JP3061220B2 - Manufacturing method of flat wire harness - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a flat wire harness mainly used for electric wiring of a vehicle.

[0002]

2. Description of the Related Art Instead of a conventional wire harness, the applicant has proposed a flat wire harness (FIG. 11 to FIG. 13) as shown in FIGS. (Japanese Patent Application No. 2-115827)
Suggested.

[0003] In FIG. 11, on a long which is formed along the arrangement設経path in the vehicle of the insulating plate 1, a plurality of relay circuit boards 2, 2 ₁ at a predetermined interval as the relay circuit board, 2 ₂ ... fixed Have been. Each relay circuit board is formed by press-fitting and fixing a junction bar 4 as an internal circuit conductor to a plurality of slits 3a arranged in parallel on the circuit board 3, as represented by reference numeral 2 in FIG. The junction bar 4 has tabs 4a formed at both ends or one end thereof, and a press-contact terminal portion 4b having a slot 4c at one side edge is protrudingly provided. 5, 5 '
5 shows a connector mounted on the tab 4a, which is configured by inserting a female-female relay terminal 6 into a terminal accommodating chamber 5b in a connector housing 5a.

[0004] Electrical connection of the relay circuit plates by known automatic wiring machine 10, and pressed against one end of the covered electric wire 7, for example, in pressure contact terminal portion of the slot indicated by the relay circuit board 2 _first code 4b ₁ after, adjacent toward the relay circuit board 2 ₂ wired, and pressed into the bottom of the press-connecting terminal portion 4b ₂ of the slot, wherein either the cutting, toward the next relay circuit board 2 ₃ without cutting distribution To search. Hereafter, by repeating this arrangement in sequence,
A circuit is formed to conduct with the connectors 5, 5 '.

[0005] After forming a predetermined circuit, as shown in FIG. 13, the adhesive protective sheet 8, the insulating plates 1 and the relay circuit board 2, 2 _1, 2 ₂ ... put on using a heating roller R ,
The fixed group of covered electric wires 7 is fixed and protected, and a protective cover 9 is further attached as necessary to form a flat wire harness.

As shown in FIG. 14, the adhesive protective sheet 8 is a composite sheet in which a plastic film a is provided with a self-adhesive adhesive layer b such as butyl rubber.
The adhesive layer is melted by the heating roller R, and the adhesive is spread around the group of covered electric wires 7 and the circuit conductors, so that the group of covered electric wires 7 and the circuit conductors and the protective sheet 8 are adhered and fixed. I am trying to do it.

However, such an insulating sheet 8
In the case where the arrangement density of the insulated wires 7 and the circuit conductors is increased, the molten adhesive does not sufficiently spread around the densely insulated wires 7 and the circuit conductors, and the bonding is incomplete. There is a problem that it hinders the fixing and protection of the circuit conductor.

[0008]

SUMMARY OF THE INVENTION The present invention is directed to a method of manufacturing a flat wire harness with improved reliability which can securely fix a wiring conductor even to a high-density wiring conductor by focusing on the above problems. The task is to provide

[0009]

Means for Solving the Problems In order to achieve the above object, the present invention provides an insulating sheet provided with a hot melt adhesive layer having a large number of protrusions made of a hot melt adhesive formed on the surface of a synthetic resin sheet. A plurality of relay circuit boards provided with a plurality of circuit conductors inside the case and a connector provided at least at one end of the case and electrically connected to the circuit conductors are arranged at predetermined intervals, and electric wires are provided between these relay circuit boards. After arranging and forming a circuit that connects the desired circuit conductor and the electric wire and conducts with the connector, the relay circuit board and the electric wire laid between the relay circuit boards are covered with a protective sheet. By heating, the hot melt adhesive is melted to fix the insulation sheet and the protection sheet to the relay circuit board and the wires routed between the relay circuit boards. The features.

Further, a wiring conductor supporting projection for wiring made of a hot melt adhesive is formed on the hot melt adhesive layer of the insulating sheet, and an electric wire routed between the relay circuit boards is bent at the wiring conductor supporting projection. Then, it is preferable to form a circuit that is electrically connected to the connector by connecting to a terminal terminal incorporated in the connector (claim 2).

[0011]

According to the present invention, the wiring conductor is heated together with the superposed protective sheet while being held between the multiple protrusions made of the hot melt adhesive provided on the hot melt adhesive layer of the insulating sheet, and the hot conductor is heated. A large number of protrusions made of the melt adhesive are melted, and the periphery of the wiring conductor is adhered in a mesh-like manner, and can be securely fixed. When a flat wire harness is formed by bending a wiring conductor using a corner pin, a wiring conductor supporting projection made of a hot-melt adhesive can be used for the wiring instead of the corner pin.

[0012]

FIG. 1 is a perspective view of an insulating sheet A used in an embodiment of the present invention. The insulating sheet A is a synthetic resin sheet 1
It has a two-layer structure in which a hot-melt adhesive layer 13 having a large number of cilia-like projections 12 made of a hot-melt adhesive is provided on the surface of the substrate 1.

The cilia-like projections 12 are formed on the synthetic resin film 1.
1, a metal plate provided with a large number of fine holes, which is provided densely in an unspecified shape and not shown,
It can be formed by pouring a hot melt adhesive melted by heating, cooling and hardening the hot melt adhesive, and then peeling the metal plate from the synthetic resin film 11. The shape of the cilia-like projections 12 can be arbitrarily changed from a fine cilia-like shape to a strong shape capable of supporting a thick wiring conductor like a corner pin described later by changing a fine hole provided in the metal plate. Can be formed.

Next, a method of manufacturing a flat wire harness using the insulating sheet A will be described. FIG. 2 shows that the relay circuit boards 2, 2 ₁ , 2 ₂ ,.
The state which covered wire 7 as a wiring conductor by a known automatic wiring machine is shown. As shown in FIG. 3, the covered electric wire 7 is held in a stable state by a large number of cilia-like projections 12 formed on the hot melt adhesive layer 13.

[0015] with respect to each of the relay circuit board 2, 2 _1, 2 ₂ ...,
After the wiring is performed in the same manner as in the case of FIG. 9, as shown in FIG. 4, the hot melt adhesive is melted by overlapping the protective sheet 14 and heating using the heating roller R, and the coated coating is formed. wire 7 and the relay circuit board 2, 2 _1, 2 ₂ ... a and bonded and fixed to the protective sheet 14 and insulating sheet 13 and the coating to form a flat wire harness. The protective sheet 14 has a large number of ciliated protrusions 12 like the insulating sheet A.
Although the composite sheet having the hot melt adhesive layer 13 formed with the above is used, a synthetic resin sheet having no cilia-like projections can be used.

In a state where the hot-melt adhesive is melted and bonded, as shown in a cross section in FIG. 5, cilia-like projections 12 are adhered to the periphery of the covered electric wire 7 in a mesh form. Are securely fixed between the insulating sheet A and the protective sheet 14. The relay circuit board 15 shown in FIGS. 6 and 7 is an example in which the weight is reduced by using the covered electric wire 7 instead of the junction bar 4 as the internal circuit conductor.

As shown in FIG. 6, the relay circuit board 15 includes a box-shaped lower case 16a formed of a synthetic resin material and a plate-shaped upper case 16b formed with a press-contact hole 16c. A plurality of insulation displacement terminals 17 are provided as conductors, and a connector 18 is provided at least at one end.

As shown in FIG. 7, inside the relay circuit board 15, in order to make the press contact terminal 17 and the connector 18 conductive,
Connector terminal 19 housed in connector 18 and pressure contact terminal 1
7 and a covered electric wire 7 is connected. ID terminal 17
Is formed by pressing or bending a single conductive metal plate, and includes a board portion 17a, a pair of external electric wire press-contact portions 17b erected at both ends thereof, and an inner erected joint at one side thereof. The lower case 1 comprises an electric wire pressure contact portion 17c and a clip-shaped engaging claw 17d downwardly coupled to the other side.
6a is fixed by engaging a locking claw 17d with a locking hole 16e of a bottom wall 16d. The outer wire press-contact portion 17b and the internal wire press-contact portion 17c are formed with slots 17e and 17f for wire press-fitting, respectively, and a height difference is provided between the external wire press-contact portion 17b and the internal wire press-contact portion 17c to cover the wire. The electric wire 7 can be connected so as to cross vertically, and the bottom of the slot 17f is formed one step (larger than the outer diameter of the electric wire) lower than the bottom of the slot 17e.

On the other hand, the structure of the connector terminal 19 is such that an electric contact portion 19b for the mating terminal is provided at one end of the substrate portion 19a, and a wire press-contact portion 19c having a slot 19d is provided at the other end. Is press-fitted, and the other end of the insulated wire 7 is
Press-fit terminal 17 and connector terminal 1
9 is electrically connected. The electrical connection between the press contact terminal 17 and the connector 18 is performed by accommodating and locking the electric contact portion 19b of the connector terminal 19 in the terminal accommodating chamber 18b formed in the connector housing 18a by a known means.

Since the relay circuit board P employs the above-described configuration, it is possible to omit useless circuit conductors in the case, and the weight of the entire flat wire harness is significantly reduced by reducing the weight of the relay circuit board. it can. Next, another embodiment of the present invention will be described. Before that, a method of manufacturing a flat wire harness using a corner pin will be described with reference to FIG.

A plurality of corner pins 21 are protruded at predetermined positions on the insulating plate 20, and between the connectors 23 provided at the ends of the plurality of relay circuit boards 22 disposed on the insulating plate 20. After bending the insulated wire 7 at the corner pins 21 and connecting it to the terminal terminal built in the connector 23, a conventional protective sheet (not shown) is coated and adhered to form a flat wire harness (not shown).

FIG. 7 is an explanatory view of a process of manufacturing a flat wire harness using an insulating sheet B as another embodiment of the present invention. The insulating sheet B is formed on the surface of a synthetic resin film 11 (not shown) similar to the insulating sheet A, in addition to a large number of cilia-like projections 12 made of a hot-melt adhesive, as well as hot-melt adhesive acting as a corner pin. It has a two-layer structure in which a hot melt adhesive layer 25 having a plurality of wiring conductor supporting protrusions 24 made of an agent is provided.

The wiring conductor supporting projections 24 are formed to be considerably thicker than the cilia-shaped projections 12 so as to sufficiently withstand the stress applied when the coated electric wire 7 is bent. In addition to the fine holes in the metal plate used to form the ciliated protrusions 12A of FIG.
By providing a slightly larger hole for 4, cilia-like projections 12 can be formed and at the same time, can be formed by the same operation as in the case of the insulating sheet A.

Next, a method of manufacturing a flat wire harness using the insulating sheet B will be described. Insulating sheet B
A plurality of relay circuit boards 22 each having a connector 23 at an end thereof are arranged at predetermined upper positions, and the covered electric wire 7 is bent at the wiring conductor supporting protrusions 24 of the insulating sheet B by a known automatic wiring machine. Wiring, connector 23 of each relay circuit board 22
After being connected to the terminal terminal incorporated in the hot melt adhesive layer 2 as in the above embodiment, the protective sheet 14 is covered and heated by the heating roller R as shown in FIG.
5 is melted, and the insulating sheet B and the protective sheet 14 are bonded to form a flat wire harness.

At this time, as shown in the cross section in FIG. 8, the portion where the wiring conductor supporting projections 24 are formed has a large amount of hot melt adhesive, so that the bonding becomes strong and the bent coated electric wire 7 Again, it can be fixed securely.

[0026]

According to the present invention, a large number of protrusions made of a hot-melt adhesive provided on an insulating sheet are melted to bond the periphery of a wiring conductor constituting a flat wire harness in a mesh-like manner. The hot-melt adhesive spreads to every corner of the wiring conductor and is securely fixed, so that the reliability is remarkably improved. In addition, when a flat wire harness is formed by bending a wiring conductor using a corner pin, a wiring conductor supporting projection made of a hot-melt adhesive can be used in place of the corner pin, thereby reducing the number of parts and the process. Has the advantage of helping to improve the productivity by simplifying the process.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a main part of an insulating sheet used in the method of the present invention.

FIG. 2 is an explanatory diagram of a method of manufacturing a flat wire harness using the insulating sheet of FIG.

FIG. 3 is a sectional view taken along line XX of FIG. 2;

FIG. 4 is an explanatory view of a step of coating a protective sheet on the insulating sheet on which the wiring of FIG. 2 has been performed.

FIG. 5 is a sectional view taken along line YY of FIG. 4;

FIG. 6 is an exploded perspective view showing another embodiment of the relay circuit board according to the present invention.

FIG. 7 is an enlarged perspective view of a portion of the press contact terminal and the connector terminal of FIG. 6;

FIG. 8 is an explanatory diagram of a method of manufacturing a flat wire harness using a corner pin.

FIG. 9 is an illustration of a method of manufacturing a flat wire harness according to another embodiment of the present invention.

FIG. 10 is an explanatory diagram showing a cross section of a flat wire harness formed by covering a protective sheet on an insulating sheet on which the wiring of FIG. 7 has been performed.

FIG. 11 is an explanatory diagram of a conventional flat wire harness.

FIG. 12 is an exploded perspective view of the relay circuit board of FIG. 11;

FIG. 13 is an explanatory diagram of a method of covering the protection sheet of the flat wire harness of FIG. 11;

FIG. 14 is a perspective view showing a main part of the protective sheet of FIG.

[Explanation of symbols]

A, B Insulating sheet 2, 2, ₁ , 2 ₂ ... Relay circuit board 4 Junction bar 5 Connector 7 Insulated wire 11 Synthetic resin sheet 12 Projection 13 Hot melt adhesive layer 14 Protection sheet 22 Relay circuit board 23 Connector 24 Wiring conductor support projection 25 Hot melt adhesive layer

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI H01B 7/08 H01B 7/08 (72) Inventor Toshiyuki Kamano 1500 Onjuku 1500, Susono-shi, Shizuoka Yazaki Sogyo Co., Ltd. In-house (56) References Special JP-A-5-62540 (JP, A) JP-A-3-149709 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) H01B 13/00 513 H01B 13/00 525 H01B 7 / 00 H01B 7/08

Claims (2)

(57) [Claims] A plurality of circuit conductors are provided inside a case on an insulating sheet provided with a hot melt adhesive layer having a large number of protrusions made of a hot melt adhesive formed on a surface of a synthetic resin sheet, and at least one end of the case. A plurality of relay circuit boards provided with connectors that conduct with the circuit conductors are arranged at predetermined intervals, wires are routed between these relay circuit boards, and a desired circuit conductor and the wires are connected. After forming a circuit that conducts with the connector, the relay circuit board and the wires routed between the relay circuit boards are covered with a protective sheet and heated, thereby melting the hot melt adhesive and insulating the insulation. A method for manufacturing a flat wire harness, comprising fixing a sheet and a protection sheet to the relay circuit board and electric wires routed between the relay circuit boards. 2. A wiring conductor supporting projection for wiring made of a hot melt adhesive is formed on a hot melt adhesive layer of an insulating sheet, and an electric wire routed between relay circuit boards is bent at the wiring conductor supporting projection. The method for manufacturing a flat wire harness according to claim 1, wherein a circuit that is electrically connected to the connector is formed by connecting the terminal to a terminal terminal incorporated in the connector.