JP5446855B2 - Manufacturing method of wire harness - Google Patents

Description

  The present invention relates to a method of manufacturing a wire harness, and more particularly, to a method of manufacturing a wire harness provided with a protector that protects an electric wire (single electric wire and a plurality of electric wire groups) constituting the wire harness. .

  Inside a vehicle such as an automobile, a wire harness for connecting electrical devices and electronic devices to each other is routed. The wire harness is formed by bundling a predetermined type of electric wire into a predetermined shape. A protector may be attached to a predetermined portion of the electric wire constituting the wire harness in order to prevent damage due to an external load or the like.

  There are various types of protectors. For example, a molded product having a hollow shell shape is widely used. According to the configuration to which the protector of the molded product is applied, it is possible to prevent a load from being applied to the electric wire from the outside by accommodating the electric wire in the space inside the protector. For this reason, damage of an electric wire etc. can be prevented. However, the configuration to which the protector for a molded product is applied has the following problems.

  First, in order to manufacture a protector for a molded product, a mold is required. Since the mold is generally expensive, the manufacturing cost and the price of the protector are increased, and as a result, the price of the wire harness may be increased. Further, in the configuration in which the electric wire is accommodated in the protector of the shell-shaped molded product, a gap may exist between the inner peripheral surface of the protector and the electric wire. For this reason, when vibration or impact is applied to the wire harness, the electric wire may collide with the inner peripheral surface of the protector, and a collision sound may be generated. Since such a collision sound may be recognized as an abnormal sound by the user, there is a risk of degrading the quality of a product to which such a wire harness is applied (such as a vehicle in which such a wire harness is routed). There is. Moreover, when an electric wire collides with the internal peripheral surface of a protector, an impact is added to an electric wire and there exists a possibility that an electric wire may be damaged.

  As a configuration using a protector that is not a molded product, for example, a configuration described in Patent Document 1 may be used. In the configuration described in Patent Document 1, a sheet material is wound around an electric wire group constituting a wire harness, and after overlapping the overlapping portions of the wound sheet material, the overlapped portions are added by a thermocompression bonding machine. It is welded by pressure and heating. According to such a structure, the sheet | seat material wound around the electric wire group turns into a protector which protects an electric wire group. Since the sheet material is less expensive than the molded product, the component cost can be reduced as compared with the configuration in which the protector of the molded product is applied.

  However, in the said structure, since the welding part (= surplus part) of a sheet | seat material protrudes outside from the surface of an electric wire group, the external dimension of a protector becomes large. For this reason, when wiring the wire harness in a narrow place, there is a possibility that the surplus part may be an obstacle to the wiring work.

  As a configuration in which the welded portion does not protrude from the outer peripheral surface of the electric wire group, for example, the configuration of Patent Document 2 has been proposed. In the configuration described in Patent Document 2, a group of electric wires constituting a wire harness is covered with a flexible sheet, and both side portions of the flexible sheet are superimposed on the outer peripheral surface of the group of electric wires. An adhesive for melting is applied, and in this state, the electric wire group and the flexible sheet are pressed while being heated by a heating press. When the overlapped portion of the flexible sheet is pressurized and heated, the overlapped portion is bonded by an adhesive for hot melt.

  According to the configuration described in Patent Literature 2, the joint portion of the flexible sheet is formed along the outer peripheral surface of the electric wire group. For this reason, a junction part does not protrude from the outer peripheral surface of an electric wire group. However, the configuration described in Patent Document 2 has the following problems.

  First, the heating press presses and heats not only the overlapping portion of the flexible sheet but also the electric wire group constituting the wire harness. Each electric wire constituting the wire harness generally has a configuration in which a conductive wire is covered with a covering material, and the covering material is formed of a resin composition having thermoplasticity. For this reason, when an electric wire group is heated, the coating | covering material of each electric wire may be damaged with a heat | fever, and there exists a possibility that the function which protects a conducting wire, or the function to insulate may fall or be lost.

  In addition, the configuration of Patent Document 2 is not a configuration in which only the overlapping portion of the flexible sheet is directly pressed by the pressing die of the heating press, but the side portion of the flexible sheet that forms the overlapping portion. One of these is indirectly pressurized through a group of wires. For this reason, if the electric wire group is deformed at the time of pressurization, there is a possibility that sufficient pressurizing force may not be applied to the overlapping portion of the flexible sheet. For this reason, the overlapping portion of the flexible sheet is not sufficiently bonded, and the bonding strength may be reduced. If the applied pressure is increased in order to improve the bonding strength, the applied pressure applied to the electric wire group also increases, which may damage the electric wire group.

  Furthermore, the pressure applied to the overlapping portion of the flexible sheet during pressurization may be affected by the deformation mode of the wire group, but it is possible to control the deformation of the wire group to be uniform. Since it is difficult, the pressure applied to the overlapping portion of the flexible sheet may be non-uniform. As a result, there is a possibility that the bonding strength of the overlapped portion is not uniform.

Japanese Patent Laid-Open No. 11-7856 JP-A-9-298015

  In view of the above situation, the problem to be solved by the present invention is to provide a method of manufacturing a wire harness capable of reducing the size of the protector, or to reduce the joint strength at the joint portion of the material constituting the protector. Providing a method of manufacturing a wire harness capable of preventing or improving the bonding strength, or preventing a decrease in the bonding strength at the bonding portion while preventing the bonding portion of the material constituting the protector from projecting to the outside or It is providing the manufacturing method of the wire harness which can aim at the improvement of joining strength.

  In order to solve the above problems, the present invention wraps a sheet-like member around an outer peripheral surface of a predetermined portion of an electric wire (including a single electric wire and a bundle of electric wires including a plurality of electric wires), and the sheet-like member. Between the outer peripheral surface of the predetermined portion of the electric wire and the inner peripheral surface of the overlapped portion of the sheet-like member. And a step of pressurizing and welding at least a part of the overlapped portion of the sheet-like member with a provided jig and a pressure member of a welding machine. .

  In the case of a single electric wire, the “outer peripheral surface of the electric wire” refers to the outer peripheral surface of the member provided on the outermost side of the single electric wire (generally, the outer peripheral surface of the covering material). If the wire bundle is made of a wire bundle, the outer peripheral surface of the object when the wire bundle is regarded as a single object (however, the fine irregularities formed by each wire and the gaps formed between the wires are ignored. The outer surface of the modeled object).

  An ultrasonic welding machine can be applied to the welding machine, and in this case, a member made of a material capable of ultrasonic welding can be applied to the sheet-like member. And the structure welded by applying an ultrasonic vibration, pressing at least one part of the said overlapped part of the said sheet-like member is applicable.

  A substantially rod-shaped member having a predetermined length can be applied to the jig.

  The jig is disposed in advance on the outer peripheral surface of the predetermined portion of the electric wire before the sheet-like member is wound around the predetermined portion of the electric wire, A configuration in which the jig is superposed on the outer peripheral surface of the jig may be employed.

  In addition, after the sheet-like member is wound around the outer peripheral surface of the predetermined portion of the electric wire, the jig is configured such that the outer peripheral surface of the predetermined portion of the electric wire and the overlapped portion of the sheet-like member The structure inserted between these may be sufficient.

  According to the present invention, a portion where sheet-like members constituting the protector overlap (= portion where a joint portion is formed) can be formed along the outer peripheral surface of the electric wire. For this reason, the protector which does not have a part which protrudes outside can be formed. Therefore, the size of the protector can be reduced.

  According to the method for manufacturing a wire harness according to the embodiment of the present invention, in the step of joining both side portions of the sheet-like member, at least a part of both side portions of the sheet-like member is a pressure member (welding of the welding machine). If the machine is an ultrasonic welder, it is sandwiched between the horn of the ultrasonic welder and the jig and pressed. For this reason, a predetermined pressurizing force can be applied to a predetermined portion of the sheet-like member (that is, a portion serving as a joint portion). For this reason, compared with the structure which does not use a jig | tool, the applied pressure applied to a sheet-like member can be enlarged, and the improvement of the joint strength in a junction part can be aimed at. Furthermore, since it becomes easy to control the applied pressure, when joining a plurality of locations sequentially, a uniform applied pressure can be applied to all locations, and the joining strength can be made uniform. Therefore, the quality of the wire harness is stabilized and quality control becomes easy.

  According to the method for manufacturing a wire harness according to the embodiment of the present invention, the surface of the electric wire constituting the wire harness is heated by heat transfer, but the temperature rise is small and the covering material for the electric wire is not damaged. Therefore, the function of protecting the conducting wire of the wire covering material and the function of insulating the conducting wire are not deteriorated or lost. Furthermore, since the electric wire is not pressurized when the both side portions of the sheet-like member are joined, the electric wire is prevented from being damaged by the applied pressure. Therefore, the reliability of the wire harness can be maintained.

  Moreover, according to the manufacturing method of the wire harness concerning embodiment of this invention, the part which the both sides of a sheet-like member overlap is formed so that the outer peripheral surface of an electric wire bundle may be followed. For this reason, in the conventional configuration in which a portion where both side portions of the sheet-like member overlap is projected outward, it is necessary to remove (= trim) unnecessary portions after joining. In the manufacturing method of the wire harness concerning embodiment, such a process is unnecessary. Therefore, the number of manufacturing steps can be reduced, and the manufacturing cost can be reduced.

  According to the present invention, it is possible to prevent a decrease in the bonding strength or improve the bonding strength at the bonding portion while the bonding portion of the material constituting the protector does not protrude to the outside.

It is the figure which showed typically the structure of the wire harness manufactured using the manufacturing method of the wire harness concerning embodiment of this invention, and (a) is the external appearance perspective view which extracted and showed each, b) is a sectional view taken along line AA of (a), and is a sectional view schematically showing a sectional structure. It is the figure which showed typically the structure of the jig | tool used in the manufacturing method of the wire harness concerning embodiment of this invention, (a) is an external appearance perspective view of a jig | tool, (b) is a jig | tool, It is the perspective view which showed the state arrange | positioned by the outer peripheral surface of an electric wire bundle, and the inner peripheral surface of a protector (= sheet-like member). It is the cross-sectional schematic diagram which showed typically the predetermined | prescribed process of the manufacturing method of the protector concerning embodiment of this invention, (a) is the figure which showed the state before winding a sheet-like member around an electric wire bundle, (b) ) Is a view showing a state in which a sheet-like member is wound around the wire bundle. It is the cross-sectional schematic diagram which showed typically the predetermined | prescribed process of the manufacturing method of the protector concerning embodiment of this invention, (a) shows the state by which the sheet-like member 14 was wound around the wire bundle 12, b) shows a state in which the jig 5 is inserted between the outer peripheral surface of the wire bundle 12 and the sheet-like member 14. It is the cross-sectional schematic diagram which showed typically the predetermined | prescribed process of the manufacturing method of the protector concerning embodiment of this invention, (a) is ultrasonic welding the one side part and the other side part of a sheet-like member The figure which shows the process welded with an apparatus, (b) is the figure which showed the state which welding was completed.

  Embodiments of the present invention will be described below in detail with reference to the drawings.

  Drawing 1 is a figure showing typically composition of wire harness 1 manufactured using a manufacturing method of a wire harness concerning an embodiment of the present invention. FIG. 1A is an external perspective view showing a part extracted, and FIG. 1B is a cross-sectional view taken along line AA of FIG. 1A, schematically showing a cross-sectional structure. FIG. Hereinafter, the wire harness manufactured using the method for manufacturing the wire harness according to the embodiment of the present invention may be referred to as “the present wire harness”.

  The wire harness 1 as a whole has a configuration in which a predetermined type and a predetermined number of electric wires 11 are bundled to form an electric wire bundle 12, and the electric wire bundle 12 is formed in a predetermined shape. Predetermined connectors are attached to the end portions of the electric wires 11 constituting the electric wire bundle 12 of the wire harness 1 (not shown). And as shown to FIG. 1 (a), (b), the protector 13 is provided in the outer peripheral surface of the predetermined part of the wire bundle 12 of this wire harness 1. FIG. In addition, although the protector 13 is provided in the part which wants to protect among the wire bundles 12 of this wire harness 1, the structure provided in a part of the wire bundle 12 of this wire harness 1 may be sufficient, and it is provided in the whole. It may be a configuration.

  The “outer peripheral surface of the wire bundle 12” means the outer peripheral surface of the object when the wire bundle 12 is regarded as a single object (however, fine irregularities formed by the electric wires 11 and The outer surface of the modeled object ignoring the gap formed between the two.

  The protector 13 is formed by a sheet-like member 14 made of a material capable of ultrasonic welding (that is, a material having thermoplasticity). For example, sheets, nonwoven fabrics, foams and the like formed from various thermoplastic resin compositions can be applied.

  A nonwoven fabric having a configuration in which basic fibers and binder fibers are intertwined can be applied. The basic fiber is formed of a thermoplastic resin composition having a predetermined melting point. The binder fiber has a configuration in which a binder material layer is formed on the outer periphery of the core fiber. This core fiber is formed of the same thermoplastic resin composition as the basic fiber. The binder material layer is formed of a thermoplastic resin composition having a melting point lower than that of the basic fiber and the core fiber. When the nonwoven fabric having such a structure is heated to a temperature higher than the melting point of the binder material and lower than the melting point of the basic fiber, the basic fiber and the core fiber are not melted but maintain the fiber state. The binder material melts.

  For this reason, the nonwoven fabrics are brought into contact with each other and pressed, and ultrasonic vibration is applied to the contacted and pressed parts, so that the melting point of the binder material is lower than the melting point of the core fiber and the core fiber of the binder fiber. When heated to the above temperature, the binder material melts and penetrates between the basic fibers and the core fibers. Thereafter, when the temperature returns to a temperature lower than the above temperature, the melted binder material is solidified to bond the basic fibers and the core fibers. For this reason, the contacted and pressurized portions are joined (= welded).

  The material of the basic fiber of the nonwoven fabric and the core fiber of the binder fiber and the material of the binder material of the binder fiber are not particularly limited as long as the above conditions are satisfied. For example, the basic fiber is made of PET (polyethylene terephthalate), the core fiber of the binder fiber is made of PET, and the binder material of the binder fiber is a non-woven fabric composed of a copolymer resin of PET and PEI (polyethylene isophthalate). In such a configuration, the melting point of the basic fiber and the core fiber (that is, PET) is about 250 ° C. The melting point of the binder material is 110 to 150 ° C. For this reason, when this non-woven fabric is heated to a temperature of 110 to 250 ° C., the basic fiber and the core fiber are not melted and maintain the fiber state, but the binder material is melted and the basic fiber and the core fiber are not melted. Soaks in. Thereafter, when the temperature returns to a temperature lower than the above temperature, the binder material is solidified to bond the basic fibers and the core fibers.

  The protector 13 has a configuration in which a sheet-like member 14 is wound around the outer peripheral surface of the wire bundle 12. In other words, the protector 13 is formed by winding the sheet-like member 14 around the outer peripheral surface of the wire bundle 12.

  The protector 13 is formed with an overlapping portion 131. The overlapping portion 131 is a portion where one side portion 141 and the other side portion 142 of the sheet-like member 14 overlap on the outer peripheral surface of the wire bundle 12. Specifically, the overlapping portion 131 is disposed such that one side portion 141 of the sheet-like member 14 is along the outer peripheral surface of the wire bundle 12, and the other side portion 142 is outside the one side portion 141. Are formed so as to overlap each other. For this reason, in the overlapping part 131, the outer surface of one side 141 of the sheet-like member 14 (= the surface opposite to the wire bundle 12) and the inner surface of the other side 142 (= electric wires). The outer surface of one side 141 and the inner surface of the other side 142 are substantially parallel to the outer peripheral surface of the wire bundle 12. That is, the overlapping portion 131 is formed along the outer peripheral surface of the wire bundle 12, and the overlapping portion 131 (that is, both side portions 141 and 142 of the sheet-like member 14) protrudes away from the outer peripheral surface of the wire bundle 12. do not do.

  A joining portion 132 is formed in the overlapping portion 131. The joining portion 132 is a portion where the outer surface of one side portion 141 of the sheet-like member 14 and the inner surface of the other side portion 142 are joined, and is a portion welded by ultrasonic welding. is there. For this reason, the protector 13 has a substantially cylindrical structure as a whole. The wire bundle 12 is accommodated inside the protector 13. According to such a configuration, the wire bundle 12 is protected by the protector 13.

  The protector 13 has a configuration in which the joining portion 132 is formed over the entire length in the axial direction of the wire bundle 12 (= the both side portions 141 and 142 of the sheet-like member 14 have no gap over the entire length in the axial direction of the wire bundle 12. A configuration in which the joining portions 132 are formed at a predetermined interval (= a configuration in which the sheet-like member 14 is partially joined along the axial direction of the wire bundle 12). ). FIG. 1A shows a configuration in which the joints 132 are formed at a predetermined interval.

  As described above, in the wire harness 1, the overlapping portion 131 and the joining portion 132 of the sheet-like member 14 constituting the protector 13 are formed along the outer peripheral surface of the wire bundle 12. For this reason, the overlapping part 131 of the sheet-like member 14 constituting the protector 13 is configured not to protrude outward from the other part of the protector 13. Accordingly, the protector 13 can be reduced in size (particularly, the size and shape of the cut surface cut by a plane substantially perpendicular to the axial direction of the wire bundle 12), and can be easily routed in a narrow space. . And since the part which protrudes toward the outer side from the outer peripheral surface of the wire bundle 12 is not formed in the protector 13, handling of this wire harness 1 becomes convenient. That is, if the protector 13 has a portion projecting outward, the projecting portion may be hindered by other objects and hinder routing work, etc. In the wire harness 1, There is no such thing.

  Next, the manufacturing method of the protector concerning embodiment of this invention is demonstrated. In the method for manufacturing a wire harness according to the embodiment of the present invention, an ultrasonic welder and a jig 5 having a predetermined shape are used.

  A conventional general ultrasonic welding machine (preferably, an ultrasonic spot welding machine, that is, an ultrasonic welding machine capable of welding an arbitrary specific range) can be applied to the method of manufacturing the wire harness according to the embodiment of the present invention. . Therefore, detailed description is omitted. Briefly, a general ultrasonic welding machine includes an ultrasonic oscillator, an ultrasonic vibrator, and a horn. The ultrasonic oscillator can generate an electrical signal having an ultrasonic frequency (for example, AC electricity having an ultrasonic frequency). The ultrasonic vibrator is vibrated by an electric signal generated by the ultrasonic oscillator and generates ultrasonic waves. The horn (pressure member) is a resonator that vibrates in resonance with the ultrasonic wave generated by the ultrasonic vibrator, and is a member that transmits the ultrasonic wave to the object to be welded. Some ultrasonic welding machines include an anvil, and have a configuration in which an object to be welded is sandwiched between a horn (pressurizing member) and an anvil to be welded, but according to an embodiment of the present invention. The ultrasonic welding machine used in the method for manufacturing a wire harness may not have an anvil. That is, since the jig 5 functions as an anvil, the ultrasonic welding machine may not include the anvil.

  FIG. 2 is a diagram schematically showing the configuration of the jig 5 used in the method for manufacturing the wire harness according to the embodiment of the present invention, and FIG. 2 (a) is an external perspective view of the jig 5. FIG. 2B is a perspective view showing a state in which the jig 5 is disposed on the outer peripheral surface of the wire bundle 12 and the inner peripheral surface of the protector 13 (= sheet-like member 14). As shown in FIGS. 2A and 2B, the jig is a substantially rod-shaped member having a predetermined length dimension and a predetermined width dimension.

  The jig 5 is a member that receives the pressure applied by the horn 6 of the ultrasonic welder in the step of joining the side portions 141 and 142 of the sheet-like member 14. That is, pressure is applied to both side portions 141 and 142 of the sheet-like member 14 by sandwiching both side portions 141 and 142 of the sheet-like member 14 between the horn 6 and the jig 5 of the ultrasonic welder. For this reason, the jig 5 has a strength that does not deform (or hardly deforms) even when it is subjected to the pressure applied by the horn 6 of the ultrasonic welder. However, the thickness dimension is preferably as small as possible. For this reason, the jig 5 is formed of, for example, a metal plate.

  The width dimension of the jig 5 is set based on the dimension and shape of the joint portion 132 of the protector 13. In other words, a portion pressed between the horn and the jig of the ultrasonic welder becomes the joint 132. For this reason, for example, when the size and shape of the joining portion 132 is the joining portion 132 that is the entire portion pressed against the tip of the horn of the ultrasonic welder, the tip of the horn 6 of the ultrasonic welder is used. The size and shape are set larger than the size and shape.

  The jig 5 may have a substantially flat plate shape as shown in FIGS. 2 (a) and 2 (b). However, the jig 5 has a predetermined cross-sectional shape (the cross section here is the longitudinal direction). It may be a structure having a cross section in a plane perpendicular to the surface. That is, the longitudinal direction of the jig 5 and the axial direction of the wire bundle 12 of the wire harness 1 are made substantially parallel, and in this state, the outer circumferential surface of the wire bundle 12 of the wire harness 1 and the outer circumferential surface of the wire bundle 12 A shape (for example, the wire bundle 12 of the wire harness 1 or the outer peripheral surface of the wire bundle 12 that can be easily inserted between the wound sheet-like member 14 (= the protector 13) and the inner peripheral surface. A configuration having a shape in which the sheet-like member 14 is not greatly deformed) can be applied. In other words, in a state where the jig 5 is disposed between the outer peripheral surface of the wire bundle 12 and the inner peripheral surface of the sheet-like member 14 (= protector 13) wound around the outer peripheral surface of the wire bundle 12. Between the outer peripheral surface of the wire bundle 12 and the inner peripheral surface of the sheet-like member 14, between the jig 5 and the outer peripheral surface of the electric wire bundle 12, and the inner peripheral surface of the jig 5 and the sheet-like member 14 A configuration having a shape in which no gap is formed (or small even if a gap is formed) can be applied. Specifically, it is formed in a shape substantially equal to the shape of the outer peripheral surface of the wire bundle 12 of the wire harness 1. For example, if the wire bundle 12 of the wire harness 1 is formed to have a substantially circular cross section, the wire harness 1 is formed to have a curved surface having a radius of curvature substantially equal to the radius of the circle formed by the wire bundle 12 of the wire harness 1. Is applicable.

  The length dimension of the jig 5 is the length dimension in the axial direction of the wire bundle 12 of the sheet-like member 14 (= protector 13) and the position where the joint 132 is formed (specifically, the length in the axial direction of the wire bundle 12). Position). Specifically, as shown in FIG. 2B, in a state where the jig 15 is disposed between the outer peripheral surface of the wire bundle 12 and the sheet-like member 14 wound around the outer peripheral surface of the wire bundle 12. One end of the jig 5 reaches a position where the joining portion 132 is formed, and the other end is set to a dimension that can project from the end face of the sheet-like member 14. In other words, the length dimension of the jig 5 in the axial direction is set to a dimension larger than the distance from the one end in the axial direction of the wire bundle 12 of the sheet-like member 14 to the joint portion 132. For example, if the dimension is set to be slightly longer than half of the length of the sheet-like member 14, the joint 132 can be formed at any position in the axial direction of the wire bundle 12 of the sheet-like member 14. it can.

  3-5 is the cross-sectional schematic diagram which showed typically the predetermined | prescribed process of the manufacturing method of the protector concerning embodiment of this invention. Specifically, FIG. 3A shows a state before the sheet-like member 14 is wound around the wire bundle 12, and FIG. 3B shows the sheet-like member 14 around the wire bundle 12. The state where is wound is shown. 4A shows a state in which the sheet-like member 14 is wound around the wire bundle 12, and FIG. 4B shows the jig 5 between the outer peripheral surface of the wire bundle 12 and the sheet-like member 14. FIG. Indicates the inserted state. FIG. 5A shows a process of welding one side 141 and the other side 142 of the sheet-like member 14 by an ultrasonic welding machine, and FIG. 5B shows a state where the welding is completed. Show.

  As shown in FIG. 3A, a sheet-like member 14 having a predetermined width dimension is prepared. When the sheet-like member 14 is wound around the outer peripheral surface of the wire bundle 12 of the wire harness 1, the sheet-like member 14 has a width dimension on the outer surface of one side portion 141 of the sheet-like member 14. The dimension is set such that the other side portion 142 can be superimposed (= the overlapping portion 131 is formed). For example, when the electric wire bundle 12 is formed in a substantially circular cross section as a whole, the electric wire bundle 12 is formed in a dimension larger than the circular circumferential length formed by the electric wire bundle 12. When the wire bundle 12 is formed in a flat plate shape as a whole (= when forming a flat cable), the wire bundle 12 is set to a dimension larger than twice the width dimension of the wire bundle 12. When the wire bundle 12 has a substantially polygonal cross section, the dimension is set to be larger than the total length of each side of the polygon.

  The length dimension of the sheet-like member 14 is the length dimension of the protector 13. For this reason, the length dimension of the sheet-like member 14 is set based on the length of the part which the protector 13 of the electric wire bundle 12 wants to protect. Moreover, the thickness dimension of the sheet-like member 14 is not specifically limited. In other words, the sheet-shaped member 14 may have a thickness dimension capable of protecting the wire bundle 12 in a state where the protector 13 is formed by being wound around the outer peripheral surface of the wire bundle 12. For this reason, it sets suitably based on the performance of a protector, the material of the sheet-like member 14, etc. FIG.

  Then, as shown in FIGS. 3A and 3B, first, the jig 5 is disposed at a predetermined position on the outer peripheral surface of the wire bundle 12. In this state, the sheet-like member 14 is wound around the outer peripheral surface of the wire bundle 12. At this time, as shown in FIG. 2B in particular, both side portions 141 and 142 of the sheet-like member 14 are on the outer surface of the jig (the surface opposite to the surface facing or contacting the wire bundle 12). It is wound so that it is located above. In other words, both side portions 141 and 142 of the sheet-like member 14 are wound so as to overlap on the outer surface of the jig 5. Thereby, the overlapping part 131 of the sheet-like member 14 is formed on the outer peripheral surface of the jig 5.

  In addition, after the sheet-like member 14 is wound on the outer peripheral surface of the wire bundle 12, the jig is inserted between the outer peripheral surface of the wire bundle 12 and the inner peripheral surface of the sheet-like member 14. May be. That is, as shown in FIG. 4A, first, the sheet-like member 14 is wound around the outer peripheral surface of the wire bundle 12. Next, as shown in FIG. 4B, a jig is inserted between the outer peripheral surface of the wire bundle 12 and the inner peripheral surface of the sheet-like member 14. At this time, as shown in FIG. 4B, the jig 5 is between the outer peripheral surface of the wire bundle 12 and the portion where the both side portions 141 and 142 of the sheet-like member 14 overlap (= superimposed portion 131). Inserted.

  Next, as shown in FIGS. 5A and 5B, both side portions 141 and 142 (= superimposed portion 131) of the sheet-like member 14 are joined by an ultrasonic welder (not shown).

  Specifically, as shown in FIG. 5A, first, from the outer side, a portion where both side portions 141, 142 of the sheet-like member 14 wound on the outer peripheral surface of the wire bundle 12 overlap is super The horn 6 of the sonic welder is pressed by a predetermined pressure. When the horn 6 of the ultrasonic welder is pressed to a portion where both side portions 141, 142 of the sheet-like member 14 are overlapped by a predetermined pressure, of the portions where both side portions 141, 142 of the sheet-like member 14 are overlapped A predetermined part (at least a part of the overlapping part. In the embodiment of the present invention, a part of the overlapping part) is pressed between the horn 6 and the jig 5 of the ultrasonic welder. In the sandwiched and pressurized portion, the outer surface of one side 141 of the sheet-like member 14 and the inner surface of the other side 142 are in contact with each other with a predetermined pressure.

  In this state, the ultrasonic welder is operated. When the ultrasonic welder is activated, a portion of the both sides 141 and 142 of the sheet-like member 14 that comes into contact with a predetermined pressure from the horn 6 of the ultrasonic welder (= the horn 6 and the jig of the ultrasonic welder) The ultrasonic vibration is applied to the portion between and pressed by 5) and the vicinity thereof. If it does so, the surface which contacts with a predetermined pressure will be heated by ultrasonic vibration between them.

  If the sheet-like member 14 is made of a thermoplastic resin composition, the outer surface of one side portion 141 and the inner surface of the other side portion 142 of the sheet-like member 14 have a predetermined pressure. The contact surface and the vicinity thereof are heated so as to have a temperature equal to or higher than the melting point of the resin composition. If the sheet-like member 14 is made of a nonwoven fabric having the above-described configuration, the outer surface of one side 141 of the sheet-like member 14 and the inner surface of the other side 142 contact with a predetermined pressure. The surface to be heated and the vicinity thereof are heated so that the temperature is lower than the melting point of the core fiber of the basic fiber and the binder fiber and is equal to or higher than the melting point of the binder material of the core fiber.

  When heated to the above temperature, the surface where the outer surface of one side 141 of the sheet-like member 14 and the inner surface of the other side 142 come into contact with each other with a predetermined pressure and its vicinity are melted and joined. (= Welding). As a result, the outer surface of one side 141 of the sheet-like member 14 and the inner surface of the other side 142 are joined to form a joint 132. When the sheet-like member 14 is made of a non-woven fabric having the above-described configuration and is heated to the above temperature, the basic fiber and the core fiber of the binder fiber can be joined while maintaining the fiber state. The heating temperature can be appropriately set by adjusting the amplitude of the horn of the ultrasonic welder, the time for vibration, and the like.

  This step is performed at predetermined positions on both side portions 141 and 142 of the sheet-like member 14. For example, this process is performed at a plurality of positions at predetermined intervals along the axial direction of the wire bundle 12.

  After this step is completed at all of the predetermined positions, the jig 5 is extracted from between the wire bundle 12 and the sheet-like member 14.

  Through the above steps, the protector 13 made of the sheet-like member 14 is formed at a predetermined position on the outer peripheral surface of the wire bundle 12. And when the protector 13 is formed in the several position of the wire bundle 12, the above process is repeated in the position which requires. Thereby, this wire harness 1 which has a structure as shown in FIG. 1 is manufactured.

  If the jig 5 has the length dimension, the jig can be disposed at any location between the sheet-like member and the wire bundle 12. Therefore, the joint portion 132 can be formed at a predetermined location of the protector 13.

  Moreover, if the jig | tool 5 has the structure formed in the shape which followed the shape of the outer peripheral surface of the electric wire bundle 12 in the shape of a thin plate, the inner peripheral surface of the protector 13 formed with the electric wire bundle 12 The size and shape of the electric wire bundle 12 and the protector 13 do not change even if they are extracted from between the two. In particular, if the jig 5 is formed of a thin plate, there is no gap between the wire bundle 12 and the protector 13 even after the jig 5 is extracted.

  According to the method of manufacturing the wire harness according to the embodiment of the present invention, in the step of joining the both side portions 141 and 142 of the sheet-like member 14, the both side portions 141 and 142 of the sheet-like member 14 are ultrasonically welded. It is sandwiched between the machine horn 6 and the jig 5 and pressurized. As described above, the jig 5 is not deformed or hardly deformed even when the pressure of the horn 6 of the ultrasonic welder is applied. For this reason, a predetermined pressurizing force can be applied to predetermined portions of the side portions 141 and 142 of the sheet-like member 14 (that is, portions that become the joint portions 132).

  That is, in the configuration in which the jig 5 is not used, when the horn 6 of the ultrasonic welder is pressed to the outside of the side portions 141 and 142, the wire bundle 12 is deformed by the applied pressure, and the applied pressure is relaxed. . For this reason, it is difficult to apply a predetermined pressing force to both side portions 141 and 142, or it is difficult to apply a predetermined pressing force. On the other hand, according to the configuration in which the jig 5 is used, the jig 5 receives the applied pressure of the horn 6 of the ultrasonic welder. And since a part of both side parts 141 and 142 of the sheet-like member 14 are pinched | interposed between the horn 6 and the jig | tool 5 of an ultrasonic welding machine, a predetermined pressurizing force can be applied.

  For this reason, according to the manufacturing method of the wire harness concerning embodiment of this invention, compared with the structure where the jig | tool 5 is not used, it adds to the overlapped part of the both sides 141,142 of the sheet-like member 14. The applied pressure can be increased. Therefore, it is possible to maintain or improve the bonding strength at the bonding portion 132.

  Furthermore, according to the configuration in which the jig 5 is used, it is easy to control the pressure applied to the overlapped portions of the side portions 141 and 142 of the sheet-like member 14.

  That is, in the configuration in which the jig 5 is not used, when the horn 6 of the ultrasonic welding machine is pressed against the both side portions 141 and 142 from the outside, a predetermined portion of the overlapped portions of the both side portions 141 and 142 is determined. The portion is sandwiched between the horn 6 and the wire bundle 12 of the ultrasonic welder and pressed. At this time, when the electric wire bundle 12 is deformed by the applied pressure, the applied pressure applied to the predetermined portion differs depending on the deformation mode (= shape and size after deformation) of the electric wire bundle 12. Since it is difficult to control the deformation mode of the wire bundle 12 (particularly, to make the cross-sectional dimensions and shape of the wire bundle 12 after deformation uniform), the pressure applied to the predetermined portion is controlled. (Especially, making it uniform) becomes difficult. For this reason, when joining at a plurality of positions of the overlapped portions of the side portions 141 and 142, the pressure applied to the predetermined portions of the side portions 141 and 142 of the sheet-like member 14 when joining at each position is As a result, the joining strength at each joint 132 becomes non-uniform.

  On the other hand, in the configuration in which the jig 5 is used, when the horn 6 of the ultrasonic welder is pressed against a predetermined portion of the both side portions 141 and 142 of the sheet-like member 14, the jig 5 A pressure is applied by the horn 6 of the sonic welder. Since the jig 5 is not deformed or hardly deformed even when the horn 6 of the ultrasonic welder is pressed, the pressure applied to both side portions 141 of the sheet-like member 14 becomes uniform. Therefore, it is possible to make the bonding strength uniform at each bonding portion 132. As a result, the quality of the wire harness 1 is stabilized and quality control becomes easy.

  Moreover, according to the manufacturing method of the wire harness concerning embodiment of this invention, although the surface of the electric wire 11 which comprises the electric wire bundle 12 of the wire harness 1 is heated by heat transfer, the temperature rise is small. For this reason, the coating | covering material of the electric wire 11 is not damaged. Therefore, the function of protecting the conducting wire of the covering material of the electric wire 11 and the function of insulating the conducting wire are not deteriorated or lost. Furthermore, since the electric wire 11 is not pressurized in the process of joining the both side portions 141 and 142 of the sheet-like member 14, the electric wire 11 is prevented from being damaged by the applied pressure. Therefore, it is possible to maintain or improve the reliability of the wire harness 1.

  As described above, it is possible to prevent the joint strength from being reduced or improve the joint strength at the joint portion 132 while the protector 13 is configured not to have a portion protruding outward.

  Moreover, according to the manufacturing method of the wire harness concerning embodiment of this invention, the superimposition part 131 of the protector 13 is formed so that the outer peripheral surface of the wire bundle 12 may be followed. For this reason, in the conventional configuration in which the overlapping portion (= joining portion) protrudes toward the outside, it is necessary to cut out (= trimming) an unnecessary portion after joining, but according to the embodiment of the present invention. Such a process is not necessary in the manufacturing method of the wire harness. Therefore, the number of manufacturing steps can be reduced, and the manufacturing cost can be reduced.

  As mentioned above, although embodiment of this invention was described in detail, this invention is not limited to the said embodiment at all, In the range which does not deviate from the meaning of this invention, a various change is possible.

  For example, in the said embodiment, although the structure which forms a protector with a nonwoven fabric was shown, the material of a protector is not limited to a nonwoven fabric. The material and structure are not limited as long as the material can be welded by an ultrasonic welder. That is, if it is a resin composition, well-known various thermoplastic resin compositions are applicable. Moreover, the structure of a sheet-like member is not limited to a nonwoven fabric.

  In the embodiment of the present invention, the configuration in which the joining portion 132 is formed in a part of the overlapped portion of the both side portions 141 and 142 of the sheet-like member 14 is shown. The whole may be the joint 132. The point is that the joining portion 132 may be formed on at least a part of the overlapped portion.

  Moreover, in the said embodiment, although the structure in which the protector 13 was formed in the outer peripheral surface of the electric wire bundle 12 which consists of several electric wires 11 was shown, it is the structure by which a protector is formed in the outer peripheral surface of a single electric wire, Also good. In this case, what is necessary is just to read "the outer peripheral surface of the electric wire bundle 12" in the said embodiment as "the outer peripheral surface of a single electric wire."

1 Wire harness manufactured using the method for manufacturing a wire harness according to an embodiment of the present invention (this wire harness)
DESCRIPTION OF SYMBOLS 11 Electric wire 12 Wire bundle of this wire harness 13 Protector of this wire harness 131 Superposition part provided in a protector 132 Joining part formed in a superposition part 14 Sheet-like member 141 One side part 142 of sheet-like member 142 Sheet-like The other side 5 of the member 6 Jig 6 Ultrasonic welder horn

Claims (5)

Winding the sheet-like member around the outer peripheral surface of the predetermined portion of the electric wire, and superimposing both side portions of the sheet-like member on the outer peripheral surface of the predetermined portion of the electric wire;
A jig disposed between an outer peripheral surface of a predetermined portion of the electric wire and an inner peripheral surface of the overlapped portion of the sheet-like member, and a pressure member of the welding machine, Pressurizing and welding at least a part of the overlapped portion of the member;
The manufacturing method of the wire harness characterized by including.   The welding machine is an ultrasonic welding machine, and the sheet-like member is made of a material capable of ultrasonic welding, and an ultrasonic vibration is applied while pressing at least a part of the overlapped portion of the sheet-like member. The method for manufacturing a wire harness according to claim 1, wherein welding is performed.   The method of manufacturing a wire harness according to claim 1, wherein the jig is a substantially rod-shaped member having a predetermined length.   The jig is disposed in advance on the outer peripheral surface of the predetermined portion of the electric wire before the sheet-like member is wound around the predetermined portion of the electric wire, The method for manufacturing a wire harness according to any one of claims 1 to 3, wherein the wire harness is superposed on an outer peripheral surface of the jig.   The jig includes an outer peripheral surface of the predetermined portion of the electric wire and an overlapped portion of the sheet-shaped member after the sheet-like member is wound around the outer peripheral surface of the predetermined portion of the electric wire. It inserts between peripheral surfaces, The manufacturing method of the wire harness of any one of Claim 1 to 3 characterized by the above-mentioned.

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