JP3127698B2 - Wire harness splicing method - 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 splicing a wire harness, and more particularly, to a method for splicing a wire harness that can easily waterproof a splice between core wires of an electric wire or a splice between a core wire of an electric wire and a ground terminal. It is about.

[0002]

2. Description of the Related Art In a wire harness W / H for an automobile, as shown in FIG. 7, the insulating coatings of electric wires 1 to 4 connected to each other are peeled to expose the core wires 1a to 4a, and the exposed core wires 1a to 4a are exposed. 4a may be joined by crimping at the splice terminals 5,5. Each splice (joining part) S1,
S2 needs to be molded with a synthetic resin for insulation and waterproofing.

For this purpose, as shown in FIG. 8, a splice S1 or S2 of a wire harness W / H is set in a mold 6 and a thermoplastic synthetic resin 8 is injected into the mold 6 from an injection nozzle 7. After being cooled and solidified, it is taken out from the mold 6 as shown in FIG.
(See JP-A-64-63073)

[0004]

However, in the above-described molding method, a dedicated mold 6 is required for each size or branch shape of the wires 1 to 4 of the wire harness W / H. Mold work efficiency is also poor. Further, in the butyl pad method in which the splices S1 and S2 are wound with a rubber material, the splices S1 and S2 are enlarged and the weight is increased. (See Japanese Patent Publication No. 59-35510) Further, the tube method of shrinking a heat-shrinkable tube through a splice point is difficult to pass the tube through the electric wire 1 and lacks practicality.

[0005] Each of the above methods is common in that the entire splice is covered with an insulating / waterproof material. However, when the wire harness W / H is actually assembled in an automobile, even the above-described complete waterproofing is required. However, since there are many splice points that can be sufficiently used even with simple waterproofing, excessive waterproofing is performed. For example, as shown in FIG. 10, even if only the electric wire 2 needs to be waterproofed, only the electric wire 2 cannot be waterproofed, and the splice S1
Is molded with a synthetic resin 8 and waterproofed.

On the other hand, as shown in FIG. 11, a ground terminal 9 in the wire harness W / H is crimped by crimping a core wire 10a exposed by peeling off the insulation coating of the electric wire 10 with a crimping portion 9a. The ground terminal 9 is fixed to a vehicle body or the like with bolts.

However, in the above crimping method, since the core wire 10a at one end of the electric wire 10 is exposed, when the other end of the electric wire 10 is connected to the waterproof connector in the engine room, the engine room will The temperature rises during the operation of, and falls when the engine room stops. The air in the waterproof connector expands when the temperature rises, passes from the other end of the connector to the gap between the insulating coating of the electric wire 10 and each core wire, and the gap between each core wire, and from the core wire 10a at one end to the outside. So when the temperature drops,
Negative pressure is generated in the connector, and rainwater etc.
Water may be absorbed into the connector from the other end through the gap between the insulating coating of No. 0 and each core wire and the gap between each core wire. Due to this water absorption, a connection portion in the connector leaks to cause malfunction or corrosion due to moisture.

For this reason, the core wire 10a of the electric wire 10 may be soldered (dove soldering). However, it is necessary to immerse the core wire 10a together with the ground terminal 9 in a solder bath at about 270 ° C. There is a problem that the coating melts. In addition, conductive paint, conductive rubber,
The crimping portion 9 of the ground terminal 9 is formed by a conductive hot melt or the like.
Although there is a method of waterproofing a, there is a risk that a conductive material may adhere to the ground terminal 9 and the resistance of the contact portion with the body or the like may increase, thereby generating heat.

The present invention has been made in order to solve the above-mentioned problems, and provides a splicing method of a wire harness which can easily waterproof a splice portion between core wires of an electric wire or a splice portion between a core wire of an electric wire and a ground terminal. It is intended to do so.

[0010]

In order to achieve the above object, the present invention provides an electric wire which needs to be waterproofed after the insulating coating of the electric wires to be connected to each other is peeled to expose the core wire. The waterproof coating liquid material is coated over the core wire and the insulation coating, and the core wires of the electric wires are brought into contact with each other via a coating layer, and ultrasonic waves are applied. A splicing method for a wire harness, wherein welding is performed, while leaving a coating layer between the root of the core of the electric wire and the insulating coating without removing the electric wire, the electric wire is waterproofed by the remaining coating layer. To provide.

In a second aspect of the present invention, after peeling off the insulating coating of the electric wire connected to the ground terminal to expose the core wire, a waterproof coating liquid material is coated over the core wire and the insulating coating of the electric wire, The core wire of the electric wire is brought into contact with the ground terminal via the coating layer, and ultrasonic waves are applied. The coating layer of the contact portion is removed and the core wire is welded to the ground terminal. And a wire harness splicing method characterized in that the coating layer between the wire harness and the wire is left without being deleted, and the wire is waterproofed by the remaining coating layer.

[0012]

According to the first aspect of the present invention, the waterproofing is performed by immersion or the like over the core wire of the electric wire which needs to be waterproof and the insulating coating among the electric wires whose core is exposed by peeling the insulating coating. Coating the coating. Thereafter, ultrasonic waves are applied in a state where the core wires of the electric wires are in contact with each other via the coating layer, and the coating layer of the contact portion is burned and destroyed, and the core wires are welded to each other. At this time, the coating layer between the root of the core of the electric wire and the insulating coating remains without being destroyed by burning, so that only this portion is waterproofed by the coating layer.

[0013] This makes it possible to easily waterproof only the wires that require waterproofing. In addition, the equipment cost is low because the conventional mold is unnecessary,
The workability of the waterproof treatment is also improved. Further, since the coating layer is a thin film, the splice portion does not enlarge and the weight hardly increases.

According to the second aspect of the present invention, the waterproof coating material is coated by dipping or the like over the core wire and the insulating coating that have been peeled off and exposed. Thereafter, when ultrasonic waves are applied in a state where the core wire of the electric wire is in contact with the ground terminal via the coating layer, the coating layer of the contact portion is destroyed by burning, and the core wire is welded to the ground terminal. At this time, the coating layer between the root of the core of the electric wire and the insulating coating remains without being destroyed by burning, so that only this portion is waterproofed by the coating layer.

[0015] This makes it possible to easily waterproof only the wires that require waterproofing. Further, since high-temperature soldering as in the related art is not required, there is no problem that the insulating coating of the electric wire is melted. Further, the conductive material does not adhere to the ground terminal, and there is no danger of generating heat.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the illustrated embodiments. The first embodiment of the present invention shown in FIGS. 1 and 2 is an embodiment of a method for simply waterproofing the splice points S between the core wires 11a to 13a of the electric wires 11 to 13.

As shown in FIG. 1 (A), an insulating coating 11 at the ends of three wires 11 to 13 of a wire harness W / H is provided.
Peel b to 13b to expose the core wires 11a to 13a, respectively. After that, the wires requiring waterproofing are permeated into the waterproof coating material 15 in the tank 14. In this example, the core wires 11a to 13a of all the wires 11 to 13 and the insulating coatings 11b to
13b, is immersed in the waterproof coating liquid material 15 in the tank 14. Further, it is pulled out of the tank 14 and air-dried or heat-dried. Thereby, as shown in FIG. 1 (B), the waterproof coating liquid material 1 extends over the core wires 11a to 13a of the electric wires 11 to 13 and the insulating coatings 11b to 13b.
The coating is performed by the fifth coating layer 15a.

As the waterproof coating liquid material 15, for example, a solution obtained by dissolving butyl rubber in toluene is suitable. As a commercially available product, there is ELEPCOAT (trade name) manufactured by Nitto Denko Corporation. In addition, Nanocryl (trade name) manufactured by Toyo Ink Manufacturing Co., Ltd., Cemedine 240 (trade name) manufactured by Cemedine Co., Ltd., HU manufactured by Asahi Denka Kogyo Co., Ltd.
X-240 (trade name) can be used.

Then, as shown in FIG. 1C, the core wires 11a to 13a of the electric wires 11 to 13 are brought into contact with each other via the coating layers 15a,..., 15a. In this contact state, as shown in FIG. 1 (D), when an ultrasonic wave is applied to the contact portion A, the coating layers 15a,..., 15a are rubbed by vibration at the contact portion A in the ultrasonic vibration range. And at the same time, each coating layer 15a,.
The exposed core wires 11a to 13a are welded to each other by the removal of a.

At this time, the core wires 11a of the electric wires 11 to 13
, 15a between the roots of the first to 13a and the insulating coatings 11b to 13b remain without being deleted, so that only this portion remains in each of the coating layers 15a,.
5a will be waterproofed. In addition, each electric wire 1
1 to 13 core wires 11a to 13a and insulating coatings 11b to 13
b, when dipped in the waterproof coating liquid material 15, the gaps between the insulating coatings 11b to 13b of the electric wires 11 to 13 and the respective core wires 11a to 13a, and the respective core wires 11a to 1a.
Since the waterproof coating liquid material 15 naturally penetrates into the gaps 3a, these gaps are also waterproofed.

Thereafter, as shown in FIG. 2, an insulating tape 16 is wound around the splice point S to perform an insulating process.

As a result of measuring the waterproof performance of the splice portion S subjected to the simple waterproof treatment as described above, it was found that the spliced portion S had a water resistance of 0.5 kgf.
/ Square cm of waterproof performance was confirmed. It was also confirmed that the low current voltage resistance indicating the electrical connection resistance at the splice point S was 3 mΩ or less.

As described above, in the present embodiment, the process of setting the splice point S in the mold, injecting the thermoplastic synthetic resin into the mold from the injection nozzle, cooling and solidifying the resin, and removing the same from the mold is unnecessary. Yes, the workability of the waterproof treatment is also improved. Further, the coating layer 15
Since a is a thin film, the splice location S does not increase and the weight does not increase.

FIG. 3 shows a modification of the first embodiment.
In FIG. 1 and FIG. 2, the core wire 1 of all the electric wires 11 to 13 is shown.
1a to 13a and the insulating coatings 11b to 13b, the coating layers 15a,.
In FIG. 3, only one electric wire 12 requiring waterproofing is coated with the coating layer 15a, and the electric wires 11 and 13 not requiring waterproofing are not coated with the coating layer 15a in FIG. As described above, in the present embodiment, only the electric wires 11 to 13 that require waterproofing of the splice portions S of the wire harness W / H can be easily waterproofed, so that a conventional mold is not required, and equipment cost is reduced. Is cheaper.

FIG. 4 shows another modification of the first embodiment. In FIG. 4, the insulation 17b at the middle of the electric wire 17 is peeled to expose the core wire 17a, and the insulation coating 18b at the end of the electric wire 18 is peeled to expose the core wire 18a. The core wire 18a of the electric wire 18 requiring waterproofing is coated with the coating layer 15a, and the core wires 17a and 18a are welded to each other in the same manner as described above.

A second embodiment of the present invention shown in FIG.
This is an embodiment of a method for easily waterproofing the splice location S of the core wire 19a and the ground terminal 20 of the ninth embodiment. As shown in the figure, the insulating coating 19b of the terminal of the electric wire 19 connected to the ground terminal 20 is peeled off and exposed, and then, the wire is stretched over the core wire 19a and the insulating coating 19b of the electric wire 19 requiring waterproofing. 1A, the waterproof coating liquid material 1
The coating is performed with the fifth coating layer 15a.

Then, the core wire 19a of the electric wire 19 is brought into contact with the ground terminal 20 via the coating layer 15a, and in this contact state, when ultrasonic waves are applied to the contact portion A, the contact portion A in the ultrasonic vibration range is generated. At the same time that the coating layer 15a is deleted, the exposed core wire 19a is welded to the ground terminal 20 by removing the coating layer 15a.

At this time, since the coating layer 15a between the root of the core wire 19a of the electric wire 19 and the insulating coating 19b remains without being deleted, only this portion remains.
a is to be waterproofed. When immersed in the waterproof coating liquid material 15 over the core wire 19a of the electric wire 19 and the insulating coating 19b, the insulating coating 19
Since the waterproof coating liquid material 15 naturally penetrates into the gap between b and the core wire 19a and the gap between the core wires 19a, these gaps are also waterproofed.

As a result of measuring the waterproof performance of the splice portion S which has been subjected to the simple waterproof treatment as described above, the result is 0.5 kgf.
/ Square cm of waterproof performance was confirmed. It was also confirmed that the low current voltage resistance indicating the electrical connection resistance at the splice point S was 3 mΩ or less.

In FIG. 5, the electric wires 19 requiring waterproofing are shown.
Only the core wire 19a was welded to the ground terminal 20,
As shown in FIG. 6, two wires 2 that do not require waterproofing
The 1 and 22 core wires 21a and 22a can also be welded and joined at the same time. In the embodiment of FIG. 6, three wires 1
Only one of the wires 21, 9, 22 is coated with the coating layer 15a. However, when two or more wires are welded to the ground terminal 20, any number of wires are coated. It goes without saying that the layer 15a may be coated.

As described above, in the second embodiment, the electric wire 1 that needs to be waterproof at the splice point S of the wire harness W / H
9 can be easily waterproofed, so that high-temperature soldering as in the prior art is not required.
9b does not melt. Further, the conductive material does not adhere to the ground terminal 20, and there is no danger of generating heat.

[0032]

As is apparent from the above description, the splicing method according to the first aspect of the present invention is characterized in that, in each of the electric wires exposed by stripping the insulating coating, the core wires of the electric wires that need to be waterproofed. Coating the waterproof covering material by immersion etc., and then contact the core wires of each electric wire via the coating layer, apply ultrasonic waves, remove the coating layer, and weld the core wires together Since the coating layer between the root of the core wire of the electric wire and the insulating coating remains without being deleted, only this portion is waterproofed by the coating layer.

Therefore, only the electric wires requiring waterproofing can be easily subjected to waterproofing treatment, and a conventional mold is not required, so that the equipment cost is low and the workability of the waterproofing treatment is improved. Further, since the coating layer is a thin film, the splice portion does not enlarge and the weight hardly increases.

On the other hand, in the splicing method according to the second aspect of the present invention, the waterproof covering material is coated by dipping or the like over the core wire exposed by peeling the insulating coating of the electric wire and the insulating coating. The core wire contacts the ground terminal via the coating layer and applies ultrasonic waves to remove the coating layer and weld the core wire to the ground terminal. Since the coating layer between and remains without being removed, only this portion is waterproofed by the coating layer.

Therefore, only the wires requiring waterproofing can be easily waterproofed, and the conventional high-temperature soldering becomes unnecessary, so that there is no problem that the insulating coating of the wires is melted. Further, the conductive material does not adhere to the ground terminal, and there is no danger of generating heat.

[Brief description of the drawings]

FIG. 1 shows the sequence of a method of splicing electric wires according to the present invention, wherein (A) is a side view when the electric wire is immersed in a waterproof coating liquid material, (B) is a side view of the electric wire having a coating layer, (C) ) Is a side view of an electric wire in which core wires are in contact with each other,
(D) is a side view of the electric wire in which the core wires are welded to each other.

FIG. 2 is a perspective view of a wire harness in which a splice portion is tape-wound.

FIG. 3 is a modified example of FIG. 1, in which (A) is a side view of an electric wire in which core wires are in contact with each other, and (B) is a side view of an electric wire in which core wires are welded to each other.

4A is a modified example of FIG. 1, wherein FIG. 4A is a side view of an electric wire before core wires are brought into contact with each other, and FIG.

FIG. 5 shows a method of splicing an earth terminal and an electric wire according to the present invention, wherein (A) is a perspective view of the electric wire and the earth terminal before the core wire is brought into contact with the earth terminal, and (B) is a wire joined to the earth terminal by welding. It is a perspective view.

FIG. 6 is a modification of FIG. 5, wherein (A) is a perspective view of an electric wire and a ground terminal before a core wire is brought into contact with the ground terminal,
(B) is a perspective view in which the electric wire was welded to the ground terminal.

FIG. 7 is a side view of a conventional wire harness.

FIG. 8 is a perspective view of a mold.

FIG. 9 is a perspective view of a wire harness in which a splice is molded with a synthetic resin.

FIG. 10 is a side view of a splice point in FIG. 9;

FIG. 11 is a perspective view in which a wire is connected to a conventional ground terminal.

[Explanation of symbols]

W / H Wire harness A Connection part S Splice location 11-13, 17, 18, 19, 21, 22 Electric wires 11a-13a, 17a, 18a, 19a, 21a, 2
2a core wire 11b to 13b, 17b, 18b, 19b insulating coating 15 waterproof coating liquid material 15a coating layer

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) H02G 1/14 H01R 43/00

Claims (2)

(57) [Claims] 1. After peeling off the insulating coating of the electric wires to be connected to each other to expose the core wire, a waterproof coating liquid material is coated over the core wire and the insulating coating of the electric wire requiring waterproofing, The cores are brought into contact with each other via a coating layer, and ultrasonic waves are applied thereto. The coating layer at the contact portion is removed and the cores are welded to each other, while the base of the core of the electric wire is connected.
Leaving the coating layer between the and the insulating coating without removing,
The wire harness splicing method, wherein the wire is waterproofed by the remaining coating layer . 2. After peeling off the insulating coating of the electric wire connected to the ground terminal to expose the core wire, a waterproof coating liquid material is coated over the core wire and the insulating coating, and the core wire of the electric wire is removed. While contacting the ground terminal via the coating layer and applying ultrasonic waves, the coating layer at the contact portion is removed and the core wire is welded and joined to the ground terminal, while the core wire of the electric wire is
Without removing the coating layer between the root and the insulation
Leave and waterproof the wire with this remaining coating layer
Splice method of a wire harness, characterized in that it is.