JP5640907B2 - Wire harness and method of manufacturing wire harness - Google Patents

Description

  The present invention relates to a wire harness.

  Conventionally, wire harnesses having various structures have been proposed. For example, Patent Document 1 discloses a structure of a wire harness used in an automobile.

JP 2000-259883 A

  In the wire harness described in Patent Document 1, a crimp terminal is crimped to an electric wire bundle composed of a plurality of electric wires. If the crimp terminal is fixed at a location where the vibration strength is high, such as an engine, the wire bundle may be disconnected.

  Then, this invention is made | formed in view of the above-mentioned point, and it aims at providing the technique which can prevent the disconnection of an electric wire bundle.

The wire harness which concerns on a 1st aspect is a wire harness which connects a 1st location and the 2nd location where vibration intensity is larger than the said 1st location, Comprising: An electric wire bundle and one end part of the said electric wire bundle A first crimp terminal that is crimped and fixed to the first location; a second crimp terminal that is crimped to the other end of the wire bundle and that is secured to the second location; In the wire bundle to which the second crimp terminal is attached, a breakage preventing member that covers a portion to be covered from a predetermined portion of the second crimp terminal to a predetermined portion of a portion where the first and second crimp terminals are not attached. The second crimp terminal is a wire barrel that is crimped to the exposed tip end of the other end of the wire bundle that is not covered with the wire covering material, and the other end of the other end. Do not crimp the part And a insulation barrels surrounding the other parts, the disconnection preventive member is formed by the nonwoven material is hot pressed in a state of covering the covering target part, said another portion and said insulation barrel The interference between the insulation barrel and the other part due to the gap between the two is suppressed.

  The wire harness which concerns on a 2nd aspect is a wire harness which concerns on a 1st aspect, Comprising: The said electric wire bundle is a bare electric wire bundle in which the whole area | region is not covered with the electric wire coating | covering material, or at least in the said other end part A wire bundle with a covering material from which the wire covering material is stripped.

The manufacturing method of the wire harness which concerns on a 3rd aspect is a manufacturing method of the wire harness which connects a 1st location and the 2nd location where vibration intensity is larger than the said 1st location, and has an electric wire bundle, ( a) a step of crimping the first and second crimp terminals fixed respectively to the first and second locations to one end and the other end of the wire bundle; A wire barrel that is crimped to the exposed tip portion of the other end of the wire bundle that is not covered with the wire covering material, and surrounds the other portion without being crimped to the other portion of the other end. (B) In the electric wire bundle to which the first and second crimp terminals are attached, the first and second crimp terminals are attached from predetermined positions of the second crimp terminal. Where there is no part The coated target portion to portion in a state covered with a nonwoven material, by hot-pressing the nonwoven material, by gaps between said covering target part to have covering, the insulation barrels and the other portion The method further includes the step of forming a disconnection preventing member that suppresses interference between the insulation barrel and the other portion .

  According to the first to third aspects, in the electric wire bundle to which the first and second crimp terminals are attached, the non-woven member is attached to the first and second crimp terminals from a predetermined position of the second crimp terminal. Since the disconnection preventing member is formed so as to cover the covering target part by hot pressing in a state where the covering target part up to a predetermined part of the part not covered is covered, the disconnection preventing member is closely attached to the covering target part. be able to. Thereby, it can suppress that the positional relationship between the insulation barrel of a 2nd crimp terminal and an electric wire bundle changes, and it suppresses that the insulation barrel of an 2nd crimp terminal and an electric wire bundle interfere. be able to. As a result, it is possible to prevent the wire bundle from being disconnected.

  Further, since the disconnection preventing member is in close contact with the portion to be covered, the location where the vibration load is concentrated in the portion of the wire bundle where the first and second crimp terminals are not attached is from the boundary portion with the second crimp terminal. Also, it can be set as a boundary part with the disconnection prevention member which is away from the 2nd location where vibration intensity is large. Therefore, the vibration intensity at the location where the vibration load is concentrated can be reduced. As a result, it is possible to further prevent the wire bundle from being disconnected.

It is a figure which shows the structure of a wire harness. It is a figure which shows the structure of a wire harness. It is a figure which shows the structure of a wire harness. It is a top view which expands and shows the edge part by the side of the 2nd crimp terminal in a wire harness. It is a side view which expands and shows the edge part by the side of the 2nd crimp terminal in a wire harness. It is a figure which shows the cross-section of the 2nd crimp terminal of a wire harness. It is a figure which shows the structure of a comparison object wire harness. It is a side view which expands and shows the edge part by the side of the 2nd crimp terminal in a comparison object wire harness. It is a figure which shows the cross-section of the 2nd crimp terminal of a comparison object wire harness. It is a figure which shows the structure of the modification of a wire harness.

  1-3 is a figure which shows the structure of the wire harness 1 which concerns on embodiment. The wire harness 1 according to the present embodiment is an earth cable for grounding an electric device used in a vehicle such as an automobile. 1-3, the wire harness 1 fixed to the vehicle when viewed from different directions is shown. Each of FIGS. 1 to 3 shows an XYZ coordinate system so that it can be easily understood from which direction the wire harness 1 is shown.

  In the wire harness 1 according to the present embodiment, one end is fixed to an electrical device to be grounded, such as an engine, and the other end is fixed to a vehicle body. In a vehicle such as an automobile, the engine vibrates greatly, and the body hardly vibrates. Therefore, one end of the wire harness 1 is fixed to a portion having a relatively large vibration strength (hereinafter referred to as “strong vibration portion”). The other end is fixed to a location where vibration intensity is relatively small (hereinafter referred to as “weak vibration location”).

  As shown in FIGS. 1 to 3, the wire harness 1 according to the present embodiment is crimped to an electric wire bundle 10 composed of a plurality of electric wires 100 (see FIGS. 4 and 5 described later) and one end portion of the electric wire bundle 10. The first crimping terminal 11, the second crimping terminal 12 crimped to the other end of the wire bundle 10, and the disconnection preventing member 13 for preventing the wire bundle 10 from breaking. The first crimp terminal 11 is fixed to a vehicle body (weak vibration location), and the second crimp terminal 12 is fixed to an engine (strong vibration location).

  The wire bundle 10 is, for example, a bare wire bundle whose entire region is not covered with the wire covering material. That is, the wire bundle 10 according to the present embodiment can be obtained by peeling off all the wire covering materials of the wire bundle with covering material covered with the wire covering material.

  Each of the first crimping terminal 11 and the second crimping terminal 12 is, for example, a round terminal, and a fixing part that is fixed to a connection target portion with a bolt or the like, and a crimping part that is crimped to an end of the wire bundle 10 It has. 4 is an enlarged plan view showing an end portion of the wire harness 1 on the second crimp terminal 12 side, and FIG. 5 is an enlarged side view showing the end portion. 4 and 5, the outline of the outer shape of the disconnection preventing member 13 is indicated by a two-dot chain line.

  As shown in FIGS. 4 and 5, the fixing part 120 of the second crimp terminal 12 is provided with a bolt hole 120 a into which a bolt is inserted and a protrusion 120 b for preventing rotation. The crimping portion 123 of the second crimping terminal 12 includes a wire barrel 121 and an insulation barrel 122.

  The wire barrel 121 is designed so as to be crimped to an exposed portion of the bundle of electric wires with covering material from which the electric wire covering material has been peeled off. On the other hand, the insulation barrel 122 is designed to be crimped to a portion covered with the wire covering material in the wire bundle with covering material. When the wire bundle with a covering material is crimped to the second crimping terminal 12, the wire covering material is usually peeled off only at the tip portion of the wire bundle with the covering material that is crimped to the wire barrel 121. Therefore, the wire barrel 121 is pressure-bonded to the exposed wire bundle in the wire bundle with covering material, and the insulation barrel 122 is pressure-bonded to the wire covering material of the wire bundle with covering material.

  Thus, the wire barrel 121 is designed so as to be crimped to the exposed portion of the bundle of electric wires with covering material from which the electric wire covering material has been removed, and the insulation barrel 122 is an electric wire with covering material. The inner diameter of the substantially cylindrical insulation barrel 122 is larger than the inner diameter of the substantially cylindrical wire barrel 121 because the bundle is designed to be crimped to a portion covered with the wire covering material. It has become.

  In the present embodiment, since the end of the wire bundle 10 whose entire area is not covered with the wire covering material is crimped to the second crimping terminal 12, the wire bundle 121 is appropriately crimped in the wire barrel 121. However, in the insulation barrel 122 having an inner diameter larger than that of the wire barrel 121, a gap is generated between the wire barrel 10 and the wire bundle 10 is not crimped. FIG. 6 is a view showing a cross-sectional structure of the insulation barrel 122 at the second crimp terminal 12 to which the wire bundle 10 is crimped. As shown in FIG. 6, the insulation barrel 122 designed to be crimped to a portion covered with the wire covering material in the wire bundle with the covering material, and the wire covering material surrounded by the insulation barrel 122 A gap is generated between the wire bundle 10 and the wire bundle 10 not covered with the insulation barrel 122, and the insulation barrel 122 is not crimped to the wire bundle 10.

  The first crimping terminal 11 has the same structure as the second crimping terminal 12. The fixing part 110 of the first crimping terminal 11 has a bolt hole 110 a into which a bolt is inserted and a protrusion for preventing rotation. 110b is provided. The crimping portion 113 of the first crimping terminal 11 includes a wire barrel 111 and an insulation barrel 112. The wire barrel 111 is designed to be crimped to the exposed portion of the wire bundle with covering material, where the wire covering material has been peeled off, and the insulation barrel 112 is It is designed to be crimped to the part covered with the wire covering material. In the wire barrel 111, the wire bundle 10 is appropriately crimped, but in the insulation barrel 112, the wire bundle 10 is surrounded without being crimped to the wire bundle 10.

  In FIG. 5, the fixing portion 120 is shown as extending straight from the crimping portion 123, but actually, as shown in FIGS. 2 and 3, the fixing portion 120 is easily fixed to the engine. As described above, it extends slightly bent from the crimping portion 123. Similarly, in the first crimp terminal 11, the fixing part 110 extends slightly bent from the crimping part 113 so as to be easily fixed to the body.

  In the wire bundle 10 to which the first crimping terminal 11 and the second crimping terminal 12 are attached, the disconnection preventing member 13 is attached to the first crimping terminal 11 and the second crimping terminal 12 from a predetermined position of the second crimping terminal 12. It covers the periphery of the portion to be covered 200 up to a predetermined portion of the portion that is not (hereinafter referred to as “terminal unconnected portion 10a”). In the present embodiment, the covering target portion 200 is, for example, the second crimping of the terminal unconnected portion 10a of the wire bundle 10 from the vicinity of the end on the fixing portion 120 side in the wire barrel 121 of the second crimping terminal 12. The distance from the boundary with the terminal 12 is about one third. In FIGS. 1 to 3, the disconnection prevention member 13 is hatched so that the positional relationship between the disconnection prevention member 13 and the wire bundle 10 to which the first crimp terminal 11 and the second crimp terminal 12 are crimped can be easily understood. While showing, the part covered with the disconnection prevention member 13 among the said wire bundle 10 is shown as the continuous line.

  The disconnection preventing member 13 is formed by hot pressing a non-woven member (for example, a non-woven fabric) while covering the periphery of the coating target portion 200 while being in contact therewith. As this non-woven member, a non-woven member that can be hardened through a heating process can be used. As such a non-woven member, a material including a basic fiber and an adhesive resin (also called a binder) intertwined with the basic fiber can be used. The adhesive resin is a resin having a melting point (for example, 110 ° C. to 115 ° C.) lower than the melting point of the basic fiber. When the nonwoven member is heated to a processing temperature lower than the melting point of the basic fiber and higher than the melting point of the adhesive resin, the adhesive resin melts and soaks between the basic fibers. Thereafter, when the nonwoven member has a temperature lower than the melting point of the adhesive resin, the adhesive resin is solidified in a state where the basic fibers are bonded to each other. Thereby, the nonwoven member becomes harder than the state before heating, and is maintained in the molded shape at the time of heating.

  The basic fiber may be any fiber that can maintain the fiber state at the melting point of the adhesive resin, and various fibers can be used in addition to the resin fiber. As the adhesive resin, thermoplastic resin fibers having a melting point lower than that of the basic fiber can be used. The adhesive resin may be granular or fibrous. Alternatively, an adhesive resin layer may be formed on the outer periphery of the core fiber to form a binder fiber, which may be entangled with the basic fiber. As the core fiber in this case, the same material as the basic fiber can be used.

  Examples of the combination of the basic fiber and the adhesive resin include an example in which the basic fiber is a resin fiber of PET (polyethylene terephthalate) and the adhesive resin is a copolymer resin of PET and PEI (polyethylene isophthalate). In this case, the melting point of the basic fiber is approximately 250 ° C., and the melting point of the adhesive resin is 110 ° C. to 150 ° C. For this reason, when the nonwoven member is heated to a temperature of 110 ° C. to 250 ° C., the adhesive resin is melted and soaked between the basic fibers that keep the fiber shape without melting. And when a nonwoven member becomes temperature lower than melting | fusing point of adhesive resin, adhesive resin solidifies in the state which couple | bonded basic fibers, a nonwoven member becomes hard and maintains the shaping | molding shape at the time of a heating.

  Hot pressing refers to molding a nonwoven member by sandwiching a nonwoven member that is an object to be processed between molds and applying pressure to the mold in a heated state.

  As a method of covering the periphery of the covering target portion 200 with the non-woven member, for example, a method of winding a narrow belt-like and sheet-like non-woven member in a spiral shape while partially overlapping the covering target portion 200 is adopted. You may do it. Or you may employ | adopt the method of winding the strip | belt-shaped and sheet-like nonwoven member which has the same width as the length of the covering target part 200 several times around the covering target part 200 so that both ends of the width direction are aligned.

  The first crimp terminal 11 and the second crimp terminal 12 are respectively crimped to one end and the other end of the wire bundle 10, and then the nonwoven member is hot-pressed in a state where the nonwoven member is wound around the covering target portion 200. By doing so, the disconnection prevention member 13 which covers the circumference | surroundings of the coating | coated object part 200 can be formed.

  In addition, the shape of the metal mold | die used in the case of a hot press may be matched with the shape of the wire harness 1 after fixing to a vehicle (after wiring), and does not need to match. In the former case, the hot press is completed, and at the same time, the shape of the disconnection preventing member 13 is formed to match the shape of the wire harness 1 after being fixed to the vehicle. On the other hand, in the latter case, before the hot pressing is completed and the nonwoven member is hardened, the shape of the disconnection preventing member 13 is formed so as to match the shape of the wire harness 1 after being fixed to the vehicle. .

  Next, the reason why the wire bundle 10 can be prevented from being disconnected by the disconnection preventing member 13 will be described. Hereinafter, the reason why the breakage of the wire bundle 10 can be prevented by the breakage prevention member 13 will be described while comparing the wire harness 500 shown in FIG. 7 and the wire harness 1 according to the present embodiment. Hereinafter, the wire harness 500 is referred to as a “comparison wire harness 500”.

  As shown in FIG. 7, the wire harness 500 to be compared includes a wire bundle 510 with a covering material, the above-described first crimp terminal 11 crimped to one end of the wire bundle 510 with a covering material, and the covering material. The second crimping terminal 12 is crimped to the other end of the attached wire bundle 510. Hereinafter, the portion of the wire bundle with covering material 510 where the first crimp terminal 11 and the second crimp terminal 12 are not attached is referred to as a “terminal unconnected portion 510 a”.

  The wire covering material is stripped off at the tip of one end of the wire bundle with covering 510, and the wire barrel 111 of the first crimping terminal 11 is crimped to the tip. The insulation barrel 112 of the first crimp terminal 11 is a portion excluding the tip portion of one end portion of the wire bundle 510 with covering material, that is, the wire covering material in one end portion of the wire bundle 510 with covering material. It is crimped to the part covered with.

  Similarly, the wire covering material is peeled off at the tip end portion of the other end portion of the wire bundle 510 with covering material, and the wire barrel 121 of the second crimping terminal 12 is crimped to the tip end portion. The insulation barrel 122 of the second crimp terminal 12 is a portion excluding the tip portion of the other end portion of the wire bundle 510 with covering material, that is, the wire covering material of the other end portion of the wire bundle 510 with covering material. It is crimped to the part covered with. The first crimp terminal 11 is fixed to the vehicle body (weak vibration location), and the second crimp terminal 12 is fixed to the engine (strong vibration location).

  In such a comparative wire harness 500, since the second crimp terminal 12 is fixed at a strong vibration location, the boundary portion 600 with the second crimp terminal 12 in the terminal unconnected portion 510a of the sheathed wire bundle 510 is provided. The vibration load comes to concentrate. Therefore, the wire bundle with covering material 510 may be disconnected at the boundary portion 600.

  Therefore, the wire covering material of the wire bundle with covering material 510 is peeled off at least to the portion where the insulation barrel 122 of the second crimp terminal 12 is crimped, and the insulation barrel as in the wire harness 1 according to the present embodiment. By preventing 122 from being crimped to the wire bundle 510 with a covering material (see FIG. 6 described above), it is possible to prevent the vibration load from concentrating on the boundary portion 600. In this case, the second crimp terminal 12 is crimped only to the exposed wire bundle without being crimped to the wire coating material. Hereinafter, the portion of the wire bundle with covering material 510 from which the wire covering material has been removed is referred to as “exposed wire bundle 510b”.

  Thus, when the wire covering material of the wire bundle with covering material 510 is peeled off at least to the portion where the insulation barrel 122 of the second crimping terminal 12 is crimped, the insulation barrel 122 and the exposed wire bundle 510b. Since the second crimping terminal 12 fixed to the strong vibration portion vibrates, the second crimping terminal 12 and the exposed wire bundle 510b interfere with each other. Therefore, although it can suppress that a vibration load concentrates on said boundary part 600, the electric wire bundle 510 with a covering material may be disconnected by this interference.

  In order to solve such a problem, as shown in FIG. 8, a predetermined portion of the second crimp terminal 12 to a predetermined portion of the terminal unconnected portion 510a is covered with a heat shrinkable tube 600, and the heat shrinkable tube 600 is concerned. Is heated and shrunk to prevent the positional relationship between the second crimp terminal 12 and the exposed wire bundle 510b from changing, and thereby the second crimp terminal 12 and the exposed wire bundle 510b are It is conceivable to suppress interference. In FIG. 8, the heat shrinkable tube 600 after heat shrinkage is indicated by a two-dot chain line. FIG. 9 is a view showing a cross-sectional structure of the insulation barrel 122 shown in FIG. In FIG. 9, the shape of the heat shrinkable tube 600 before heat shrinkage is indicated by a solid line. Moreover, in FIG. 9, the shape of the part surrounding the terminal unconnected part 510a among the heat-shrinkable tubes 600 after heat-shrinking is shown by wavy lines.

  Thus, by using the heat-shrinkable tube 600, it is possible to suppress to some extent the change in the positional relationship between the second crimp terminal 12 and the exposed wire bundle 510b. However, due to the difference between the outer diameter of the insulation barrel 122 of the second crimp terminal 12 and the outer diameter of the exposed wire bundle 510b, the heat shrinkable tube 600 and the exposed wire bundle are shown in FIGS. A gap 700 is inevitably generated between the gap 510b. Therefore, even if the heat-shrinkable tube 600 is used, the positional relationship between the second crimp terminal 12 and the exposed wire bundle 510b changes, and the second crimp terminal 12 and the exposed wire bundle 510b interfere with each other. . As a result, even if the heat-shrinkable tube 600 is used, there is a possibility that the wire bundle with covering material 510 is disconnected.

  On the other hand, in the wire harness 1 according to the present embodiment, in the wire bundle 10 in which the first crimping terminal 11 and the second crimping terminal 12 are crimped, the non-woven member starts from a predetermined position of the second crimping terminal 12. Since the disconnection preventing member 13 is formed so as to cover the covering target portion 200 by being hot pressed in a state of covering the covering target portion 200 up to a predetermined portion of the terminal unconnected portion 10a of the wire bundle 10, the disconnection prevention is performed. The member 13 can be brought into close contact with the covering target portion 200. Thereby, it can suppress that the positional relationship between the 2nd crimp terminal 12 and the wire bundle 10 changes, and it can suppress that the 2nd crimp terminal 12 and the wire bundle 10 interfere. As a result, the wire bundle 10 can be prevented from being disconnected.

  Furthermore, since the disconnection preventing member 13 is in close contact with the covering target portion 200, the portion where the vibration load is concentrated in the terminal unconnected portion 10 a is defined as the boundary portion with the second crimp terminal 12 (the boundary portion in the comparison target wire harness 500. The portion 300 (see FIG. 2) with the disconnection preventing member 13 that is farther away from the strong vibration location (engine) than the portion (corresponding to 600). Therefore, the vibration intensity at the location where the vibration load is concentrated can be reduced. As a result, the wire bundle 10 can be further prevented from being disconnected.

  In addition, if a vibration load concentrates on the boundary part with the 1st crimp terminal 11 in the terminal unconnected part 10a of the electric wire bundle 10, the electric wire bundle 10 will be easy to disconnect. Considering this, although the vibration strength at the location where the vibration load is concentrated as the one end of the disconnection prevention member 13 on the first crimping terminal 11 side is away from the strong vibration location, the first of the disconnection prevention member 13 can be reduced. It is preferable that one end on the side of the first crimp terminal 11 does not extend to a boundary portion with the first crimp terminal 11 in the terminal unconnected portion 10a. FIG. 10 is a diagram illustrating a state in which one end of the disconnection preventing member 13 on the first crimp terminal 11 side is extended to a boundary portion with the first crimp terminal 11 in the terminal unconnected portion 10a.

  In the present embodiment, the wire bundle 10 is obtained by peeling off the wire covering material in the entire region of the wire bundle with the covering material, and the wire bundle in which the entire region is not covered with the wire covering material is used. You may use the electric wire bundle | flux with a coating | covering material from which the electric wire coating | coated material is stripped off at least in the whole area | region of the edge part to which the 2nd crimp terminal 12 is attached. That is, for the wire bundle 10, the wire covering material is peeled off at the end where the crimping portion 123 (the wire barrel 121 and the insulation barrel 122) of the second crimping terminal 12 fixed to the strong vibration location (engine) is attached. If so, the wire covering material may or may not be peeled off at other portions.

DESCRIPTION OF SYMBOLS 1 Wire harness 10 Wire bundle 10a Terminal unconnected part 11 1st crimp terminal 12 2nd crimp terminal 13 Disconnection prevention member 121 Wire barrel 122 Insulation barrel 200 Covering object part

Claims (3)

A wire harness connecting the first location and a second location having a greater vibration intensity than the first location,
A bundle of wires,
A first crimp terminal that is crimped to one end of the wire bundle and fixed to the first location;
A second crimp terminal that is crimped to the other end of the wire bundle and fixed to the second location;
In the electric wire bundle to which the first and second crimp terminals are attached, a covering target portion from a predetermined position of the second crimp terminal to a predetermined position of a portion where the first and second crimp terminals are not attached. A disconnection prevention member covering,
The second crimp terminal is crimped to a wire barrel that is crimped to the exposed end portion of the other end of the wire bundle that is not covered with the wire covering material, and to the other portion of the other end. An insulation barrel surrounding the other part without
The disconnection preventing member is formed by hot pressing a non-woven member covering the portion to be coated, and the insulation barrel and the other portion are formed by a gap between the insulation barrel and the other portion. Wire harness that suppresses interference with other parts . The wire harness according to claim 1,
The wire bundle is a wire harness that is a bare wire bundle whose entire region is not covered with a wire covering material, or a wire bundle with covering material in which the wire covering material is peeled off at least at the other end. A method of manufacturing a wire harness having a bundle of wires by connecting a first location and a second location having a greater vibration strength than the first location,
(A) a step of crimping the first and second crimp terminals fixed respectively to the first and second locations to one end and the other end of the wire bundle;
The second crimp terminal is crimped to a wire barrel that is crimped to the exposed end portion of the other end of the wire bundle that is not covered with the wire covering material, and to the other portion of the other end. An insulation barrel surrounding the other part without
(B) In the electric wire bundle to which the first and second crimp terminals are attached, covering from a predetermined place of the second crimp terminal to a predetermined place of a portion where the first and second crimp terminals are not attached. while covering the target portion in the nonwoven material, the nonwoven material by hot pressing, not covering the covering target part, by the gap between the insulation barrel and the other portion, the insulation The manufacturing method of a wire harness further provided with the process of forming the disconnection prevention member which suppresses interference with a barrel and said other part .

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