JP2021192367A - Wire harness - Google Patents

Wire harness Download PDF

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JP2021192367A
JP2021192367A JP2021127902A JP2021127902A JP2021192367A JP 2021192367 A JP2021192367 A JP 2021192367A JP 2021127902 A JP2021127902 A JP 2021127902A JP 2021127902 A JP2021127902 A JP 2021127902A JP 2021192367 A JP2021192367 A JP 2021192367A
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molded product
injection molded
insulated wires
exposed portion
wire harness
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JP7394091B2 (en
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亮 浜崎
Akira Hamazaki
正司 藤井
Masaji Fujii
大樹 舩岡
Hiroki Funaoka
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Toyobo Co Ltd
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Toyobo Co Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G1/00—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
    • H02G1/14—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines for joining or terminating cables
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/02—Cable terminations
    • H02G15/04—Cable-end sealings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables

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  • Insulated Conductors (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

To provide a wire harness capable of meeting various needs of users.SOLUTION: This wire harness has a plurality of sealed insulated electric wires each having an insulation layer coating a surface of a conductor. The insulated electric wires have an exposed portion not coated with the insulation layers and having the conductors exposed at an end thereof; the exposed portions are joined together; at least the exposed portion is sealed by an injection molded product; the plurality of insulated electric wires is present at one end in the axial direction of the injection molded product, on an opposite side to the exposed portion; the exposed portion is present further on the other end side than a position (a 1/3 position) separated from the one end by a distance of 1/3 of the axial length of the injection molded product; an outermost tangential line of the plurality of insulated electric wires in a first cross-section orthogonal to the axial direction at the one end, is longer than the outermost tangential line of the plurality of insulated electric wires in a second cross-section orthogonal to the axial direction at the 1/3 position; and the surface of the injection molded product is exposed on a position further on the other end side relative to the 1/3 position.SELECTED DRAWING: Figure 1

Description

本発明は、複数の絶縁電線が射出成形物により封止されているワイヤハーネスに関する。 The present invention relates to a wire harness in which a plurality of insulated wires are sealed by an injection molded product.

従来、バイクや自動車等の車両には、複数の絶縁電線を部分的に一括して、収容しやすくしたワイヤハーネスが設置されている。絶縁電線束を一括するために、絶縁電線の絶縁層を部分的に剥いで導体を露出させて、この露出部を溶接、圧着等により接合する場合がある。この場合、露出部から浸水したり漏電したりする問題があった。このような問題を解決するために露出部を樹脂で封止する技術が知られている。 Conventionally, in vehicles such as motorcycles and automobiles, wire harnesses have been installed in which a plurality of insulated electric wires are partially grouped together to facilitate accommodation. In order to bundle the insulated wire bundles together, the insulating layer of the insulated wires may be partially peeled off to expose the conductor, and the exposed portions may be joined by welding, crimping, or the like. In this case, there is a problem that water infiltrates or leaks from the exposed portion. In order to solve such a problem, a technique of sealing the exposed portion with a resin is known.

例えば、特許文献１には、絶縁電線の露出部を光硬化樹脂によって封止したワイヤハーネスが開示されている。 For example, Patent Document 1 discloses a wire harness in which an exposed portion of an insulated wire is sealed with a photocurable resin.

特開２０１１−１１３６９２号公報Japanese Unexamined Patent Publication No. 2011-113692

近年、ワイヤハーネスの封止部分に対する利用者のニーズが多様化している。 In recent years, user needs for the sealed portion of a wire harness have diversified.

本発明は上記事情に鑑みてなされたものであり、その目的は、利用者の様々なニーズに応えることが可能なワイヤハーネスを提供することにある。 The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a wire harness capable of meeting various needs of users.

本発明者らは、前記課題を解決するために鋭意研究を重ねた。その結果、導体の表面に絶縁層が被覆されている複数の絶縁電線が封止されているワイヤハーネスであって、前記絶縁電線は、前記絶縁層が被覆されておらず前記導体が露出している露出部を有し、少なくとも前記露出部は、射出成形物により封止されており、前記射出成形物の軸方向の一端部であって前記露出部の反対側には、前記複数の絶縁電線が存在しており、前記一端部から前記射出成形物の軸方向長さの１／３離れた位置（以下、１／３位置という）よりも他端部側に前記露出部が存在し、前記一端部における前記軸方向に垂直な第１の断面での前記複数の絶縁電線の最外接線は、前記１／３位置における前記軸方向に垂直な第２の断面での前記複数の絶縁電線の最外接線よりも長いことで、様々な場所に収容し易いワイヤハーネスを得ることができることを見出し、本発明を完成した。 The present inventors have conducted intensive studies to solve the above-mentioned problems. As a result, the wire harness is a wire harness in which a plurality of insulated wires having an insulating layer coated on the surface of the conductor are sealed, and the insulated wires are not covered with the insulating layer and the conductor is exposed. The exposed portion has an exposed portion, and at least the exposed portion is sealed by an injection molded product, and the plurality of insulated wires are provided on one end portion in the axial direction of the injection molded product and on the opposite side of the exposed portion. Is present, and the exposed portion is present on the other end side of the position separated from the one end portion by 1/3 of the axial length of the injection molded product (hereinafter referred to as 1/3 position). The outermost wires of the plurality of insulated wires in the first cross section perpendicular to the axial direction at one end are the outermost wires of the plurality of insulated wires in the second cross section perpendicular to the axial direction at the 1/3 position. We have found that a wire harness that is longer than the outermost wire can be easily accommodated in various places, and completed the present invention.

本発明の構成は以下のとおりである。
項１．導体の表面に絶縁層が被覆されている複数の絶縁電線が封止されているワイヤハーネスであって、
前記絶縁電線は、前記絶縁層が被覆されておらず前記導体が露出している露出部を有し、
少なくとも前記露出部は、射出成形物により封止されており、
前記射出成形物の軸方向の一端部であって前記露出部の反対側には、前記複数の絶縁電線が存在しており、
前記一端部から前記射出成形物の軸方向長さの１／３離れた位置（以下、１／３位置という）よりも他端部側に前記露出部が存在し、
前記一端部における前記軸方向に垂直な第１の断面での前記複数の絶縁電線の最外接線は、
前記１／３位置における前記軸方向に垂直な第２の断面での前記複数の絶縁電線の最外接線よりも長いことを特徴とするワイヤハーネス。
項２．前記露出部は、互いに接合している項１に記載のワイヤハーネス。
項３．前記第１の断面における前記複数の絶縁電線のうち少なくとも一部の絶縁電線は、互いに接触していない項１または２に記載のワイヤハーネス。
項４．前記第１の断面における前記複数の絶縁電線の合計面積率は２０面積％以上、９０面積％以下である項１〜３のいずれかに記載のワイヤハーネス。
項５．前記第１の断面における前記複数の絶縁電線の最外接線で囲まれた領域に対する前記複数の絶縁電線の合計面積率は５０面積％以上、９０面積％以下である項１〜４のいずれかに記載のワイヤハーネス。
項６．前記複数の絶縁電線のうち一部の絶縁電線は、
前記軸方向に前記他端部から突出している項１〜５のいずれかに記載のワイヤハーネス。 The configuration of the present invention is as follows.
Item 1. A wire harness in which a plurality of insulated wires having an insulating layer coated on the surface of a conductor are sealed.
The insulated wire has an exposed portion in which the insulating layer is not covered and the conductor is exposed.
At least the exposed portion is sealed with an injection molded product, and the exposed portion is sealed.
The plurality of insulated wires exist on one end of the injection molded product in the axial direction and on the opposite side of the exposed portion.
The exposed portion is located on the other end side of the position separated from the one end portion by 1/3 of the axial length of the injection molded product (hereinafter referred to as 1/3 position).
The outermost circumscribed wire of the plurality of insulated wires in the first cross section perpendicular to the axial direction at one end thereof is
A wire harness characterized by being longer than the outermost circumscribed wire of the plurality of insulated wires in a second cross section perpendicular to the axial direction at the 1/3 position.
Item 2. Item 2. The wire harness according to Item 1, wherein the exposed portions are joined to each other.
Item 3. Item 2. The wire harness according to Item 1 or 2, wherein at least a part of the plurality of insulated wires in the first cross section is not in contact with each other.
Item 4. Item 3. The wire harness according to any one of Items 1 to 3, wherein the total area ratio of the plurality of insulated wires in the first cross section is 20 area% or more and 90 area% or less.
Item 5. Item 1 to which the total area ratio of the plurality of insulated wires is 50 area% or more and 90 area% or less with respect to the region surrounded by the outermost wires of the plurality of insulated wires in the first cross section. The described wire harness.
Item 6. Some of the insulated wires among the plurality of insulated wires are
Item 2. The wire harness according to any one of Items 1 to 5, which protrudes from the other end in the axial direction.

本発明によれば、上記構成により、様々な場所に収容し易く、封止部の気密性に優れたワイヤハーネスを得ることができる。 According to the present invention, according to the above configuration, it is possible to obtain a wire harness that can be easily accommodated in various places and has an excellent airtightness of the sealing portion.

図１（ａ）は、第１の実施形態におけるワイヤハーネスの射出成形物およびその周辺部の平面図である。図１（ｂ）は、図１（ａ）の射出成形物内を透視した図である。FIG. 1A is a plan view of an injection molded product of a wire harness according to the first embodiment and a peripheral portion thereof. FIG. 1 (b) is a perspective view of the inside of the injection molded product of FIG. 1 (a). 図２（ａ）は、図１（ａ）に示した射出成形物のＸ−Ｘ断面図である。図２（ｂ）は、図１（ａ）に示した射出成形物のＹ−Ｙ断面図である。FIG. 2A is a cross-sectional view taken along the line XX of the injection-molded article shown in FIG. 1A. FIG. 2B is a cross-sectional view taken along the line YY of the injection-molded article shown in FIG. 1A. 図３（ａ）は、第２の実施形態におけるワイヤハーネスの射出成形物およびその周辺部の平面図である。図３（ｂ）は、図３（ａ）の射出成形物内を透視した図である。FIG. 3A is a plan view of the injection molded product of the wire harness and its peripheral portion in the second embodiment. FIG. 3B is a perspective view of the inside of the injection molded product of FIG. 3A. 図４は、射出成形の概略説明図である。FIG. 4 is a schematic explanatory view of injection molding. 図５（ａ）は、射出成形に用いる入れ駒内部の断面図である。図５（ｂ）は、射出成形に用いる金型内部の断面図である。FIG. 5A is a cross-sectional view of the inside of the insert piece used for injection molding. FIG. 5B is a cross-sectional view of the inside of the mold used for injection molding.

本発明のワイヤハーネスは、導体の表面に絶縁層が被覆されている複数の絶縁電線が封止されているワイヤハーネスであって、上記絶縁電線は、上記絶縁層が被覆されておらず上記導体が露出している露出部を有し、少なくとも上記露出部は、射出成形物により封止されており、上記射出成形物の軸方向の一端部であって上記露出部の反対側には、上記複数の絶縁電線が存在しており、上記一端部から上記射出成形物の軸方向長さの１／３離れた位置（以下、１／３位置という）よりも他端部側に上記露出部が存在し、上記一端部における上記軸方向に垂直な第１の断面での上記複数の絶縁電線の最外接線は、上記１／３位置における上記軸方向に垂直な第２の断面での上記複数の絶縁電線の最外接線よりも長いものである。 The wire harness of the present invention is a wire harness in which a plurality of insulated wires having an insulating layer coated on the surface of a conductor are sealed, and the insulated wire is the conductor without the insulating layer coated. Has an exposed portion, at least the exposed portion is sealed by an injection molded product, and the axial end portion of the injection molded product and the opposite side of the exposed portion is the above. There are a plurality of insulated wires, and the exposed portion is located on the other end side of the position separated from the one end portion by 1/3 of the axial length of the injection molded product (hereinafter referred to as 1/3 position). The outermost wires of the plurality of insulated wires in the first cross section perpendicular to the axial direction at one end thereof are the plurality of in the second cross section perpendicular to the axial direction at the 1/3 position. It is longer than the outermost wire of the insulated wire.

以下、本発明のワイヤハーネスについて図面を参照しつつ説明する。 Hereinafter, the wire harness of the present invention will be described with reference to the drawings.

（第１の実施形態）
図１（ａ）は、第１の実施形態におけるワイヤハーネスの射出成形物およびその周辺部の平面図である。図１（ａ）に示すように、複数の絶縁電線１は、射出成形物４によって封止されている。 (First Embodiment)
FIG. 1A is a plan view of an injection molded product of a wire harness according to the first embodiment and a peripheral portion thereof. As shown in FIG. 1A, the plurality of insulated wires 1 are sealed by the injection molded product 4.

図１（ｂ）は、図１（ａ）の射出成形物内を透視した図である。図１（ｂ）中、二点鎖線は射出成形物４が存在する部分を示す。図１（ｂ）に示すように、絶縁電線１は導体２の表面に絶縁層３が被覆されているものであるが、絶縁電線１の先端部には、絶縁層３が被覆されておらず導体２が露出している露出部５が存在している。露出部５は射出成形物４によって封止されている。露出部５は互いに接合している。 FIG. 1 (b) is a perspective view of the inside of the injection molded product of FIG. 1 (a). In FIG. 1 (b), the alternate long and short dash line indicates the portion where the injection molded product 4 is present. As shown in FIG. 1 (b), the insulated wire 1 has an insulating layer 3 coated on the surface of the conductor 2, but the tip of the insulated wire 1 is not coated with the insulating layer 3. There is an exposed portion 5 in which the conductor 2 is exposed. The exposed portion 5 is sealed by the injection molded product 4. The exposed portions 5 are joined to each other.

本発明では、少なくとも露出部５が射出成形物４によって封止されていればよく、これにより浸水や漏電を防止し易くすることができる。浸水や漏電防止の観点より、図１（ｂ）に示すように、露出部５と共に、絶縁電線１の露出部５と隣接する部分についても、射出成形物４によって封止されていることが好ましい。 In the present invention, at least the exposed portion 5 may be sealed with the injection molded product 4, which makes it easy to prevent water ingress and electric leakage. From the viewpoint of preventing water ingress and electric leakage, as shown in FIG. 1B, it is preferable that not only the exposed portion 5 but also the portion adjacent to the exposed portion 5 of the insulated wire 1 is sealed by the injection molded product 4. ..

射出成形物４の形状は、第１の実施形態では円柱形である。射出成形物４は、樹脂を射出成形して得られるものであるため、その形状は様々であり、円柱の他、楕円柱、立方体、直方体等の形状が挙げられる。このように射出成形物４の形状は様々であるため、様々な場所に収容することができる。 The shape of the injection molded product 4 is a cylinder in the first embodiment. Since the injection-molded product 4 is obtained by injection-molding a resin, its shape is various, and examples thereof include a cylinder, an elliptical pillar, a cube, and a rectangular parallelepiped. Since the shape of the injection molded product 4 is various as described above, it can be accommodated in various places.

射出成形物４の素材は、特に限定されないが、絶縁層３、露出部５との接着性を考慮すると、ポリオレフィン、ポリアミド、ポリエステル等の樹脂が好ましい。そのうちポリエステル樹脂がより好ましい。市販品としてバイロショット（登録商標、東洋紡株式会社製）が挙げられる。バイロショットは、低圧でも射出することができるため、射出成形時の絶縁電線１の損傷を抑制し易くすることができる。そのためにバイロショットが更に好ましい。バイロショットとして、例えばバイロショット（登録商標）ＧＭ−９５５シリーズ、ＧＭ−９６０シリーズ等が挙げられる。 The material of the injection molded product 4 is not particularly limited, but resins such as polyolefin, polyamide, and polyester are preferable in consideration of the adhesiveness to the insulating layer 3 and the exposed portion 5. Of these, polyester resin is more preferable. As a commercially available product, Viloshot (registered trademark, manufactured by Toyobo Co., Ltd.) can be mentioned. Since the byloshot can be injected even at a low pressure, it is possible to easily suppress damage to the insulated wire 1 during injection molding. Therefore, bylo shot is more preferable. Examples of the Biroshot include the Biroshot (registered trademark) GM-955 series and the GM-960 series.

本発明において、射出成形物４の特性を損なわない範囲で、従来の各種添加剤を添加することができる。添加剤として、シリカ、タルク等の充填剤；酸化アンチモン、水酸化アルミ、水酸化マグネシウム等の難燃剤；フタル酸エステル、アジピン酸エステル等の可塑剤；ポリエチレンワックス、シリコーンオイル等の離型剤；カルボジイミド等の加水分解抑制剤等が挙げられる。これらの添加剤は、その一種のみを単独で用いてもよく、二種以上を組み合わせて用いてもよい。添加剤の含有量は、射出成形物４の素材として用いられる樹脂１００質量部に対して、おおよそ０．１質量部以上、５０質量部以下であることが好ましい。添加剤の含有量は、より好ましくは１質量部以上、３０質量部以下、更に好ましくは５質量部以上、２０質量部以下である。 In the present invention, various conventional additives can be added as long as the characteristics of the injection molded product 4 are not impaired. As additives, fillers such as silica and talc; flame retardants such as antimony oxide, aluminum hydroxide and magnesium hydroxide; plasticizers such as phthalates and adipates; mold release agents such as polyethylene wax and silicone oil; Examples thereof include hydrolysis inhibitors such as carbodiimide. These additives may be used alone or in combination of two or more. The content of the additive is preferably about 0.1 part by mass or more and 50 parts by mass or less with respect to 100 parts by mass of the resin used as the material of the injection molded product 4. The content of the additive is more preferably 1 part by mass or more and 30 parts by mass or less, and further preferably 5 parts by mass or more and 20 parts by mass or less.

露出部５は、必ずしも互いに接合している必要はないが、接合している方が露出部５を封止し易くなる。そのために、露出部５どうし互いに接合していることが好ましい。接合方法は、公知の方法である溶接、圧着等を行えば良い。 The exposed portions 5 do not necessarily have to be joined to each other, but it is easier to seal the exposed portions 5 if they are joined. Therefore, it is preferable that the exposed portions 5 are joined to each other. As the joining method, known methods such as welding and crimping may be performed.

露出部５は、必ずしも絶縁電線１の先端に存在する必要はないが、露出部５の接合のし易さの観点より、露出部５は絶縁電線１の先端に存在することが好ましい。 The exposed portion 5 does not necessarily exist at the tip of the insulated wire 1, but it is preferable that the exposed portion 5 exists at the tip of the insulated wire 1 from the viewpoint of ease of joining the exposed portion 5.

絶縁電線１は、バイク等に用いられる一般的な絶縁電線である。導体２の素材は、銅、銅合金、アルミニウム、銀、またはこれらを金メッキ、錫メッキしたもの等が挙げられる。絶縁層３の素材は、ポリ塩化ビニル、ポリエチレン、ポリプロピレン等の樹脂が挙げられる。 The insulated wire 1 is a general insulated wire used for motorcycles and the like. Examples of the material of the conductor 2 include copper, a copper alloy, aluminum, silver, or gold-plated or tin-plated materials thereof. Examples of the material of the insulating layer 3 include resins such as polyvinyl chloride, polyethylene, and polypropylene.

図１（ａ）、（ｂ）中、破線矢印は、射出成形物４の軸方向を示す。 In FIGS. 1 (a) and 1 (b), the broken line arrow indicates the axial direction of the injection molded product 4.

図１（ｂ）に示すとおり、射出成形物４の軸方向の一端部Ａは、露出部５の反対側に位置し、一端部Ａには複数の絶縁電線１が存在している。射出成形物４の一端部Ａから、射出成形物４の軸方向長さ（破線矢印の長さ）の１／３離れた１／３位置（以下では、位置Ｃと呼ぶ）よりも他端部Ｂ側に露出部５が存在している。 As shown in FIG. 1 (b), one end A of the injection molded product 4 in the axial direction is located on the opposite side of the exposed portion 5, and a plurality of insulated wires 1 are present at one end A. The other end of the injection molded product 4 from one end A at a position 1/3 away from the axial length (length of the broken line arrow) of the injection molded product 4 (hereinafter referred to as position C). The exposed portion 5 exists on the B side.

射出成形物４の一端部Ａは、複数の絶縁電線１が陥入している部分であるため、経年劣化等による隙間が生じ易い。この隙間から浸水した場合、露出部５が一端部Ａに近すぎると、露出部５をつたって絶縁電線１の内部まで浸水するおそれがあるが、露出部５を一端部Ａから離れた位置に存在させることにより、浸水を防止し易くすることができる。そのために、露出部５は、軸方向に位置Ｃよりも他端部Ｂ側に存在する。更に露出部５は、一端部Ａから、射出成形物４の軸方向長さの１／２離れた１／２位置よりも他端部Ｂ側に存在することが好ましい。 Since one end A of the injection molded product 4 is a portion in which a plurality of insulated wires 1 are embedded, gaps are likely to occur due to aged deterioration or the like. When water is flooded through this gap, if the exposed portion 5 is too close to the one end portion A, the exposed portion 5 may be flooded to the inside of the insulated wire 1, but the exposed portion 5 may be located away from the one end portion A. By presenting it, it is possible to easily prevent flooding. Therefore, the exposed portion 5 exists on the other end portion B side of the position C in the axial direction. Further, it is preferable that the exposed portion 5 is located on the other end portion B side of the one end portion A at a position 1/2 away from the axial length of the injection molded product 4.

一方、露出部５が他端部Ｂに近すぎると、他端部Ｂが損傷した場合、露出部５が外部に露出するおそれがある。そのために露出部５は、他端部Ｂから、射出成形物４の軸方向長さの１／２０離れた位置よりも一端部Ａ側に存在することが好ましい。 On the other hand, if the exposed portion 5 is too close to the other end portion B, the exposed portion 5 may be exposed to the outside if the other end portion B is damaged. Therefore, it is preferable that the exposed portion 5 is located on the one end portion A side of the other end portion B at a position separated by 1/20 of the axial length of the injection molded product 4.

射出成形物４の軸方向長さは、特に限定されないが、おおよそ１〜２０ｃｍである。 The axial length of the injection molded product 4 is not particularly limited, but is approximately 1 to 20 cm.

図２（ａ）は、図１（ａ）の一端部Ａにおける軸方向に垂直なＸ−Ｘ断面図である。図２（ｂ）は、図１（ａ）の位置Ｃにおける軸方向に垂直なＹ−Ｙ断面図である。以下では、Ｘ−Ｘ断面を単に第１の断面と呼ぶ場合がある。また、Ｙ−Ｙ断面を単に第２の断面と呼ぶ場合がある。 FIG. 2A is a sectional view taken along line XX perpendicular to the axial direction at one end A of FIG. 1A. FIG. 2B is a sectional view taken along the line YY perpendicular to the axial direction at position C in FIG. 1A. Hereinafter, the XX cross section may be simply referred to as a first cross section. Further, the YY cross section may be simply referred to as a second cross section.

図２（ａ）、（ｂ）中、破線は各断面における複数の絶縁電線１の最外接線を示す。図２（ａ）に示す第１の断面における複数の絶縁電線１の最外接線は、図２（ｂ）に示す第１の断面における複数の絶縁電線１の最外接線よりも長くなっている。このように第１の断面の各絶縁電線１の間隔を広くすることにより、射出成形時に樹脂が内部まで充填され易くなり、その結果、射出成形物４の気密性を高めることができる。特に第１の断面は、絶縁電線１と樹脂との間に間隙が生じ易いため、この部分の樹脂の充填度を高めておくことが浸水を防止する上で有効である。 In FIGS. 2A and 2B, the broken line indicates the outermost circumscribed line of the plurality of insulated wires 1 in each cross section. The outermost circumscribed line of the plurality of insulated wires 1 in the first cross section shown in FIG. 2 (a) is longer than the outermost circumscribed line of the plurality of insulated wires 1 in the first cross section shown in FIG. 2 (b). .. By widening the distance between the insulated wires 1 in the first cross section in this way, the resin can be easily filled to the inside during injection molding, and as a result, the airtightness of the injection molded product 4 can be improved. In particular, in the first cross section, a gap is likely to occur between the insulated wire 1 and the resin, so it is effective to increase the filling degree of the resin in this portion in order to prevent water ingress.

本発明における最外接線とは、射出成形物４の軸方向に垂直な断面において、複数の絶縁電線１を囲むようにして複数の絶縁電線１と外接する接線であって、最短のものを意味する。 The outermost tangent line in the present invention means the shortest tangent line that circumscribes a plurality of insulated wires 1 so as to surround the plurality of insulated wires 1 in a cross section perpendicular to the axial direction of the injection molded product 4.

図２（ａ）に示すとおり、第１の断面における複数の絶縁電線１のうち少なくとも一部の絶縁電線１は、互いに接触していないことが好ましい。絶縁電線１と樹脂との間に間隙が生じた場合、互いに接触していない絶縁電線１が多い程、その間隙が連結しにくくなるため、気密性を維持し易くすることができる。そのために第１の断面において、全ての複数の絶縁電線１が互いに接触していないことが最も好ましい。 As shown in FIG. 2A, it is preferable that at least a part of the insulated wires 1 in the first cross section is not in contact with each other. When a gap is generated between the insulated wire 1 and the resin, the more the insulated wires 1 are not in contact with each other, the more difficult it is to connect the gap, so that the airtightness can be easily maintained. Therefore, in the first cross section, it is most preferable that all the plurality of insulated wires 1 are not in contact with each other.

第１の断面における複数の絶縁電線１の合計面積率は、好ましくは２０面積％以上、９０面積％以下である。合計面積率が２０面積％以上であることにより、射出成形物４に用いる樹脂量を少なくすることができ、コストを低減することができる。合計面積率は、より好ましくは３０面積％以上、更に好ましくは４０面積％以上である。一方、合計面積率が９０面積％以下であることにより、射出成形物４が損傷しても、導体２が外部に露出しにくくなる。合計面積率は、より好ましくは８０面積％以下、更に好ましくは７０面積％以下である。 The total area ratio of the plurality of insulated wires 1 in the first cross section is preferably 20 area% or more and 90 area% or less. When the total area ratio is 20 area% or more, the amount of resin used for the injection molded product 4 can be reduced, and the cost can be reduced. The total area ratio is more preferably 30 area% or more, still more preferably 40 area% or more. On the other hand, when the total area ratio is 90 area% or less, even if the injection molded product 4 is damaged, the conductor 2 is less likely to be exposed to the outside. The total area ratio is more preferably 80 area% or less, still more preferably 70 area% or less.

第１の断面における複数の絶縁電線１の最外接線で囲まれた領域（以下、第１の最外接線領域と呼ぶ）に対する複数の絶縁電線１の合計面積率は、好ましくは５０面積％以上、９０面積％以下である。第１の最外接線領域に対する合計面積率が９０面積％以下であることにより、樹脂が充填され易くなり、射出成形物４の気密性が高くなる。合計面積率は、より好ましくは８０面積％以下、更に好ましくは７０面積％以下である。一方、第１の最外接線領域に対する合計面積率が５０面積％以上であることにより、射出成形物４に用いる樹脂量を少なくすることができ、コストを低減することができる。合計面積率は、より好ましくは５５面積％以上、更に好ましくは６０面積％以上である。 The total area ratio of the plurality of insulated wires 1 to the region surrounded by the outermost wires of the plurality of insulated wires 1 in the first cross section (hereinafter referred to as the first outermost circumscribed wire region) is preferably 50 area% or more. , 90 area% or less. When the total area ratio with respect to the first circumscribed line region is 90 area% or less, the resin can be easily filled and the airtightness of the injection molded product 4 becomes high. The total area ratio is more preferably 80 area% or less, still more preferably 70 area% or less. On the other hand, when the total area ratio with respect to the first outermost circumscribed line region is 50 area% or more, the amount of resin used for the injection molded product 4 can be reduced, and the cost can be reduced. The total area ratio is more preferably 55 area% or more, still more preferably 60 area% or more.

第２の断面における複数の絶縁電線１の好ましい合計面積率は、第１の断面における複数の絶縁電線１の好ましい合計面積率と同じである。 The preferred total area ratio of the plurality of insulated wires 1 in the second cross section is the same as the preferred total area ratio of the plurality of insulated wires 1 in the first cross section.

第２の断面における複数の絶縁電線１の最外接線で囲まれた領域（以下、第２の最外接線領域と呼ぶ）に対する複数の絶縁電線１の合計面積率は、好ましくは６０面積％以上、９５面積％以下である。第２の最外接線領域に対する合計面積率が６０面積％以上であることにより、射出成形物４に用いる樹脂量を少なくすることができ、コストを低減することができる。合計面積率は、より好ましくは７０面積％以上、更に好ましくは８０面積％以上である。一方、第２の最外接線領域に対する合計面積率が９５面積％以下であることにより、位置Ｃにおいても樹脂が充填され易くなり、射出成形物４の気密性を高めることができる。合計面積率は、より好ましくは９０面積％以下、更に好ましくは８５面積％以下である。 The total area ratio of the plurality of insulated wires 1 to the region surrounded by the outermost wires of the plurality of insulated wires 1 in the second cross section (hereinafter referred to as the second outermost circumscribed wire region) is preferably 60 area% or more. , 95 area% or less. When the total area ratio with respect to the second circumscribed line region is 60 area% or more, the amount of resin used for the injection molded product 4 can be reduced, and the cost can be reduced. The total area ratio is more preferably 70 area% or more, still more preferably 80 area% or more. On the other hand, when the total area ratio with respect to the second circumscribed line region is 95 area% or less, the resin can be easily filled even at the position C, and the airtightness of the injection molded product 4 can be improved. The total area ratio is more preferably 90 area% or less, still more preferably 85 area% or less.

図２（ａ）、（ｂ）に示すとおり、第１の実施形態では、複数の絶縁電線１は、それぞれ同じ径であるが、それぞれ異なる径のものを用いても良い。 As shown in FIGS. 2A and 2B, in the first embodiment, the plurality of insulated wires 1 have the same diameter, but different diameters may be used.

絶縁電線１の径は、特に限定されないが、おおよそ０．３〜１０ｍｍである。 The diameter of the insulated wire 1 is not particularly limited, but is approximately 0.3 to 10 mm.

射出成形物４の径は、特に限定されないが、おおよそ２〜１００ｍｍである。 The diameter of the injection molded product 4 is not particularly limited, but is approximately 2 to 100 mm.

（第２の実施形態）
図３（ａ）は、第２の実施形態におけるワイヤハーネスの射出成形物およびその周辺部の平面図である。図３（ｂ）は、図３（ａ）の射出成形物内を透視した図である。なお、第１の実施形態のワイヤハーネス１０と同様の構成要素には同一番号を記し、その説明を省略する。 (Second embodiment)
FIG. 3A is a plan view of the injection molded product of the wire harness and its peripheral portion in the second embodiment. FIG. 3B is a perspective view of the inside of the injection molded product of FIG. 3A. The same number is given to the same components as the wire harness 10 of the first embodiment, and the description thereof will be omitted.

図３（ａ）に示すように、複数の絶縁電線１は、射出成形物４によって封止されている。複数の絶縁電線１のうち一部の絶縁電線１は、射出成形物４の他端部Ｂから突出している。 As shown in FIG. 3A, the plurality of insulated wires 1 are sealed by the injection molded product 4. A part of the insulated wires 1 out of the plurality of insulated wires 1 protrudes from the other end B of the injection molded product 4.

本発明では、露出部５が射出成形物４により封止されていればよく、一部の絶縁電線１を射出成形物４から突出させることもできる。これにより、本発明のワイヤハーネス１０は、様々な用途に使用し易いものになる。 In the present invention, the exposed portion 5 may be sealed by the injection molded product 4, and a part of the insulated wire 1 can be projected from the injection molded product 4. This makes the wire harness 10 of the present invention easy to use for various purposes.

なお、図３（ｂ）に示すように、本発明では、射出成形物４内において、必ずしも全ての絶縁電線１に露出部５が存在する必要はなく、一部の絶縁電線１に露出部５が存在する態様であっても良い。 As shown in FIG. 3B, in the present invention, it is not always necessary that all the insulated wires 1 have the exposed portions 5 in the injection molded product 4, and some of the insulated wires 1 do not have the exposed portions 5. May be present.

次に、ワイヤハーネス１０の製造方法について、図４、５を参照しつつ説明する。 Next, a method of manufacturing the wire harness 10 will be described with reference to FIGS. 4 and 5.

図４は、射出成形の概略説明図である。図５（ａ）は、入れ駒内部の断面図である。図５（ｂ）は、金型内部の断面図である。 FIG. 4 is a schematic explanatory view of injection molding. FIG. 5A is a cross-sectional view of the inside of the insert piece. FIG. 5B is a cross-sectional view of the inside of the mold.

図４の下側金型３０ａには、３つの溝部２１ａが設けられた下側入れ駒２０ａが陥入されている。更に、下側金型３０ａには溝部３１ａが設けられている。 In the lower mold 30a of FIG. 4, a lower insertion piece 20a provided with three groove portions 21a is recessed. Further, the lower mold 30a is provided with a groove portion 31a.

まず、下側金型３０ａの溝部３１ａに絶縁電線１の露出部５が位置するように複数の絶縁電線１を配置する。次に、図５（ａ）に示すとおり、下側入れ駒２０ａの３つの溝部２１ａに、絶縁電線１をそれぞれはめこむ。これにより、各溝部２１ａ間の距離だけ絶縁電線１の間隔が広がった状態になる。溝部２１ａの数は特に限定されず、２つ以上あれば良い。各溝部２１ａ間の距離を変えることにより、複数の絶縁電線１の疎密を制御することができる。 First, a plurality of insulated wires 1 are arranged so that the exposed portion 5 of the insulated wire 1 is located in the groove portion 31a of the lower mold 30a. Next, as shown in FIG. 5A, the insulated wire 1 is fitted into each of the three groove portions 21a of the lower insertion piece 20a. As a result, the distance between the insulated wires 1 is widened by the distance between the groove portions 21a. The number of the groove portions 21a is not particularly limited, and may be two or more. By changing the distance between the groove portions 21a, it is possible to control the sparseness and tightness of the plurality of insulated wires 1.

図５（ｂ）は、図４の下側金型３０ａに上側金型３０ｂを重ね合わせたときの金型内部断面図である。下側金型３０ａの溝部３１ａと、上側金型３０ｂの溝部３１ｂにより形成される空間に樹脂を充填する。 FIG. 5B is a cross-sectional view of the inside of the mold when the upper mold 30b is superposed on the lower mold 30a of FIG. The space formed by the groove portion 31a of the lower mold 30a and the groove portion 31b of the upper mold 30b is filled with resin.

樹脂の充填は、溶融状態の樹脂を金型内に射出して行う。その際に、例えば、図４に示すようなランナー３２を介して、矢印方向に樹脂を流し込めば良い。なお、図４には１つのランナーと１つの流動方向を示しているが、金型にランナーを複数個設けて、複数個射出成形物を成型しても何ら問題ない。 The resin is filled by injecting the molten resin into the mold. At that time, for example, the resin may be poured in the direction of the arrow via the runner 32 as shown in FIG. Although FIG. 4 shows one runner and one flow direction, there is no problem even if a plurality of runners are provided in the mold to mold a plurality of injection molded products.

このようにして樹脂を充填した後、冷却して、余分な部分を除去することにより射出成形物４が形成され、ワイヤハーネス１０が得られる。 After filling the resin in this way, the resin is cooled and cooled to remove the excess portion, whereby the injection molded product 4 is formed, and the wire harness 10 is obtained.

射出圧力は、特に限定されないが０．０５ＭＰａ以上、５０ＭＰａ以下であることが好ましい。射出圧力を５０ＭＰａ以下とすることにより、射出時の絶縁電線１の動きを抑制することができ、絶縁電線１の損傷を抑制し易くすることができる。一方、射出圧力を０．０５ＭＰａ以上とすることにより、樹脂を充填し易くすることができる。なお、樹脂としてバイロショットを用いる場合は、０．１ＭＰａ以上、３０ＭＰａ以下の低い射出圧力で成形することができる。 The injection pressure is not particularly limited, but is preferably 0.05 MPa or more and 50 MPa or less. By setting the injection pressure to 50 MPa or less, the movement of the insulated wire 1 at the time of injection can be suppressed, and damage to the insulated wire 1 can be easily suppressed. On the other hand, by setting the injection pressure to 0.05 MPa or more, it is possible to facilitate filling with the resin. When Viloshot is used as the resin, it can be molded at a low injection pressure of 0.1 MPa or more and 30 MPa or less.

本願は、２０１６年５月１９日に出願された日本国特許出願第２０１６−１００４２７号に基づく優先権の利益を主張するものである。２０１６年５月１９日に出願された日本国特許出願第２０１６−１００４２７号の明細書の全内容が、本願に参考のため援用される。 This application claims the benefit of priority under Japanese Patent Application No. 2016-100427 filed on May 19, 2016. The entire contents of the specification of Japanese Patent Application No. 2016-100427 filed on May 19, 2016 are incorporated herein by reference.

１ 絶縁電線
２ 導体
３ 絶縁層
４ 射出成形物
５ 露出部
１０ ワイヤハーネス
２０ａ 下側入れ駒
２１ａ 下側入れ駒の溝部
３０ａ 下側金型
３０ｂ 上側金型
３１ａ 下側金型の溝部
３１ｂ 上側金型の溝部
３２ ランナー
Ａ 一端部 Ｂ 他端部
Ｃ １／３位置 1 Insulated wire 2 Conductor 3 Insulated layer 4 Injection molded product 5 Exposed part 10 Wire harness 20a Lower insert piece 21a Lower insert piece groove 30a Lower mold 30b Upper mold 31a Lower mold groove 31b Upper mold Groove 32 Runner A One end B The other end C 1/3 position

Claims (5)

導体の表面に絶縁層が被覆されている複数の絶縁電線が封止されているワイヤハーネスであって、
前記絶縁電線は、前記絶縁層が被覆されておらず前記導体が露出している露出部を端部に有し、前記露出部は、互いに接合しており、
少なくとも前記露出部は、射出成形物により封止されており、
前記射出成形物の軸方向の一端部であって前記露出部の反対側には、前記複数の絶縁電線が存在しており、
前記一端部から前記射出成形物の軸方向長さの１／３離れた位置（以下、１／３位置という）よりも他端部側に前記露出部が存在し、
前記一端部における前記軸方向に垂直な第１の断面での前記複数の絶縁電線の最外接線は、
前記１／３位置における前記軸方向に垂直な第２の断面での前記複数の絶縁電線の最外接線よりも長く、
前記１／３位置よりも他端部側の前記射出成形物の表面は露出していることを特徴とするワイヤハーネス。 A wire harness in which a plurality of insulated wires having an insulating layer coated on the surface of a conductor are sealed.
The insulated wire has an exposed portion at the end where the insulating layer is not covered and the conductor is exposed, and the exposed portions are joined to each other.
At least the exposed portion is sealed with an injection molded product, and the exposed portion is sealed.
The plurality of insulated wires exist on one end of the injection molded product in the axial direction and on the opposite side of the exposed portion.
The exposed portion is located on the other end side of the position separated from the one end portion by 1/3 of the axial length of the injection molded product (hereinafter referred to as 1/3 position).
The outermost circumscribed wire of the plurality of insulated wires in the first cross section perpendicular to the axial direction at one end thereof is
Longer than the outermost wire of the plurality of insulated wires in the second cross section perpendicular to the axial direction at the 1/3 position.
A wire harness characterized in that the surface of the injection molded product on the other end side of the 1/3 position is exposed. 前記第１の断面における前記複数の絶縁電線のうち少なくとも一部の絶縁電線は、互いに接触していない請求項１に記載のワイヤハーネス。 The wire harness according to claim 1, wherein at least a part of the insulated wires in the first cross section is not in contact with each other. 前記第１の断面における前記複数の絶縁電線の合計面積率は２０面積％以上、９０面積％以下である請求項１または２に記載のワイヤハーネス。 The wire harness according to claim 1 or 2, wherein the total area ratio of the plurality of insulated wires in the first cross section is 20 area% or more and 90 area% or less. 前記第１の断面における前記複数の絶縁電線の最外接線で囲まれた領域に対する前記複数の絶縁電線の合計面積率は５０面積％以上、９０面積％以下である請求項１〜３のいずれかに記載のワイヤハーネス。 One of claims 1 to 3 in which the total area ratio of the plurality of insulated wires to the region surrounded by the outermost wires of the plurality of insulated wires in the first cross section is 50 area% or more and 90 area% or less. Wire harness described in. 前記複数の絶縁電線のうち一部の絶縁電線は、
前記軸方向に前記他端部から突出している請求項１〜４のいずれかに記載のワイヤハーネス。 Some of the insulated wires among the plurality of insulated wires are
The wire harness according to any one of claims 1 to 4, which protrudes from the other end in the axial direction.
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