JP3092395B2 - Manufacturing method of 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 of manufacturing a wire harness, and more particularly to a method of manufacturing a wire harness suitable for manufacturing a sub-harness of an automotive lamp.

[0002]

2. Description of the Related Art When a wire harness is manufactured by connecting fitting terminals to a common wiring wire, a portion of the wire to be branched is marked, and a branch wire is branched and fitted to this portion. Either a method of crimping a mating terminal or a method of crimping a press-connecting terminal for branching at each part to be branched.

[0003]

In the conventional manufacturing method described above, there is a problem that the workability is not good because it is necessary to check the portion to be branched and connect the terminals one by one.

[0004] The present invention has been made in view of the above problems, and has as its object to provide a manufacturing method capable of easily manufacturing a wire harness having a fitting terminal for branching.

[0005]

According to a first aspect of the present invention, a fitting terminal is connected to a common wiring wire, and each fitting terminal is connected to a plurality of electric devices. In manufacturing the wire harness, a press-fit terminal portion is formed at one end and a mating terminal having a mating terminal portion formed at the other end is held at a predetermined distance, and the press-connecting terminal portion of each mating terminal is faced. The wire for wiring is routed to the position where it is to be pressed, and each fitting terminal is pressed toward the press contact terminal portion.

[0006]

According to the first aspect of the present invention, a fitting terminal having a press contact terminal at one end and a fitting terminal at the other end is held at a predetermined distance in advance. In advance, an electric wire for wiring is routed to a position facing the press contact terminal portion in each fitting terminal. Then, when each fitting terminal is pressed toward the press contact terminal portion side, each fitting terminal is press contacted to the wiring wire at the press contact terminal portion at a predetermined distance, and a wire harness branched at a necessary portion. Is manufactured.

[0007]

As described above, according to the present invention, it is possible to manufacture a wire harness only by pressing the fitting terminals after positioning the wiring wires and the fitting terminals in a predetermined relationship.

[0008]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view showing a procedure for manufacturing a wire harness according to the present invention, and FIG. 2 is a perspective view showing a state where the present invention is applied to a sub-harness actually used in a rear combination lamp of an automobile. Before describing a method of manufacturing a wire harness, fitting terminals and the like used in the wire harness will be described. In FIG. 2, the negative wire W
Numeral 0 is common to the valve sockets 10, the through type junction connector 20 shown in FIG. 3 is connected at a predetermined distance in the middle, and the closed type junction connector 30 shown in FIG. Is connected.
The positive wires W1 and W2 are connected to each valve socket 1.
0, respectively, and the closed type junction connector 30 is connected to the end thereof.

[0009] Through-type junction connector 2
0 comprises a housing 21 and a branch terminal 22. As shown in FIG. 4, the housing 21 includes an electric wire support tubular portion 21a into which electric wires can be inserted and which communicates to the left and right.
The cylindrical fitting insertion portion 21 faces downward from the housing 21.
b is protruded, and a terminal support hole 21c communicating from the lower surface toward the intermediate portion of the electric wire support tube portion 21a is formed. Note that a rubber packing 23 for sealing is mounted on the outer surface of the fitting insertion portion 21b. As shown in FIG. 3, the branch terminal 22 (fitting terminal) forms a notch 22a1 that opens upward with respect to the two wing portions 22a of the T-shaped metal plate, and the two wing portions 22a.
Are bent to face each other, and a fitting terminal portion 22b1 for fitting connection is formed below the vertical piece 22b of the metal plate. A claw 22b2 is formed on a side surface of the vertical piece 22b, and the terminal support hole 21c is formed.
It is locked to the wall of the hood to prevent it from falling off. In this embodiment, the cuts 22a1 are formed in the two wing portions 22a of the T-shaped metal plate material. However, the cut may be formed in the upper end of the vertical piece 22b without providing the wing portions 22a. .

On the other hand, the closed type junction connector 30 comprises a housing 31 and a branch terminal (fitting terminal) 32. The junction connector 30 is different from the junction connector 20 in that the housing 31 has a wire support tube portion 31a having one end closed instead of the wire support tube portion 21a communicating left and right in the housing 31. A terminal support hole 31c communicates with an electric wire support tubular portion 31a, except that a single wing portion 32a is provided instead of the portion 22a.
The basic structure such as having a rubber packing 33 is substantially the same. In this branch terminal 32, a cut may be formed at the upper end of the vertical piece 32b without providing the wing portion 32a.

A valve socket (electric device) 10 is shown in FIG.
As shown in FIG. 3, the fitting insertion portion 21 has an opening at the bottom and has a cylindrical portion 11 into which the electrode portion 41 of the lamp 40 is inserted.
b, 31b can be inserted into the positive terminal hole 12 and the negative terminal hole 1 can be inserted from the upper surface into the peripheral portion of the bottom surface of the cylindrical portion 11 and can be inserted with the fitting insertion portions 21b, 31b.
3 is provided. The cylindrical portion 11 is provided in the positive terminal hole 12.
The plus terminal 14 is inserted from the side of. At the upper end of the plus terminal 14, the junction connectors 20, 30 are provided.
The female-side fitting terminal portion 14a is formed so as to be fitted and connected to the fitting terminal portions 22b1 and 32b1, and the lower end is formed with a gently folded spring-like contact electrode portion 14b.

The cylindrical portion 1 is located in the negative terminal hole 13.
A plate-like negative terminal 15 is inserted from the side of the first terminal. At the upper end of the minus terminal 15, a female-side fitting terminal portion 15a is formed to be fitted and connected to the fitting terminal portions 22b1 and 32b1 of the junction connectors 20 and 30, and at the lower end the inner portion faces the inner surface of the cylindrical portion 11. A leaf spring-shaped contact electrode portion 15b cut and raised is formed. The jig 50 can be divided into right and left along the longitudinal direction, and semicircular wire holding grooves 51, 51 are formed in the connection surface so that the wire W can pass therethrough. A pair of connector holding grooves 52, 5 in which the junction connectors 20, 30 can be inserted at a predetermined distance between the grooves 51, 51.
2 is formed. The connector holding grooves 52 and 52 are integrally formed so that the junction connectors 20 and 30 can be inserted therein. At this time, the wire support tubular portions 21 a and 31 a of the housings 21 and 31 are directly connected to the wire holding grooves 51 and 51. It has an internal shape that is lined up on a line. Further, the press plate 60 disposed above the jig 50 can approach and separate from the jig 50 by a predetermined distance.

Next, a method of manufacturing a sub-harness using these will be described. When the jig 50 is assembled, the connector holding grooves 52, 52 are opened at a predetermined distance, and the junction connectors 20, 30 are inserted into the openings.
Are inserted. The number of the housings 21 is reduced by one less than the number of the valve sockets 10, and inserted from the ends of the connector holding grooves 52, 52. Further, the housing 31 is inserted from the end into the last connector holding grooves 52, 52 into which the housing 21 is inserted. When the housings 21 and 31 are inserted into the connector holding grooves 52 and 52, the electric wire support cylindrical portion 2 is inserted.
1a, 31a and the electric wire holding grooves 51, 51 are arranged in a straight line, and the electric wire holding grooves 51,
An electric wire W0 serving as a common line is inserted into the opening 51. Electric wire W
While passing through the wire holding groove 51, the wire 0 passes through the wire support tube portion 21a in the housing 21 on the way. Then, when it enters into the electric wire support tube portion 31a of the last housing 31, it hits and cannot enter any more.

When the electric wire W0 is inserted in this manner, the branch terminal 22 is inserted into the terminal support hole 21c of the housing 21.
The branch terminal 32 is inserted into the terminal support hole 31c of the housing 31 from the side of the wing portions 22a, 32a, respectively. However, in the housing 21, the electric wire W0 is inserted into the electric wire support cylindrical portion 21a, and when the branch terminal 22 is inserted from the terminal support hole 21c which intersects the electric wire support cylindrical portion 21a at right angles, the wing portion 22a becomes perpendicular to the electric wire W0. Abut. Also in the housing 31, the wing portion 32a of the branch terminal 32 abuts on the electric wire W0 inserted into the electric wire support tubular portion 31a. In this state, the jig 50 is moved below the press plate 60 as shown in FIG.
Is lowered.

The press plate 60 descends, and the branch terminal 22,
It contacts the upper end of 32 and descends further. by the way,
Since the notch 22a1 is formed in the wing portion 22a along the traveling direction of the press plate 60, the press plate 60
Is lowered, the electric wire W0 is pressed against the opening of the cut 22a1, and the cut 22a1 is
And the core wire is pushed into the cut 22a1. Therefore, the electric wire W0 and the branch terminal 22 are electrically connected by the pressure connection. On the other hand, also in the branch terminal 32, the cut 32a provided in the wing portion 32a is provided.
1 cuts the sheath of the electric wire W0 and press-connects to the core wire.

Note that the branch terminals 22 and 32 are connected to the terminal support holes 2.
When pushing deep into 1c and 31c, the claw 22b
2, 32b2 are engaged with the wall surfaces of the terminal support holes 21c, 31c and press-fitted, so that even if the branch terminals 22, 32 are pulled out, they are prevented from falling off. Press plate 60
When the jig 50 is separated to the left and right to take out the electric wire W0, the junction connectors 20, 30 are attached to the portion of the electric wire W0 to be branched. That is,
Even if the branch position is not determined in consideration of the distance between the junction connectors 20 and 30, etc., the branch fitting terminal can be easily formed simply by inserting the jig 50 into the connector holding grooves 52 and 52. Can connect.

Thereafter, in order to improve the waterproofness of the electric wire W0 coming out of the electric wire supporting cylinders 21a, 31a, the outlet portion is welded to the peripheral surface of the electric wire W0, and the rubber packings 23, 33 are fitted into the fitting insertion portions. Cover around 21b and 31b. On the other hand, the ends of the electric wires W1 and W2 are inserted into the electric wire support tube 31a of the housing 31, and the branch terminal 32 is pushed into the terminal support hole 31c from the wing portion 32a side. Then, the cut 32 provided in the wing portion 32a
Since a1 cuts the covering and press-connects to the core wire, when the branch terminal 32 is pushed all the way, the outlet portion of the wire support tubular portion 31a is welded to the peripheral surfaces of the wires W1 and W2.

When the ends of the electric wires W0, W1, W2 are connected to the connector, a sub-harness portion is completed, and wiring to the valve socket 10 is performed. The junction connector 30 connected to the ends of the electric wires W1 and W2 is inserted into the positive terminal hole 12 of the bulb socket 10 from the side of the fitting insertion portion 31b. Then, the fitting terminal portion 32b1 of the branch terminal 32 held in the terminal support hole 31c becomes the plus terminal 1 held in the plus side terminal hole 12.
4 is inserted into the female-side fitting terminal portion 14a formed at the upper end of the connector 4, and is fitted and connected. Also, for the junction connector 20 and the junction connector 30 connected to the middle and the end of the wire W0, the fitting insertion portions 21b, 31
b, the negative terminal hole 13 of the bulb socket 10
Insert Then, the fitting terminal portion 22b of the branch terminal 22
1 and the fitting terminal portion 32b1 of the branch terminal 32 are fitted and connected to the female fitting terminal portion 15a formed at the upper end of the minus terminal 15 held in the minus terminal hole 13. The rubber packings 23 and 33 covering the periphery of the fitting insertion portions 21b and 31b are interposed between the positive terminal hole 12 and the inner peripheral surface of the negative terminal hole 13 to prevent water from entering these portions. .

In this embodiment, the junctions 20 and 30 having the above-described structure are used for one-touch branching. However, as a branching terminal, a fitting terminal portion and a press contact terminal portion are integrated. The configuration of the cut in the press contact terminal portion may be changed to another configuration. Although the closed type junction connector 30 is also used, the through type junction connector 20 can be used at the end. Further, the present invention is not limited to a rear combination lamp of an automobile, and can be applied to any type of branch wiring to a plurality of electric devices. In addition, the rubber packings 23 and 33 may be mounted in advance, or the relationship between the male and female in the valve socket and the junction connector may be reversed.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a procedure for manufacturing a wire harness according to the present invention.

FIG. 2 is a perspective view of a sub harness.

FIG. 3 is a perspective view of a through-type junction connector.

FIG. 4 is a sectional view of a through-type junction connector.

FIG. 5 is a perspective view of a junction connector of a closed type.

FIG. 6 is a sectional view of a junction connector of a closed type.

FIG. 7 is a transparent perspective view of a valve socket.

FIG. 8 is a perspective view of a jig showing a manufacturing procedure.

FIG. 9 is a sectional view of a jig showing a manufacturing procedure.

FIG. 10 is a sectional view of a jig showing a manufacturing procedure.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 ... Valve socket 22, 32 ... Branch terminal 22a, 32a ... Wing part 22a1, 32a1 ... Cut 22b1, 32b1 ... Fitting terminal part 40 ... Lamp 50 ... Jig 51 ... Wire holding groove 52 ... Connector holding groove W0, W1, W2: Electric wire

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) H01B 13/00 B60R 16/02 H01R 4/24 H01R 43/01

Claims (1)

(57) [Claims] When manufacturing a wire harness for connecting a fitting terminal to a common wiring wire and connecting each fitting terminal to a plurality of electric devices, a press contact terminal portion is formed at one end and a press contact terminal portion is formed at the other end. While holding the fitting terminals forming the fitting terminal portions at a predetermined distance, the wires for wiring are routed to the positions facing the press contact terminal portions in each fitting terminal, and each fitting terminal is connected to the press contact terminal portion. A method for manufacturing a wire harness, wherein the wire harness is pressed toward a side.