in various places such as the left and right of the vehicle front, the center, the left and right of the vehicle rear, and the communication circuit of each auxiliary machine is connected to a closer communication control unit according to the mounting position, The structure which shortens a communication circuit by connecting to control ECU by the multiplex communication of each communication control part is mentioned.

  Here, there is a type that distributes power by connecting power distribution boxes distributed in various places of a vehicle to a battery and a generator disposed in the vehicle via a power supply trunk line. Similarly, there is one that performs multiplex communication by bus-connecting communication control units distributed at various locations of a vehicle via a communication trunk line. As such a technique, for the purpose of simplifying the routing route, a power trunk extending in the front-rear direction near the center in the width direction of the vehicle, and extending in a direction that branches from the power trunk and intersects the front-rear direction. There is disclosed a wire harness including a power supply branch line, a communication trunk line routed along the power supply trunk line, and a communication branch line that branches from the communication trunk line and extends in a direction crossing the front-rear direction (patent) Reference 1).

  Specifically, the power supply trunk line and the communication trunk line are flat wiring members having a rectangular shape and stacked on each other, and a plurality of power supply trunk line units are connected via a terminal block. The multiple power supply branch units are connected to the power supply trunk unit via the terminal block. When the communication trunk line is a twisted wire, the terminal block may be a pressure contact terminal or may be branched by ultrasonic bonding. The power supply trunk unit and the power supply branch unit may be connected by metal bonding, and the metal bonding may be, for example, cold pressure welding, ultrasonic welding, laser welding, or the like. It is disclosed.

JP 2017-185996 A

  However, the power supply trunk line and the communication trunk line are routed in the vehicle front-rear direction and the vehicle width direction, and the length of the trunk line may range, for example, from 2 m to 5 m. If the material or structure is not flexible and is not easily deformed by an external force, the manufacturing process of the flat electric wire becomes complicated, and handling when the flat electric wire is assembled to the vehicle is difficult. In recent years, the route for wiring the wire harness tends to be complicated as the performance of the vehicle is improved and the function is increased, and the above problem becomes remarkable.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a flat wire connection structure that facilitates handling at the time of manufacture and assembly to a vehicle while maintaining electrical connection reliability, and a wire harness including the connection structure. It is in.

In order to achieve the above object, the flat wire connecting structure of the present invention is provided on the first flat plate conductor and the second flat plate conductor, and locks the convex portion. A concave portion, and
The convex portion is locked to the concave portion, whereby the first flat conductor and the second flat conductor are electrically connected to each other. The portion is a protrusion formed integrally with the end portion of the first flat conductor, and the tip end side is wider than the base side,
The concave portion is a cutout portion formed at an end portion of the second flat plate-like conductor and having a back side wider than the entrance side, and the protruding portion is formed from the end portion of the first flat plate-like conductor to the first portion. The flat conductor extends in the longitudinal direction, and / or the notch extends from the end of the second flat conductor in the longitudinal direction of the second flat conductor, and the protrusion is the first In the front view of the flat conductor, the first flat conductor has a tapered shape that at least partially tapers from one main surface side to the other main surface side, and the notch portion is the second conductor surface. In the front view of the flat conductor, the second flat conductor has a narrow shape that is at least partially narrow from one main surface side to the other main surface side.

  The convex portion and the concave portion may have a dovetail shape.

  The connection structure of the flat wire may further include a first insulation coating layer that insulates the first flat conductor and a second insulation coating layer that insulates the second flat conductor. .

  The flat wire connecting structure of the present invention includes a convex portion provided on the first flat conductor, and a concave portion provided on the second flat conductor and locking the convex portion, A first insulating covering layer for insulatingly covering the first flat conductor; and a second insulating covering layer for insulatingly covering the second flat conductor, wherein the convex portion is locked to the concave portion. In this connection structure, the first flat conductor and the second flat conductor are electrically connected to each other, and the convex portion is connected to the end of the first flat conductor. A protrusion formed integrally and having a distal end side wider than the base side, and the concave portion is formed at an end of the second flat conductor, and a notch portion whose back side is wider than the inlet side The protrusion extends from the end of the first flat conductor in the longitudinal direction of the first flat conductor, and / or The notch extends from the end of the second flat plate conductor in the longitudinal direction of the second flat plate conductor, and the protrusion and the notch include the first insulating coating layer and the second insulation. The pressure contact state between the first flat conductor and the second flat conductor is maintained by the elastic force in the width direction of the flat electric wire acting between the covering layers.

  The convex portion and the concave portion may have a dovetail shape.

  The connection structure of the flat wire is a connection auxiliary member that covers the locking portion between the convex portion and the concave portion, is fixed to the locking portion, and suppresses the separation between the convex portion and the concave portion. May be further provided.

  The connection auxiliary member includes a base portion, a lid portion attached to the base portion so as to be openable and closable, and a fixing portion that fixes the lid portion to the base portion, and the lid portion is fixed to the base portion. In this state, it is preferable that the convex portion and the concave portion are sandwiched between the base portion and the lid portion, respectively.

  In a state where the lid portion is fixed to the base portion, the convex portion is sandwiched between the base portion and the lid portion via the first insulating coating layer, and the concave portion is the second insulating coating layer. It is preferable to be sandwiched between the base portion and the lid portion via the gap.

  A conductive member may be disposed at a locking portion between the convex portion and the concave portion.

  The connection auxiliary member may be a cylindrical member that covers a connection portion between the first flat conductor and the second flat conductor.

  The flat wire connecting structure of the present invention includes a convex portion provided on the first flat conductor, and a concave portion provided on the second flat conductor and locking the convex portion, A connecting structure for a flat electric wire, wherein the first flat conductor and the second flat conductor are electrically connected by engaging a convex portion with the concave portion. The convex portion is constituted by an end portion of the first flat plate conductor, and the concave portion is provided by the second flat plate conductor, and is formed by an insertion port provided with a plurality of protrusions inside thereof. The plurality of protrusions are pressed into contact with the end portions of the first flat plate conductor in a state where the end portions of the first flat plate conductor are inserted into the insertion port of the second flat plate conductor. .

  The oxide film at the end of the first flat conductor may be removed at the portion where the plurality of protrusions at the end of the first flat conductor are engaged.

  The end portion of the first flat plate conductor may be inserted into the insertion port of the second flat plate conductor while the end portion of the first flat plate conductor is covered.

  It is preferable that the first flat conductor and the second flat conductor constitute a power trunk of the vehicle or a communication trunk of the vehicle.

  One or both of the first flat conductor and the second flat conductor may be formed of a metal flat heat pipe.

  It is preferable that the connection structure of the flat wire is provided on at least one of a power supply trunk line, a communication trunk line, and a ground trunk line of the vehicle.

  Moreover, it is preferable that the wire harness provided with at least 1 connection structure of the said flat wire is provided.

  A wire harness in which at least one of the first flat conductor or the second flat conductor is bent may be used.

  The wire harness in which the shape of the convex part and the concave part of the connection structure of the plurality of flat electric wires is different for each connection structure is preferable.

  ADVANTAGE OF THE INVENTION According to this invention, the handling at the time of a connection operation | work and the assembly | attachment to a vehicle is easy, and connection reliability can be improved.

It is a perspective view showing roughly an example of composition of a wire harness concerning an embodiment of the present invention. It is the elements on larger scale which show an example of the power supply trunk line (X part in FIG. 1) in the wire harness of FIG. 1, (a) The state before connection of the connection structure of flat wire, (b) is the state after connection Indicates. (A) is a perspective view showing a detailed configuration of the connection structure of FIG. 2, (b) is a plan view of a convex portion of the connection structure of (a), (c) is a bottom view, and (d) is a bottom view. It is a front view. (A) is a top view of the recessed part of the connection structure of Fig.3 (a), (b) is a bottom view, (c) is a front view. (A)-(c) is a figure explaining an example of the connection method using the connection structure of FIG. (A)-(b) is a perspective view which shows an example of the connection structure of a flat wire-power supply box. (A)-(b) is a perspective view which shows the other example of the connection structure of a flat wire-power supply box. (A)-(c) is width direction sectional drawing which shows the modification of the connection structure of flat electric wires. (A)-(b) is a top view which shows the other modification of the connection structure of flat electric wires. (A)-(c) is a top view which shows the other modification of the connection structure of flat electric wires. (A)-(c) is a top view which shows the other modification of the connection structure of flat electric wires. (A)-(b) is a side view which shows the modification of the connection auxiliary | assistance member in FIG.5 (b)-(c). (A)-(d) is a figure explaining the other example of the connection method of flat electric wires. (A)-(d) is a figure explaining the other example of the connection method of flat electric wires. (A)-(b) is a figure explaining the other example of the connection method of a flat wire-twisted electric wire. It is a perspective view explaining the other example of the connection method of a flat wire-twisted wire, (a) shows the state before connection, (b) shows the state after connection, (c) shows the state of (b). It is an end elevation along line AA. It is a perspective view explaining the other example of the connection method of a flat wire-twisted wire, (a) shows the state before connection, (b) shows the state after connection, (c) shows the state of (b). It is an end elevation along line BB. It is a perspective view explaining the other example of the connection method of a flat wire-twisted wire, (a) shows the state before a connection, (b) shows the state after a connection. These are perspective views which show the other example of the connection structure of a flat wire-power supply box, (a) shows the state before connection, (b) shows the state after connection.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  1 is a perspective view schematically showing an example of a configuration of a wire harness according to an embodiment of the present invention, and FIG. 2 is a partially enlarged view showing an example of a flat wire connection structure in the wire harness of FIG. (A) is the state before connection of flat wire, (b) shows the state after connection. In the present embodiment, a vehicle such as an automobile will be described as an example of a moving body on which a wire harness is installed. In addition, the structure of the wire harness shown in FIG. 1 and the installation position of this wire harness show an example, and the wire harness of this invention and its installation position are not restricted to what is shown in FIG.

  As shown in FIG. 1, the wire harness 1 connects, for example, a power distribution box 2 mounted on the right side of the instrument panel 201 of the vehicle 200 and a power distribution box 3 mounted on the left side of the instrument panel 201. Power supply main line 10A, power supply distribution box 2 and power supply main line 10B for connecting power distribution box 4 mounted on the right side of floor panel 202 and on the rear side of vehicle 200, power distribution box 3 and floor panel 202 A power supply trunk line 10 </ b> C that connects the power distribution box 5 mounted on the left side and on the rear side of the vehicle 200 is provided. In the present embodiment, the power distribution box 4, the power trunk 10B, the power distribution box 2, the power trunk 10A, the power distribution box 3, the power trunk 10C, and the power distribution box 5 are connected in this order from the right side to the left side of the vehicle 200. Thus, a power circuit in the vehicle 200 is configured. The power supply trunk lines 10A to 10C are constituted by flat-plate electric wires to be described later. In FIG. 1, it is assumed that the power supply voltage supplied to the power supply main line is DC 60 V or less that does not require excessive attention in handling. Specifically, they are DC12V, DC24V, DC48V, etc.

  In addition, the wire harness 1 includes, for example, a plurality of communication control units (not shown) arranged in the same manner as the plurality of power distribution boxes of the power circuit, and a plurality of communications arranged in the same manner as the plurality of power supply trunks. And a trunk line (not shown). Since the configuration of the communication circuit is the same as that of the power circuit, the illustration is omitted. That is, the wire harness 1 connects the first communication control unit mounted on the right side of the instrument panel 201 of the vehicle 200 and the second communication control unit mounted on the left side of the instrument panel 201. A second communication trunk line connecting the first communication control unit and the third communication control unit mounted on the right side of the floor panel 202 and on the rear side of the vehicle 200, and the second communication control unit and the floor panel 202 And a third communication trunk that connects a fourth communication control unit mounted on the left side and on the rear side of the vehicle 200. Thus, from the right side to the left side of the vehicle 200, the third communication control unit, the second communication main line, the first communication control unit, the first communication main line, the second communication control unit, the third communication main line, and the fourth communication. A control part is connected in this order, and comprises the communication circuit in the vehicle 200. FIG. The 1st communication trunk line-the 3rd communication trunk line are comprised by the flat electric wire similarly to the power supply trunk lines 10A-10C, for example.

  The wire harness 1 is similar to the power circuit and the communication circuit, and is similar to the plurality of ground portions (not shown) arranged in the same manner as the plurality of power distribution boxes of the power circuit and the plurality of power supply trunks. And a plurality of ground trunks (not shown) arranged in the network. Moreover, the several earth trunk line may be comprised with the flat electric wire.

2 is a partially enlarged view showing an example of a power supply trunk line 10B (X portion in FIG. 1) in the wire harness 1 of FIG. 1, (a) a state before connection of a connection structure between flat wire, (b ) Shows the state after connection.
As shown to Fig.2 (a), the power supply trunk line 10B is comprised by several flat electric wire 10B-1, 10B-2, 10B-3, 10B-4, 10B-5, 10B-6. The power supply trunk line 10B is basically routed along the floor panel 202, but for the purpose of bypassing various devices, members, etc. mounted on the vehicle 200, a plurality of flat wires 10B-1 to 10B are provided. It has a predetermined bending shape at a necessary portion of -6. The predetermined bending shape is formed by various bending processes such as oblique bending, edgewise bending, and flatwise bending.

  For example, when the wire harness 1 is manufactured at a harness factory, taking the power supply trunk line 10B as an example, the plurality of plate-like electric wires 10B-1 to 10B-6 are divided and shipped to an assembly factory or the like of the vehicle 200. Is done. When the vehicle is assembled, the divided flat electric wires 10B-1 and 10B-2 are arranged at predetermined positions of the vehicle 200, and the flat electric wires 10B-1 and 10B-2 are connected by the connection structure Y1 (FIG. 2B). )). Similarly, the flat electric wires 10B-2 and 10B-3 are connected with the connecting structure Y2, the flat electric wires 10B-3 and 10B-4 are connected with the connecting structure Y3, and the flat electric wires 10B-4 and 10B-5 are connected with the connecting structure Y4. Thus, by connecting the flat electric wires 10B-5 and 10B-6 with the connection structure Y5, the power supply trunk line 10B having a desired shape is formed. This power supply trunk line 10B is routed in its shape.

  In this way, the power supply trunk line 10B is configured by a plurality of flat-plate electric wires 10B-1 to 10B-6 that can be divided or connected, so that the entire power supply trunk line 10B is integrally formed, In the manufacturing process, it is only necessary to manufacture a plurality of flat-shaped electric wires 10B-1 to 10B-6 that are smaller than the entire power supply main line 10B. Therefore, productivity of the wire harness 1 is improved, and a plurality of power supply main lines 10B are provided at the time of shipment. Therefore, it is easier to carry than the whole power supply trunk line 10 </ b> B. Moreover, the manufacturing method of the wire harness 1 can be changed, for example, manufactured for each flat electric wire or each shape according to the required specifications, and early and flexible correspondence is possible according to the specifications.

  3A is a perspective view showing a detailed configuration of the connection structure Y1 in FIG. 2, FIG. 3B is a plan view of a convex portion of the connection structure in FIG. 3A, and FIG. A bottom view and FIG. 3D are front views. 4A is a plan view of a concave portion in the connection structure of FIG. 3A, FIG. 4B is a bottom view, and FIG. 4C is a front view. Since the connection structures Y2 to Y5 can be the same as the connection structure Y1, description thereof will be omitted.

  As shown in FIG. 3 (a), the flat wire connection structure Y1 includes the convex portion 12 provided on the first flat conductor 11 of the flat wire 10B-1 and the flat wire 10B-2. 2 provided with a flat plate conductor 21 and a concave portion 22 for locking the convex portion 12, and the first flat plate conductor 11 and the second flat plate shape when the convex portion 12 is locked to the concave portion 22. The conductor 21 is electrically connected.

  The first flat conductor 11 has two convex portions 12, and the second flat conductor 21 has two concave portions 22. The first flat conductor 11 may have one convex portion 12, and the second flat conductor 21 may have one concave portion 22. Further, the first flat conductor 11 may have a plurality of convex portions 12, and the second flat conductor 21 may have a plurality of concave portions 22.

The first flat conductor 11 and the second flat conductor 21 are made of, for example, aluminum, an aluminum alloy, copper, or a copper alloy. The first flat conductor 11 and the second flat conductor 21 are formed of, for example, a flat plate, and when used for a power supply trunk line or a ground trunk line, the conductor cross-sectional area is 5 mm ² or more and 200 mm ² or less, and the conductor width direction. The ratio in the thickness direction is preferably 2 or more and 50 or less. When used in other circuits, the conductor dimensions are appropriately determined according to the purpose.

  For example, as shown in FIGS. 3B to 3C, the convex portion 12 is formed integrally with the end portion 11 a of the first flat plate-like conductor 11, and the distal end side is wider than the base side. It is a protrusion. For example, as shown in FIGS. 4A and 4B, the concave portion 22 is a notch portion formed at the end portion 21 a of the second flat conductor 21 and having a back side wider than the inlet side. is there. And the said protrusion part fits into the said notch part (refer FIG.5 (b)). When the tensile stress is generated along the longitudinal direction of the first flat conductor 11 (or the second flat conductor 21) due to the above-described shapes of the convex portion 12 and the concave portion 22, Separation of the two flat conductors 21 can be prevented.

  The convex portion 12 and the concave portion 22 have, for example, a so-called dovetail shape as shown in FIGS. 3 and 4, but are not limited thereto. When a tensile stress is generated along the longitudinal direction of the first flat conductor 11 (or the second flat conductor 21), the first flat conductor 11 and the second flat conductor 21 can be prevented from being separated. If it exists, it may have another shape, for example, it may have a sickle joint shape.

  For example, as shown in FIGS. 3B to 3C, the protrusion extends from the end 11 a of the first flat conductor 11 in the longitudinal direction of the first flat conductor 11, and One flat conductor 11 has a tapered shape that tapers from one main surface 11b side to the other main surface 11c side of the first flat conductor 11 in a front view. Moreover, in this embodiment, the said projection part has a pair of 1st inclined surface 12a, 12a inclined with respect to the thickness direction of the 1st flat conductor 11 (FIG.3 (d)). The pair of first inclined surfaces 12 a and 12 a are formed so as to be line symmetric in the front view of the first flat conductor 11. The tapered shape described above may be formed at any portion from the one main surface 11b side of the first flat conductor 11 toward the other main surface 11c side.

  Moreover, the said notch part is extended in the longitudinal direction of the said 2nd flat plate conductor 21 from the edge part 21a of the 2nd flat plate conductor 21, as shown in FIG.4 (b), for example. In the front view of the flat conductor 21, the second flat conductor 21 has a narrow shape that is narrower from one main surface 21 b side to the other main surface 21 c side. In the present embodiment, the notch has a pair of second inclined surfaces 22a, 22a that are inclined with respect to the thickness direction of the second flat conductor 21 and abut against the pair of first inclined surfaces 12a, 12a. (FIG. 4C). The pair of second inclined surfaces 22 a and 22 a are formed so as to be line symmetric in the front view of the second flat conductor 21. Thus, by providing the pair of first inclined surfaces 12a, 12a and the pair of second inclined surfaces 22a, 22a, the contact area between the first flat conductor 11 and the second flat conductor 21 can be increased. . The narrow width shape described above may be formed in any part from the one main surface 21b side of the second flat conductor 21 toward the other main surface 21c side.

  Due to the shape of the protrusion and the notch, in the state where the first flat conductor 11 and the second flat conductor 21 are connected, the first main face 11b to the other main face 11c of the first flat conductor 11 are connected. Even when an external force is applied from one main surface 21b side of the second flat conductor 21 to the other main surface 21c side, the first flat conductor 11 and the second flat conductor 21 Can be prevented from separating.

  As shown in FIGS. 3 and 4, the connection structure Y1 of the flat electric wires 10B-1 and 10B-2 includes a first insulating coating layer 13 for insulatingly covering the first flat conductor 11, and a second flat plate shape. You may further have the 2nd insulation coating layer 23 which carries out insulation coating of the conductor 21. FIG. Thereby, sufficient insulation of the 1st flat conductor 11 and the 2nd flat conductor 21 is ensured.

  The first insulating coating layer 13 and the second insulating coating layer 23 are made of, for example, a resin such as polyvinyl chloride (PVC) (here, a soft polyvinyl chloride resin) and used for a power supply trunk line or a ground trunk line. The thickness of the coating is preferably 0.1 mm or more and 3 mm or less. When used in other circuits, the conductor dimensions are appropriately determined according to the purpose.

  FIG. 5A to FIG. 5C are diagrams for explaining an example of a connection method using the connection structure Y1 of FIG. As shown in FIG. 5A, for example, the first flat plate conductor 11 of the flat wire 10B-1 is processed by trimming the first flat plate conductor 11 that is covered with the first insulating cover layer 13 so as to be trimmed. Two convex portions 12, 12 are formed on the end portion 11 a of the conductor 11. Similarly, trimming is performed on the second flat conductor 21 insulated with the second insulating cover layer 23 to process the entire cover, and two ends 21a of the second flat conductor 21 of the flat electric wire 10B-2 are formed. Concave portions 22 and 22 are formed.

  Then, as shown in FIG. 5B, the convex portion 12 is inserted into the concave portion 22, and the convex portion 12 is locked to the concave portion 22, so that the first flat conductor 11 and the second flat conductor. 12 are half-fitted together.

  At this time, a connection auxiliary member can be provided at the connection portion between the first flat conductor 11 and the second flat conductor 12. For example, as shown in the figure, the connection structure of the flat electric wires 10B-1 and 10B-2 covers the locking portion between the convex portion 12 and the concave portion 22 and is fixed to the locking portion. You may further provide the connection auxiliary member 30 which suppresses separation | separation with the part 12 and the recessed part 22. FIG.

  The connection auxiliary member 30 includes, for example, a base portion 31, a lid portion 32 that is attached to the base portion 31 so as to be opened and closed, and a fixing portion 33 that fixes the lid portion 32 to the base portion 31. The base portion 31 is, for example, a substantially U-shaped housing that can accommodate a locking portion between the convex portion 12 and the concave portion 22. The lid portion 32 is, for example, a plate-like body that is rotatably attached to the housing via a hinge or the like. The fixing portion 33 is, for example, a screw that is attached to the lid portion 32 and is fixed to the housing with screws. The lid portion 32 is fixed to the base portion 31 via the fixing portion 33, whereby the convex portion 12 and the concave portion 22 are sandwiched between the base portion 31 and the lid portion 32, respectively.

  When this connection assisting member 30 is used, the locking portion between the convex portion 12 and the concave portion 22 is set on the base portion 31 with the lid portion 32 opened. At this time, it is preferable that the entire locking portion between the convex portion 12 and the concave portion 22 is accommodated in the base portion 31. Thereafter, the lid portion 32 is closed, and the lid portion 32 is fixed to the base portion 31 by the tightening torque of the fixing portion 33 (FIG. 5C). In the present embodiment, in a state where the lid portion 32 is fixed to the base portion 31, the convex portion 12 is sandwiched between the base portion 31 and the lid portion 32 via the first insulating coating layer 13, and the concave portion 22 is the first portion. 2 is sandwiched between the base portion 31 and the lid portion 32 via the insulating coating layer 23. Thereby, even if it is a case where flat electric wire 10B-1 and 10B-2 receive a vibration, separation | spacing with the convex part 12 and the concave part 22 is prevented.

  When both the first insulating coating layer 13 and the second insulating coating layer 23 are not provided in the engaging portion between the convex portion 12 and the concave portion 22 (see FIGS. 3 and 4), the base portion 31. The convex portion 12 and the concave portion 22 may be directly sandwiched between the base portion 31 and the lid portion 32 in a state where the lid portion 32 is fixed to the base portion 31. In this case, from the viewpoint of ensuring sufficient insulation of the connection auxiliary member 30 with respect to the vehicle body, the connection auxiliary member 30 is preferably made of an insulating material.

  As described above, according to the present embodiment, the flat wire connection structure Y1 includes the convex portion 12 provided on the first flat conductor 11 of the flat wire 10B-1 and the flat wire 10B-2. The second flat conductor 21 is provided with a concave portion 22 that locks the convex portion 12, and the convex portion 12 is locked to the concave portion 22 so that the first flat conductor 11 and the second flat plate are engaged. Since the conductors 21 are electrically connected, the electrical connection in the power supply trunk line 10B can be easily and reliably performed. Moreover, since the power supply trunk line 10B is configured to be divided into a plurality of flat conductors, it can be divided into a plurality of flat conductors when being manufactured or transported. In addition, at the time of assembly to the vehicle 200, after the divided flat conductors are arranged at predetermined positions of the vehicle 200, a plurality of flat conductors can be connected to each other, and handling properties are greatly improved. Therefore, handling at the time of manufacture of a flat electric wire or assembly to the vehicle 200 becomes easy while maintaining electrical connection reliability.

  In addition, the flat conductor connection structure Y1 is provided on at least one of the power supply trunk line, the communication trunk line, and the ground trunk line of the vehicle 200, so that the flat conductors constituting the power trunk line routed in the vehicle 200 are connected to each other. , Electrical connection between the flat conductors constituting the communication trunk line, and / or electrical connection between the flat conductors constituting the ground trunk line can be easily and reliably performed. In particular, since the wire harness 1 includes the connection structure for flat electric wires, all the wiring work of the power supply trunk line, the communication trunk line, and the ground trunk line wired in the vehicle 200 can be facilitated.

  FIG. 6A to FIG. 6B are perspective views showing an example of a flat wire-power supply box connection structure. As shown in FIG. 6A, the connection structure of the flat wire is, for example, the second flat plate conductor 81 constituting the power supply trunk line and the second bar connected to the bus bar (not shown) in the power distribution box 2. A flat conductor 91, a convex portion 82 provided on the first flat conductor 81, and a concave portion 92 provided on the second flat conductor 91 and locking the convex portion 82 are provided.

  The convex portion 82 is configured by, for example, an end portion 81 a of the first flat conductor 81. The concave portion 92 is formed, for example, by an insertion port provided in the second flat conductor 91 and provided with a plurality of protrusions 93 on the inner side thereof (FIG. 6A). The concave portion 92 is formed by, for example, a substantially U-shaped frame attached to one main surface 91 a of the second flat conductor 91 along the width direction of the second flat conductor 91. . The plurality of protrusions 93 are formed by, for example, a comb-shaped member that is attached to the frame and is disposed so as to protrude toward one main surface 91a of the second flat conductor 91. For example, the comb-shaped member is rotatably attached to the frame body. When the convex portion 82 of the first flat plate member is inserted into the concave portion 92, the left side of the drawing corresponds to the insertion. Rotate in the direction, and then rotate in the right direction in the drawing in response to the movement of the protruding portion 82 of the first flat plate member, and the state shown in FIG. 6B is obtained.

  In this configuration, as shown in FIG. 6B, the plurality of protrusions 93 are the first flat plate in a state where the end portion 81 a of the first flat plate conductor 81 is inserted into the insertion port of the second flat plate conductor 91. By pressing into the end portion 81 a of the conductor 81, it is pressed. Further, the first flat conductor 81 can be pressed against the second flat conductor 91 by the press contact between the first flat conductor 81 and the plurality of protrusions 93, and the first flat conductor 81 and the second flat conductor 91 can be pressed. The contact area with can be increased. In addition, since the plurality of protrusions 93 bite into the end portions 81a of the first flat conductor 81, the metal of the conductor can be bonded by breaking through the metal oxide film formed on the surface of the first flat conductor 81. it can. In this way, the first flat conductor 81 and the second flat conductor 91 are electrically connected by the convex portion 82 being locked to the concave portion 92. Therefore, when connecting a flat wire and a power supply box such as a power distribution box in the vehicle 200, easy electrical connection between the flat wire and the power supply box is realized while maintaining electrical connection reliability. be able to. When the materials of the first flat conductor 81, the second flat conductor 91, and the comb-shaped member having the plurality of protrusions 93 are different (for example, when the first flat conductor 81 is aluminum-based and the other is copper-based). It is preferable to surround the connecting portion and its periphery with a resin or the like to prevent corrosion. Further, regarding the present embodiment, FIGS. 6A to 6B show a state in which the covering of the end portion 81a of the first flat conductor 81 is removed. Depending on the material, the comb-shaped member may be connected while the end 81a of the first flat conductor 81 is covered.

  Fig.7 (a)-FIG.7 (b) are perspective views which show the other example of the connection structure of a flat wire-power supply box. As shown in FIG. 7A and FIG. 7B, the connection structure of the flat electric wires includes, for example, a first flat conductor 101 constituting a power trunk and a bus bar (not shown) in the power distribution box 2. A second flat conductor 111 connected to the first flat conductor 101, a convex portion 102 provided on the first flat conductor 101, and a concave portion 112 provided on the second flat conductor 111 for locking the convex portion 102. It has.

  The convex portion 102 is constituted by, for example, a male screw portion attached to the first flat conductor 101. The concave portion 112 is constituted by, for example, a through hole provided in the second flat conductor 111 and a female screw portion arranged substantially concentrically with the through hole. The male screw part is, for example, a bolt fixed to the first flat conductor 101 in a penetrating state. An internal thread part is a nut screwed together with the above-mentioned bolt, for example.

  In this configuration, as shown in FIG. 7B, the male screw portion is inserted into the through hole of the second flat plate conductor 111 while the male screw portion of the first flat plate conductor 101 is inserted into the through screw. It is fastened and fixed by screwing with the part. In addition, the first flat conductor 81 can be pressed against the second flat conductor 91 by tightening and fixing the male screw portion and the female screw portion. Thus, the convex part 102 is latched by the concave part 112, and the 1st flat conductor 101 and the 2nd flat conductor 111 are connected. Therefore, as in the case of FIG. 6, when connecting a flat electric wire and a power supply box such as a power distribution box in the vehicle 200, it is easy to connect the flat electric wire and the power supply box while maintaining electrical connection reliability. Electrical connection can be realized. In addition, when the material of the 1st flat conductor 101, the convex part 102, the 2nd flat conductor 111, and the concave part 112 is different (for example, when the 1st flat conductor 101 is aluminum type, others are copper type), It is preferable to protect the connection portion and its periphery by surrounding it with a resin or the like.

Fig.8 (a)-FIG.8 (c) are the width direction end views which show the modification of the connection structure of flat electric wires.
As shown in FIGS. 8A to 8C, the flat wire connection structure Y1 includes a convex portion 12A provided on the first flat conductor 11A of the flat wire 10B-1 and a flat plate shape. A concave portion 22A provided on the second flat conductor 21A of the electric wire 10B-2 and locking the convex portion 12A may be provided. At this time, the convex portion 12A has a width direction outer dimension larger than the width direction inner dimension of the concave portion 22A in the cross section in the width direction. The shape of the convex portion 12A is, for example, a trapezoidal shape (FIG. 8A), a shape in which the central portions in the thickness direction of both side portions are depressed (FIG. 8B), or a rectangular shape (FIG. c)).

  In the configuration of FIG. 8A, when connecting the flat electric wires 10B-1 and 10B-2, for example, the convex portion 12A is positioned by being semi-fitted to the concave portion 22A, and then a press fitting is used. The convex portion 12A and the concave portion 22A are completely fitted. By this press-fitting, the metal oxide film formed on the surface of the first flat conductor 11A or the surface of the second flat conductor 21A is scraped off, and between the first insulating coating layer 13A and the second insulating coating layer 23A. The press contact state between the first flat conductor 11A and the second flat conductor 21A is maintained by the elastic force in the width direction of the flat electric wires 10B-1 and 10B-2 acting on the wire, and the connection reliability can be improved. .

  Similarly, the metal oxide film formed on the surface of the first plate-like conductor 11B or the surface of the second plate-like conductor 21B through the half-fitting and complete-fitting steps in the configuration of FIG. 8B as well. And the first flat conductor 11B and the first flat conductor 11B are connected to the first flat conductor 11B by the elastic force in the width direction of the flat electric wires 10B-1 and 10B-2 acting between the first insulating cover layer 13B and the second insulating cover layer 23B. The pressure contact state with the two flat conductors 21B is maintained, and the connection reliability can be improved. Similarly, in the configuration of FIG. 8C, the metal formed on the surface of the first flat conductor 11C or the surface of the second flat conductor 21C through the semi-fitting and complete fitting processes. The oxide film is scraped off, and the first flat conductor 11C is caused by the elastic force in the width direction of the flat electric wires 10B-1 and 10B-2 acting between the first insulating coating layer 13C and the second insulating coating layer 23C. And the second flat conductor 21C are kept in pressure contact, and connection reliability can be improved. 8A to 8C, when the metal oxide film formed on the surface of the first flat conductor and the surface of the second flat conductor is scraped off, the aluminum-based material Even with such a conductor on which an oxide film is easily formed, electrical connection can be reliably performed, and connection reliability can be improved.

  8A to 8C, from the viewpoint of further improving connection reliability, at least one of the first insulating coating layer and the second insulating coating layer is made of soft polyvinyl chloride (PVC) or the like. The resin may be made of a resin having higher rigidity than the general resin, such as hard polyvinyl chloride (PVC) or polypropylene (PP). Moreover, after press-fitting the first insulating coating layer into the second insulating coating layer, the first insulating coating layer and the second insulating coating layer may be thermally welded.

  Fig.9 (a)-FIG.9 (b) are top views which show the other modification of the connection structure of flat electric wire 10B-1 and 10B-2. The connection structure between the flat electric wires is a cylindrical member that covers at least the connection portion between the first flat plate conductor 11 and the second flat plate conductor 12 as another connection auxiliary member from the viewpoint of improving insulation and connection reliability. 121 (FIG. 9A), or may further include a cylindrical member 121 that covers at least the connecting portion of the first flat conductor 11 and the second flat conductor 12, and at least It may be a hard resin member 122 that covers the connection part (FIG. 9B), or may further have a hard resin member 122 that covers at least the connection part. The cylindrical member 121 is, for example, a heat shrinkable tube. The resin member 122 is, for example, a member in which a base portion, a lid portion, and a fixed portion are integrally formed of resin. At this time, the fixing portion may be configured by, for example, a snap structure (not shown), and the resin member 122 is connected to the first flat plate conductor 11 and the second flat plate conductor 12 by fitting the snap structure. Fixed to.

  Further, as another connection auxiliary member, a tape material (not shown) that covers at least the connection portion of the first flat conductor 11 and the second flat conductor 12 may be provided, or a soft resin material may be applied. A configured resin portion (not shown) may be provided. Moreover, you may use the connection auxiliary member similar to the connection auxiliary member 30 shown by FIG. When the first flat conductor 11 and the second flat conductor 12 are made of different materials (for example, when the first flat conductor 11 is an aluminum-based material and the second flat conductor 12 is a copper-based material), the connecting portion The connection assisting member is arranged so as to exhibit the anticorrosion effect.

  Fig.10 (a)-FIG.10 (c) are top views which show the other modification of the connection structure of flat electric wires. As shown in FIG. 10 (a), from the viewpoint of easy fitting, the convex portion 12D of the first flat conductor 11D and the concave portion 22D of the second flat conductor 21D have a gap portion 123 therebetween. It may be configured to be provided. At this time, for example, after engaging the convex portion 12A with the concave portion 22A, an indeterminate conductive member 124 ′ is embedded in the gap 123 between the convex portion 12D and the concave portion 22D (FIG. 10B). Thereafter, the conductive portion 124 is formed in the gap portion 123 by removing the excess conductive member 124 'and curing it (FIG. 10C). The amorphous conductive member 124 ′ is, for example, a conductive material-containing resin such as a metal nanopaste, and the conductive portion 124 can be formed by heating such as sintering. In addition, from the viewpoint of further improving insulation and connection reliability, after forming the conductive portion 124, the above-described connection auxiliary member is attached to at least the connection portion of the first flat conductor 11 and the second flat conductor 12. May be.

Fig.11 (a)-FIG.11 (c) are top views which show the other modification of the connection structure of flat electric wires.
In the above embodiment, the convex portion 12 and the concave portion 22 are substantially trapezoidal in plan view (FIGS. 3 and 4), but may have other shapes. For example, the first flat conductor 11E may have two convex portions 12E, and the convex portion 12E may have a neck portion 125 and a head portion 126. The second flat conductor 21E may have two concave portions 22E, and the concave portion 22E may have a narrow portion 127 and a wide portion 128. In the present embodiment, the neck portion 125 and the head portion 126 are configured to be smoothly connected with curved surfaces. The narrow portion 127 and the wide portion 128 are also configured to be smoothly connected with curved surfaces corresponding to the neck portion 125 and the head portion 126. Thus, by not providing a corner portion on the convex portion 12E or the concave portion 22E, it is possible to suppress the generation of a gap at the connection interface between the convex portion 12E and the concave portion 22E and improve the connection reliability. it can.

12 (a) to 12 (b) are side views showing a modification of the connection assisting member in FIGS. 5 (b) to 5 (c).
As illustrated in FIG. 12A, the connection assisting member 130 includes, for example, a base portion 131, a lid portion 132 attached to the base portion 131 so as to be openable and closable, and a fixing portion that fixes the lid portion 32 to the base portion 131. 133 may be included.

  The base 131 is, for example, a substantially U-shaped housing that can accommodate a locking portion between the convex portion of the first flat conductor 10B-1 and the concave portion of the second flat conductor 10B-2. is there. For convenience of explanation, FIG. 12A shows a state in which only the first flat conductor 10 </ b> B- 1 is accommodated in the base portion 131. The lid portion 132 is a flexible plate-like body that is rotatably attached to the housing via a hinge or the like and is curved so as to swell toward the base portion 131 side. For example, the fixing portion 133 is a groove portion that is attached to the base portion 131 and is provided so that an outer edge portion on the free end side of the lid portion 132 can be inserted. The lid portion 132 is inserted into the fixed portion 133 and fixed to the base portion 131, so that the convex portion of the first flat conductor 10 </ b> B- 1 and the concave portion of the second flat conductor 10 </ b> B- 2 are respectively the base portion 131. And the lid portion 132. With this configuration, the clamping force can be increased with a simple configuration and a simple operation, and the separation between the convex portion 12 and the concave portion 22 can be further prevented.

As shown in FIG. 12B, the connection assisting member 140 fixes, for example, a base portion 141, a lid portion 142 attached to the base portion 141 so as to be openable and closable, and the lid portion 142 to the base portion 141. The fixing portion 143 may be included.
The base portion 141 is, for example, similar to the base portion 131 described above, for example, having a cross-section that can accommodate a locking portion between the convex portion of the first flat conductor 10B-1 and the concave portion of the second flat conductor 10B-2. It is a U-shaped housing. The lid 142 is, for example, a plate-like body that is rotatably attached to the housing via a hinge or the like, and has a plurality of protrusions 142b on the main surface 142a on the base 141 side. The fixing portion 143 is, for example, a groove portion that is attached to the lid portion 142 and is provided so that an outer edge portion on the free end side of the lid portion 142 can be inserted, similarly to the fixing portion 133 described above. The lid 142 is inserted into the fixing part 143 and fixed to the base part 141, so that the convex part of the first flat conductor 10B-1 and the concave part of the second flat conductor 10B-2 are respectively the base part 141. And the lid 142. At this time, the clamping force can be further increased by the interposition of the plurality of protrusions. With this configuration, the clamping force can be further increased with a simple configuration and a simple operation, and the separation between the convex portion 12 and the concave portion 22 can be further suppressed.

  Fig.13 (a)-FIG.13 (d) are the figures explaining the example of the connection method of flat electric wires. As other methods for connecting the flat electric wires, for example, the first flat conductor and the second flat conductor, resistance spot welding (FIG. 13A), ultrasonic soldering (FIG. 13B), friction Stir welding (FIG. 13C), electromagnetic seam pressure welding (FIG. 13D), or the like can be used. The connection structure connected by these connection methods can be used together as a connection structure of a wire harness including the connection structures of the above-described embodiments.

  In the resistance spot welding (FIG. 13A), electrodes 152 and 153 are arranged on both sides of the laminated portion 151 of the first flat conductor 11F and the second flat conductor 21F, and a voltage is applied between these electrodes 152 and 153. When applied, a large current flows, and the first flat conductor 11F and the second flat conductor 21F are welded by the heat generated by the current.

  In the ultrasonic soldering (FIG. 13B), the solder material 154 is disposed between the first flat conductor 11G and the second flat conductor 21G, and the first flat conductor 11G, the solder material 154, and the second flat conductor 11G. In a state where the laminated portion 155 of the flat conductor 21G is pressed by the pressing portions 156 and 157 from both sides, an ultrasonic wave is applied to the laminated portion 155 via the pressing portion 156, so that the solder material 154 is generated by heat generated by the ultrasonic waves. To melt the first flat conductor 11G and the second flat conductor 21G.

  In the friction stir welding (FIG. 13C), a tool 159 having a pin 159b at the lower end 159a is placed on the butting surface 158 along the butting surface 158 between the first flat conductor 11H and the second flat conductor 21H. The first flat conductor 11F and the second flat conductor 21F are welded by moving while contacting and rotating. As a result, a band-shaped joint 160 is formed at a position corresponding to the abutting surface 158.

  In the electromagnetic seam pressure welding (FIG. 13D), the first flat plate conductor 11J is fixed and the second flat plate conductor 21J is movable, and the laminated portion of the first flat plate conductor 11J and the second flat plate conductor 21J. 161, the fixing plate 162 ′ is disposed on the first flat plate conductor 11J side, the coil 163 ′ is disposed on the second flat plate conductor 21J side, and the fixing plate 162 ′ is in contact with the first flat plate conductor 11J. By generating magnetic flux in the laminated portion 161, the first flat conductor 11J and the second flat conductor 21J are welded.

  14 (a) to 14 (d) are diagrams for explaining another example of a method for connecting the flat electric wires. As other methods for connecting the flat electric wires, for example, the first flat conductor and the second flat conductor, mechanical clinch connection (FIG. 14A), flash butt welding (FIG. 14B), bolt joining (FIG. 14C), self-piercing rivet joining (FIG. 14D), or the like can be used. The connection structure connected by these connection methods can be used together as a connection structure of a wire harness including the connection structures of the above-described embodiments.

  In the mechanical clinch connection (FIG. 14A), a jig 162 having a convex portion 162b at the lower end 162a and a jig 163 having a concave mold portion 163b at the upper end 163a are connected to the first flat conductor. 11K and the second flat plate-shaped conductor 21K are arranged opposite to each other on both sides of the laminated portion 164, and the laminated portion 164 is pressed against the die portion 163b by the convex portion 162b, thereby forming the joint portion 165 having a shape corresponding to the die portion 163b. Then, the first flat conductor 11K and the second flat conductor 21K are mechanically joined.

  In the flash butt welding (FIG. 14B), the fixed electrode 166 is connected to the first flat conductor 11L, and the movable electrode 167 is connected to the second flat conductor 21L, and the first flat conductor 11L and the second flat plate 11L are connected. With the large conductor 21L in contact, a large current is allowed to flow between the fixed electrode 166 and the movable electrode 167 from the power source 168 via the transformer, thereby the first flat conductor 11L and the second flat conductor 21L. The abutting portion 169 is heated, and the abutting portion 169 is further pressurized by the second flat conductor 21L to press the first flat conductor 11L and the second flat conductor 21L.

  In the bolt joint (FIG. 14C), one or a plurality of through holes (not shown) are provided in both the first flat conductor 11M and the second flat conductor 21M, and the bolts 170 are inserted into the through holes. By tightening with the nut 171, the first flat conductor 11 </ b> M and the second flat conductor 21 </ b> M are mechanically joined. At this time, a bolt may be fixed to one of the first plate-like conductor 11M and the second plate-like conductor 21M, and a through-hole may be provided in the other and joined by tightening with a nut. In addition, a female screw part is provided in one or both of the through hole of the first flat conductor 11M and the through hole of the second flat conductor 21M, and the male screw part of the bolt is screwed into the female screw part and joined. Also good.

  In the self-piercing rivet joining (FIG. 14 (d)), a punch part 173 guided by the guide part 172 and movable in the vertical direction, and a mold part 174 having a pair of recesses 174b and 174b on the upper end part 174a, A rivet 176 having a substantially U-shaped cross-section is pressed against both sides of the laminated portion 175 of the first flat conductor 11N and the second flat conductor 21N, and is pressed against the laminated portion 175 by the punch portion 173. As a result, the pair of leg portions of the rivet 176 penetrates the laminated portion 175 and extends away from each other along the shapes of the two concave portions 174b and 174b of the mold portion 174, and is formed on the lower surface of the second flat conductor 21N. In the abutting state, the first flat conductor 11N and the second flat conductor 21N are mechanically joined.

  Thus, by using the joining method of flat electric wires as shown in FIGS. 13 to 14, electric wires of various circuits arranged in the vehicle 200 can be comprehensively connected, and vibrations It is possible to realize disconnection due to the influence of the above and the like and to realize excellent connection reliability. Furthermore, from the viewpoint of further improving insulation and connection reliability, the above-described connection assisting member may be attached to at least a connection portion between the first flat conductor and the second flat conductor.

  Fig.15 (a)-FIG.15 (b) are figures explaining the other example of the connection method of a flat wire-twisted electric wire. As another method for connecting the flat wire and the stranded wire, for example, ultrasonic welding (FIG. 15A), ultrasonic soldering (FIG. 15B), or the like can be used. The connection structure connected by these connection methods can be used together as the connection structure of the end portion of the wire harness including the connection structure of each embodiment described above.

  In the above ultrasonic welding (FIG. 15A), ultrasonic vibration is applied to the contact portion 177 between the first flat conductor 11P and the stranded wire 22P having a substantially round cross section of the stranded wire 21P through the vibrator 178. Then, while pressing the contact portion 177, the first flat conductor 11P and the stranded wire 22P are welded.

  In ultrasonic soldering (FIG. 15B), a solder material 179 is arranged between the first flat conductor 11Q and the twisted wire 22Q having a substantially round cross section of the twisted electric wire 21Q, and the first flat conductor 11Q, solder In a state where the laminated portion 180 of the material 179 and the stranded wire 22Q is pressed by the pressing portions 181 and 182 from both sides, an ultrasonic wave is applied to the laminated portion 180 via the pressing portion 181 so that the solder generated by heat generated by the ultrasonic waves The material 179 is melted to fuse the first flat conductor 11Q and the stranded wire 22Q.

  As described above, by using the flat wire-twisted wire joining method as shown in FIG. 15, the electric wires of various circuits arranged in the vehicle 200 can be comprehensively connected, and vibrations, etc. Therefore, it is possible to realize an excellent connection reliability by preventing electrical failure due to the influence of the above. Furthermore, from the viewpoint of further improving insulation and connection reliability, the above-described connection assisting member may be attached at least to the connection portion between the first flat conductor and the stranded wire. Here, when the first flat conductor 11Q and the twisted wire 21Q are made of different materials (for example, when the first flat conductor 11 is a copper-based material and the twisted wire 21Q is an aluminum-based material), the anticorrosion effect at the connecting portion is exhibited. Thus, the connection auxiliary member is arranged.

  FIG. 16 is a perspective view for explaining another example of a flat wire-twisted wire connection method, where (a) shows a state before connection, (b) shows a state after connection, and (c) shows It is an end elevation along line AA in (b). As another method of connecting the flat electric wire and the twisted electric wire, connection via a terminal shown in FIG. 16 can be used. The connection structure connected by these connection methods can be used together as the connection structure of the end portion of the wire harness including the connection structure of each embodiment described above.

  For example, as shown in FIG. 16A, the terminal 183 includes a cylindrical crimping portion 184 having a substantially flat rectangular shape in the width direction, a cylindrical crimping portion 185 having a substantially round shape in the width direction, and a cylindrical crimping portion 184. It has a connecting part 186 that connects the cylindrical crimping part 185. The terminal 183 is made of, for example, copper or a copper alloy, and the flat conductor 11R and the stranded wire 22R are made of, for example, aluminum or an aluminum alloy.

  The cylindrical crimping part 184 has a step shape and is a cylindrical member having a shape (one end closed shape) in which the connecting part 186 side is closed, and is crimped to the insulating coating layer 13R of the flat wire 10B-1. The cover crimping portion 184a and the conductor crimping portion 184b to which the flat conductor 11R is crimped are provided.

  The cylindrical crimping portion 185 has a stepped shape and is a cylindrical member having a shape (one-end closed shape) in which the connecting portion 186 side is closed, and is covered with the insulation coating layer 23R of the twisted electric wire 21R. A portion 185a, a diameter-reduced portion 185c that decreases in diameter from the wire insertion port 185b side toward the connecting portion 186, a wire crimping portion 185d that is crimped to the stranded wire 22R, and a connecting portion 186 side from the wire insertion port 185b side. And an inclined portion 185e that is inclined by welding and has an end portion closed by welding.

  The cylindrical crimping portion 185, for example, three-dimensionally presses a flatly developed metal base and forms a cylindrical body having a substantially C-shaped cross section, and an open portion (butting portion) of the cylindrical body is formed. It is formed by laser welding. Since the laser welding of the cylindrical body is performed along the longitudinal direction (X direction) of the cylindrical body, a belt-like welded portion (weld bead) is formed in the substantially same direction as the longitudinal direction, thereby forming the cylindrical shape. A crimping portion 185 is formed. Moreover, after forming the cylindrical crimping | compression-bonding part 185, it is preferable that the edge part by the side of the connection part 186 of the inclination part 185e is sealed by laser welding. This sealing welding is performed along a direction (Y direction) perpendicular to the longitudinal direction of the crimp terminal. By this sealing welding, intrusion of moisture or the like from the connecting portion 186 side is prevented. The cylindrical crimping part 184 can also be produced by a manufacturing method similar to the above-described manufacturing method of the cylindrical crimping part 185.

  When connecting using the terminal 183, the end of the twisted electric wire 21R is inserted into the cylindrical crimping portion 185, the wire crimping portion 185b is crimped, the wire crimping portion 185b is crimped to the twisted wire 22R, and the covering The crimping part 185a is crimped to crimp the covering crimping part 185a to the insulating coating layer 23R (FIG. 16B). Further, the end of the flat electric wire 10B-1 is inserted into the cylindrical crimp portion 184, and the conductor crimp portion 184b and the flat conductor 11R are joined by, for example, the above-described mechanical clinch connection (FIG. 16C). Further, the covering crimping portion 184a is crimped to crimp the covering crimping portion 184a to the insulating coating layer 13R. Thereby, the flat electric wire 10B-1 and the twisted electric wire 21R are electrically connected via the terminal 183. Further, since the insulating coating layer 13R and the coated crimping portion 184a are in close contact with each other, the water-stopping property is exhibited, and an electrical failure within the cylindrical crimping portion 184 can be prevented. Similarly, since the insulating coating layer 23R and the coated crimping portion 185a are in close contact with each other, the water-stopping property is exhibited, and an electrical failure within the cylindrical crimping portion 185 can be prevented.

  At this time, from the viewpoint of improving water-stopping or airtightness, a filler mainly composed of a resin or the like may be filled between the coated crimping portion 184a and the insulating coating layer 13R, and the coated crimping portion 185a A filler may be filled between the insulating coating layers 23R.

  Moreover, the connection method via the terminal shown in FIG. 17 can also be used as another method of connecting a flat wire and a twisted wire. As shown in FIG. 17A, the terminal 187 includes a faston part 188 (“FASTON” is a registered trademark), a cylindrical crimp part 185 having a substantially round cross section in the width direction, and a faston part 188 and a cylindrical crimp part 185. And a connecting portion 189 for connecting the two. The faston portion 188 is a flat terminal portion having a pair of claw portions 188a and 188a formed so as to be wound inside. The connection structure connected by these connection methods can be used together as the connection structure of the end portion of the wire harness including the connection structure of each embodiment described above.

  When connecting using the terminal 187, the end of the twisted wire 21R is inserted into the cylindrical crimping portion 185, the wire crimping portion 185b is crimped, and the wire crimping portion 185b is crimped to the twisted wire 22R. The crimping portion 185a is crimped to crimp the covering crimping portion 185a to the insulating coating layer 23R (FIG. 17B). Further, by inserting the end portion of the flat wire 10B-1 into the faston portion 188, the pair of claw portions 188a and 188a bite into the flat plate conductor 11R, and the pair of claw portions 188a and 188a and the flat plate conductor 11R are connected. Is done. Thereby, the flat electric wire 10B-1 and the twisted electric wire 21R are electrically connected via the terminal 187. Further, the pair of claw portions 188a and 188a may be pressed against the flat conductor 11R by pressing the pair of claw portions 188a and 188a of the faston portion 188. When the flat conductor 11R and the terminal 187 are made of different materials (for example, when the first flat conductor 11 is an aluminum material and the terminal 187 is a copper material), the connecting portion and its periphery are surrounded by a resin or the like. It is preferable to prevent corrosion.

  Moreover, the connection method via the terminal shown in FIG. 18 can also be used as another method of connecting a flat wire and a twisted wire. As shown in FIG. 18A, the terminal 190 includes a terminal portion 191 having a concave portion 191b at an end portion 191a in the longitudinal direction, a cylindrical crimping portion 185 having a substantially round cross section in the width direction, a terminal portion 191 and a tube. And a connecting portion 192 that connects the pressure-bonding portion 185. The flat wire 10B-1 has a flat conductor 11S and an insulating coating layer 13S, and the flat conductor 11S has a convex portion 12S at the end. In FIG. 18, the concave portion 191b of the terminal portion 191 and the convex portion 12S of the flat conductor 11S have a so-called body shape, but can have, for example, the above-mentioned dovetail shape. The connection structure connected by these connection methods can be used in combination as the connection structure of the end portion of the wire harness including the connection structure of each embodiment described above, in addition to the connection structure of each embodiment described above.

  When connecting using the terminal 190, the end of the twisted electric wire 21R is inserted into the cylindrical crimping portion 185, the wire crimping portion 185b is crimped, and the wire crimping portion 185b is crimped to the twisted wire 22R. The crimping part 185a is crimped and the covering crimping part 185a is crimped to the insulating coating layer 23R (FIG. 18B). Further, the convex portion 12S of the flat conductor 11S is inserted into the concave portion 191b of the terminal portion 191, and the convex portion 12S is fitted to the concave portion 191b (FIG. 18C). Thereby, the flat electric wire 10 </ b> B- 1 and the twisted electric wire 21 </ b> R are electrically connected via the terminal 190. When the material of the flat conductor 11S and the terminal 190 are different (for example, when the flat conductor 11S is aluminum-based and the terminal 190 is copper-based), the connection portion and its periphery are surrounded by a resin or the like to prevent corrosion. Is preferred.

  In this way, by using the flat wire-twisted wire joining method as shown in FIGS. 16 to 18, it is possible to comprehensively connect wires of various circuits arranged in the vehicle 200, and Further, it is possible to prevent electrical failure due to the influence of vibration or the like and to realize better connection reliability.

  FIG. 19 is a perspective view showing another example of a flat wire-power supply box connection structure, where (a) shows a state before connection, and (b) shows a state after connection. As shown in FIG. 19 (a), the connection structure of the flat electric wires is a pair of first flat conductors 193 of the flat electric wires 10B-2 and a pair of bus bars (not shown) in the power distribution box 2. Second flat conductors 194 and 194 and a concave portion 195 provided on the second flat conductor 111 and locking the first flat conductor 193 are provided. The second flat conductor 194 has, for example, a tuning fork shape, and a concave portion 195 is provided between the pair of extending portions 196 and 196.

  In this connection structure, the end of the first flat conductor 81 of the flat electric wire 10B-2 constitutes a convex portion. The first flat plate conductor 193, which is the convex portion, is fitted into the concave portion 195, and is sandwiched and locked by the pair of extending portions 196, 196 (FIG. 19 (b)), whereby the first flat plate The conductor 193 and the pair of second flat conductors 194, 194 are electrically connected.

  By using the flat wire-power supply box joining method as shown in FIG. 19, when connecting wires of various circuits routed in the vehicle 200 and various boxes, electrical due to the influence of vibration or the like. Defects can be prevented and excellent connection reliability can be realized.

  As mentioned above, although the connection structure of the flat electric wire which concerns on this embodiment was described, this invention is not limited to description embodiment, Various deformation | transformation and a change are possible based on the technical idea of this invention. .

  For example, the connection structures Y2 to Y5 in FIG. 2 are the same as the connection structure Y1, but the configuration is not limited to this, and may be different from the connection structure Y1. That is, when a plurality of connection structures are provided on one trunk line, each connection structure may be configured in any of the above-described forms according to the arrangement position of the connection structure in the vehicle 200. Moreover, the structure from which the shape of the convex part of a connection structure of a flat wire and a concave part differs for every connection structure Y1-Y5 may be sufficient. For example, for each of the connection structures Y1 to Y5 shown in FIG. 2, the connection structure shown in FIGS. 3 to 5, the connection structure shown in FIG. 8, the connection structure shown in FIG. In addition, a configuration in which the shape of the convex portion and the concave portion is different, such as a connection structure having a concave portion, may be employed. By adopting a configuration in which the shape of the convex portion and the concave portion is different for each of the connection structures Y1 to Y5, a plurality of flat-plate electric wires 10B-1, 10B-2, 10B-3, 10B-4, 10B-5, 10B- 6 can be reliably prevented, and as a result, the power supply trunk line 10B is routed accurately. Further, as long as at least one of the connection structures Y1 to Y5 is the connection structure of each of the above-described embodiments, the other connection structure may be, for example, the connection structure illustrated in FIGS.

  Also, the connection structure of the flat wire is provided at a position separated from the longitudinal end of the first flat conductor and the first hole provided at a location apart from the longitudinal end of the first flat conductor. A second end of the first flat conductor is inserted into the second hole, and a second end of the second flat conductor is inserted into the first hole. By doing so, the first flat conductor and the second flat conductor may be electrically connected. At this time, from the viewpoint of increasing the contact area between the first flat conductor and the second flat conductor, a first step portion is provided between the longitudinal end of the first flat conductor and the first hole. Moreover, you may provide a 2nd level | step-difference part between the longitudinal direction edge part of a 2nd flat conductor, and the said 2nd hole part.

  Moreover, you may use the connection via a connector as another method of connecting flat electric wires. The connector is, for example, a housing, a first insertion portion provided in the housing and into which the first flat conductor is inserted, and a second insertion provided in the housing and into which the second flat conductor is inserted. And a terminal portion that is disposed in the housing and electrically connects the first flat conductor inserted into the first insertion portion and the second flat conductor inserted into the second insertion portion. And may be provided. The terminal portion may have various shapes such as a receptacle shape, a tuning fork shape, and a card edge shape.

  As another method of connecting the flat electric wires, the first flat conductor and the second flat conductor may be joined with a metal piece such as a staple. At this time, the first flat-plate electric wire in which the first flat-plate conductor is covered with the first insulating coating layer, and the second flat-plate electric wire in which the second flat-plate conductor is covered with the second insulating coating layer, You may join by the said metal piece from the 1st, 2nd insulating coating layer. In addition, it is preferable that the metal piece penetrates and is fixed through at least one of the first flat conductor and the second flat conductor, and is fixed through both of them. In addition, from the viewpoint of further improving insulation and connection reliability, the above-described connection assisting member may be attached to at least a connection portion between the first flat conductor and the second flat conductor. When there is a dissimilar metal joint in the connection part, the connection auxiliary member is arranged so as to exhibit the anticorrosion effect in the connection part.

  As another method for connecting the flat electric wires, a connecting member for connecting the first flat conductor and the second flat conductor may be formed of a so-called buckle member (modified example of FIG. 6). In this case, the buckle-type member has, for example, a frame body and a rotating portion that is rotatably attached to the frame body and has a plurality of protrusions. In this configuration, in a state where the rotating portion is in a standing state with respect to the main surface of the second flat plate conductor, the plurality of protrusions of the rotating portion are extended in the longitudinal direction of the second flat plate conductor. Is provided. And in the state which inserted the edge part of the said 1st flat conductor in the insertion port between the said frame of the said 2nd flat conductor, and the said rotation part, the said rotation part is made into the said 2nd flat conductor. The plurality of protrusions extend in the thickness direction of the second flat conductor, and are engaged with and pressed into the end portions of the first flat conductor. Further, the buckle-type member may have two rotating portions corresponding to the first flat conductor 81 and the second flat conductor 91 shown in FIG.

  As another method of connecting the flat electric wire and the power supply box, another conductor may be disposed between the first flat conductor and the power supply box (modified example of FIG. 7). The other conductor is, for example, a metal plate-like body, and the other conductor and the first flat conductor are connected by bolts, and the other conductor and the bus bar of the power supply box are connected by bolts. Further, when both the first flat conductor and the second flat conductor are connected to the power supply box, both the first flat conductor and the flat conductor are connected to each other via the other conductor. You may connect to the bus bar of the said power supply box. At this time, the first flat conductor and the other conductor, the second flat conductor and the other conductor, and the bus bar and the other conductor are bolt-connected. In addition, from the viewpoint of further improving insulation and connection reliability, the above-described connection assisting member may be attached to at least a connection portion between the first flat conductor and the second flat conductor. Furthermore, the through hole provided in the first flat conductor or the second flat conductor in the bolt connection is one or a plurality of long holes provided in the longitudinal direction from the viewpoint of easy attachment. Is preferred.

  Further, the protrusion extends from the end of the first flat conductor in the longitudinal direction of the first flat conductor, or the notch extends from the end of the second flat conductor to the second flat shape. It may extend in the longitudinal direction of the plate conductor.

DESCRIPTION OF SYMBOLS 1 Connection structure of flat wire 2 Power distribution box 3 Power distribution box 4 Power distribution box 5 Power distribution box 10A Power supply main line 10B Power supply main line 10B-1 Flat plate electric wire 10B-2 Flat plate electric wire 10B-3 Flat plate electric wire 10B-4 Flat wire 10B-5 Flat wire 10B-6 Flat wire 10C Power supply trunk 11 Flat conductor 11A Flat conductor 11B Flat conductor 11C Flat conductor 11D Flat conductor 11E Flat conductor 11F Flat conductor 11G Flat conductor 11G 11H Flat conductor 11J Flat conductor 11K Flat conductor 11L Flat conductor 11M Flat conductor 11N Flat conductor 11P Flat conductor 11Q Flat conductor 11R Flat conductor 11S Flat conductor 11a End 11b One main surface 11c The other Main surface 12 Convex part 12a Inclined surface 12A Convex part 12D Convex part 12E Convex shape Part 12S Convex part 13 Insulation coating layer 13A Insulation coating layer 13B Insulation coating layer 13C Insulation coating layer 13R Insulation coating layer 13S Insulation coating layer 21 Flat plate conductor 21 Flat conductor 21A Flat conductor 21B Flat conductor 21C Flat conductor 21D Flat conductor 21E Flat conductor 21F Flat conductor 21G Flat conductor 21H Flat conductor 21J Flat conductor 21J Flat conductor 21K Flat conductor 21L Flat conductor 21M Flat conductor 21N Flat conductor 21P Twisted wire 21Q Twisted wire 21R Twisted wire 21a End portion 21b One main surface 21c The other main surface 22 Concave portion 22a Inclined surface 22A Concave portion 22D Concave portion 22E Concave portion 22P Twisted wire 22Q Twisted wire 22R Twisted wire 23 Insulating coating layer 23A Insulating coating layer 23B Insulating coating layer 23C Insulation Cover layer 30 Connection auxiliary member 31 Base portion 32 Lid portion 33 Fixing portion 0-1 Flat conductor 40-2 Flat conductor 40B Flat conductor 41 Convex part 42 Concave part 50 Transition part 60 Twisted wire 61 Insulation coating layer 62 Twisted wire 70 Electric wire crimping part 71 Covered crimping part 72 to be crimped Wire insertion Port 73 Reduced diameter portion 74 Wire rod crimping portion 75 Reduced diameter portion 81 Flat conductor 81a End portion 82 Convex portion 91 Flat conductor 91a One main surface 92 Concave portion 93 Flat projection 101 Flat conductor 102 Convex portion 111 Flat plate Conductive conductor 112 Concave part 121 Tubular member 122 Resin member 123 Gap part 124 Conductive part 124 ′ Conductive member 125 Neck part 126 Head part 126 and head part 127 Narrow part 128 Wide part 130 Connection auxiliary member 131 Base part 133 Fixing part 140 Connection auxiliary member 141 Base part 142 Lid part 143 Fixing part 142a Main surface 142b Protrusion 143 Fixing part 151 Laminating part 15 Electrode 153 Electrode 154 Solder material 155 Laminating portion 156 Pressing portion 157 Pressing portion 158 Abutting surface 159 Tool 159a Lower end portion 159b Pin 160 Joining portion 161 Laminating portion 162 'Fixture 162 Jig 162a Lower end portion 162b Protruding portion 163' Coil 163 Jig 163a Upper end portion 163b Mold portion 164 Lamination portion 165 Joint portion 166 Fixed electrode 167 Movable electrode 168 Power source 169 Contact portion 170 Bolt 171 Nut 172 Guide portion 173 Punch portion 174 Mold portion 174a Upper end portion 174b Recess portion 175 Stack portion 176 Rivet 177 Contact Portion 178 Vibrator 179 Solder material 180 Laminating portion 181 Pressing portion 182 Pressing portion 183 Terminal 184 Tubular crimping portion 184a Covering crimping portion 184b Conductor crimping portion 185 Tubular crimping portion 185a Covering crimping portion 185b Wire insertion port 185c Reduced diameter portion 85d Wire rod crimping portion 185e Inclined portion 186 Connection portion 187 Terminal 188 Faston portion 188a Claw portion 189 Connection portion 190 Terminal 191 Terminal portion 191a End portion 191a Concave portion 192 Connection portion 193 Flat plate conductor 194 Flat plate conductor 195 Concave portion 196 Extension portion 200 Vehicle 201 Instrument Panel 202 Floor Panel Y1 Connection Structure Y2 Connection Structure Y3 Connection Structure Y4 Connection Structure Y5 Connection Structure

Claims (21)

A convex portion provided on the first flat conductor;
A concave portion provided on the second flat conductor and locking the convex portion,
A flat wire connecting structure in which the first flat conductor and the second flat conductor are electrically connected by locking the convex portion to the concave portion,
The convex portion is a protrusion formed integrally with an end portion of the first flat conductor and having a distal end side wider than a base side,
The concave portion is a cutout portion formed at an end portion of the second flat plate-like conductor and having a back side wider than an inlet side,
The protrusion extends from the end of the first flat conductor in the longitudinal direction of the first flat conductor, and / or the notch extends from the end of the second flat conductor to the second flat shape. The protrusion extends in the longitudinal direction of the plate conductor, and the protrusion is tapered at least partially from one main surface side of the first flat conductor toward the other main surface side in a front view of the first flat conductor. The notch is at least partially narrowed from one main surface side to the other main surface side of the second flat conductor in a front view of the second flat conductor. Having a narrow shape that is width,
Flat wire connection structure.   The flat-shaped electric wire connection structure according to claim 1, wherein the convex portion and the concave portion have a dovetail shape. A first insulating coating layer for insulatingly coating the first flat conductor;
A second insulating coating layer for insulatingly coating the second flat conductor,
The flat wire connection structure according to claim 1 or 2. A convex portion provided on the first flat conductor;
A concave portion provided on the second flat conductor and locking the convex portion,
A first insulating coating layer that insulates the first flat conductor; and a second insulating coating layer that insulates the second flat conductor;
A flat wire connecting structure in which the first flat conductor and the second flat conductor are electrically connected by locking the convex portion to the concave portion,
The convex portion is a protrusion formed integrally with an end portion of the first flat conductor and having a distal end side wider than a base side,
The concave portion is a cutout portion formed at an end portion of the second flat plate-like conductor and having a back side wider than an inlet side,
The protrusion extends from the end of the first flat conductor in the longitudinal direction of the first flat conductor, and / or the notch extends from the end of the second flat conductor to the second flat conductor. Extending in the longitudinal direction of the plate conductor,
The protrusion and the notch are formed by the elastic force in the width direction of the flat electric wire acting between the first insulating covering layer and the second insulating covering layer, and the second flat conductor and the second flat conductor. The pressure contact state with the flat conductor is maintained.
Flat wire connection structure.   The flat electric wire connection structure according to claim 4, wherein the convex portion and the concave portion have a dovetail shape.   3. A connection assisting member that covers a locking portion between the convex portion and the concave portion, is fixed to the locking portion, and further suppresses separation between the convex portion and the concave portion. The connection structure of the flat wire described in 1.   6. A connection auxiliary member that covers the locking portion between the convex portion and the concave portion and is fixed to the locking portion and further suppresses the separation between the convex portion and the concave portion. The connection structure of the flat wire of any one of these. The connection auxiliary member has a base part, a lid part attached to the base part so as to be openable and closable, and a fixing part for fixing the lid part to the base part,
The flat wire connection structure according to claim 6, wherein the convex portion and the concave portion are sandwiched between the base portion and the lid portion, respectively, in a state where the lid portion is fixed to the base portion. The connection auxiliary member has a base part, a lid part attached to the base part so as to be openable and closable, and a fixing part for fixing the lid part to the base part,
The flat wire connection structure according to claim 7, wherein the convex portion and the concave portion are sandwiched between the base portion and the lid portion, respectively, in a state where the lid portion is fixed to the base portion.   In a state where the lid portion is fixed to the base portion, the convex portion is sandwiched between the base portion and the lid portion via the first insulating coating layer, and the concave portion is the second insulating coating layer. The connection structure of the flat electric wire of Claim 9 clamped by the said base part and the said cover part via a.   The connection structure of the flat wire of any one of Claims 1 thru | or 10 by which the electroconductive member is arrange | positioned at the latching | locking part of the said convex part and the said concave part.   12. The connection structure for a flat wire according to claim 6, wherein the connection auxiliary member is a cylindrical member that covers a connection portion between the first flat conductor and the second flat conductor. A convex portion provided on the first flat conductor;
A concave portion provided on the second flat conductor and locking the convex portion,
The first flat plate conductor and the second flat plate conductor are electrically connected by locking the convex portion to the concave portion. The convex portion is constituted by an end portion of the first flat conductor,
The concave portion is provided in the second flat conductor, and includes an insertion port provided with a plurality of protrusions on the inside thereof.
With the end portion of the first flat plate conductor inserted into the insertion port of the second flat plate conductor, the plurality of protrusions are pressed into contact with the end portion of the first flat plate conductor.
Flat wire connection structure.   The connection structure of the flat wire according to claim 13, wherein the oxide film on the end portion of the first flat conductor is removed at a portion where the plurality of protrusions at the end portion of the first flat conductor are engaged. .   The flat plate according to claim 13 or 14, wherein the end portion of the first flat plate conductor is inserted into the insertion port of the second flat plate conductor while the end portion of the first flat plate conductor is covered. Wire connection structure.   The flat electric wire according to any one of claims 1 to 15, wherein the first flat conductor and the second flat conductor constitute a power trunk of a vehicle or a communication trunk of a vehicle. Connection structure.   The connection structure of the flat wire of any one of Claims 1 thru | or 16 by which one or both of a said 1st flat conductor and a said 2nd flat conductor are comprised with metal flat heat pipes. .   The connection structure of the flat electric wire of any one of Claims 1 thru | or 17 provided in at least 1 of the power supply trunk line, communication trunk line, and earth trunk line of a vehicle.   A wire harness comprising at least one flat wire connection structure according to any one of claims 1 to 18.   The wire harness according to claim 19, wherein at least one of the first flat conductor or the second flat conductor is bent.   The wire harness according to claim 19 or 20, wherein shapes of the convex portions and the concave portions of the connection structure of the plurality of flat electric wires are different for each connection structure.

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