JP5889231B2 - Electric wire structure, electric connection structure, and electric wire structure manufacturing method - Google Patents

Description

  The present invention relates to, for example, an electric wire structure, an electric connection structure, and a method for manufacturing the electric wire structure.

  In recent years, a lot of various electric devices such as various lamps, audio, ABS, and rear camera are mounted on the vehicle. Wire harnesses for supplying electric power and control signals to these various electric devices are routed in the vehicle.

  Such wire harnesses differ in the type of vehicle, and even in the same vehicle type, the number of signal wires and the number of power lines differ depending on the grade and specifications, or the routing route changes depending on the arrangement of electrical equipment. For the reason, it was necessary to prepare the wire harness itself and the connector for connecting the wire harness corresponding to each vehicle type, grade, and specification.

  However, there is an increasing demand for cost reduction by making the wire harness itself and the connector for connecting the wire harness common regardless of the vehicle type, grade, and specifications. For this purpose, it is conceivable to connect the common wire harness with a connecting member according to the vehicle type, grade, and specifications.

  For example, in Patent Document 1, a group of covered electric wires formed by arranging covered electric wires in parallel is crossed and overlapped, and a desired covered electric wire that is conductively connected among intersecting portions where the covered electric wires intersect in a polymerized state. A branch connector has been proposed in which intersecting portions constituted by each other are connected so as to be electrically conductive with a crimp terminal.

  When the structure of the branch connector proposed in Patent Document 1 is used as a connecting member for connecting the wire harness as described above, among the intersecting portions where the covered wires intersect in a superposed state, the vehicle type and grade, Since the desired conductive crossing part according to the specifications is connected with the crimp terminal while checking the specifications, for example, there is a risk that the crossing part to be connected will be wrong or the connection of the crimping terminal at the crossing part will be troublesome. there were. In addition, the number of parts such as crimp terminals is increased, the production efficiency cannot be improved, and there is also a risk that the cost cannot be sufficiently reduced.

JP 2001-76779 A

  The present invention relates to an electric wire structure, an electric connection structure, and an electric wire structure that can form a desired connection path by accurately and efficiently connecting desired crossing portions among crossing portions where conductors intersect in a superposed state. It aims at providing the manufacturing method of.

This invention is exposed conductors portions exposed by removing the insulating coating of predetermined length fraction in the longitudinal direction of the conductor coated with an insulating coating, a plurality arranged along the first direction so that their is parallel a first direction exposed conductors was, the exposed conductor portion, the second direction exposed conductors which are more arranged in the second direction so that their is parallel, intersecting the polymerization unit was polymerized with crossing There are formed, between the second direction exposed conductor group and said first direction exposed conductors at the intersection polymerization unit, together with the insulating means for electrically insulating said exposed conductor portions to each other is disposed, the cross An insulating coating means is provided for covering the opposite side of the overlapping portion in the overlapping portion so as to be insulated, and the conductor is arranged at a predetermined interval in the width direction and is sandwiched between insulating films having insulating properties. Consists of a flat conductor in Le, the insulating means, among the intersection of the exposed conductor portions cross each other, the portion corresponding to the conductive cross section for conducting the conductor portions to each other out said exposure, the exposed conductors between the intersection state directly faces the window extending through is provided as, the exposed conductor portions to each other directly facing through the window portion is formed by connecting the conductively, the first direction exposing conductors are spaced apart in the longitudinal direction A plurality of second direction exposed conductor groups are superposed on each of the plurality of first direction exposed conductor groups provided in the longitudinal direction, and a plurality of cross-overlapping portions are formed in the longitudinal direction. A covering means is provided on a different opposite side in the adjacent cross polymerization portions among the plurality of cross polymerization portions, and is folded so that the plurality of cross polymerization portions are stacked in the polymerization direction to be polymerized. Wherein the provided wire construction was, and a manufacturing method.

  The conductor coated with the above-described insulation coating is a conductor in a covered electric wire configured by coating with an insulation coating for each conductor, or a plurality of conductors are directed in the same direction and arranged at a predetermined interval. A conductor such as a flat conductor in a flat cable covered with an insulating coating such as an insulating film can be used. In addition, it is a concept including a conductor composed of a single configuration conductor, a stranded wire formed by twisting strands, and the like.

The above-described exposed conductors in the crossing state face each other means a state in which the exposed conductors directly contact each other or directly face each other with a slight space therebetween through a penetrating window portion.
Moreover, as a connection method which connects the intersection part of the said exposed conductor parts and comprises a conductive intersection part, it can comprise by resistance welding, ultrasonic vibration welding, laser welding etc., for example.

  For example, in the case of overlapping in the vertical direction, the side opposite to the overlapping side in the cross-over portion described above includes a first direction exposed conductor group disposed on the lower side and a second direction exposed conductor group disposed on the upper side. While intersecting, it is made to superpose | polymerize in an up-down direction, and a cross superposition part is comprised. In this case, it is above the second direction exposed conductor group disposed below and above the first direction exposed conductor group disposed on the lower side, in other words, on the outer side in the overlapping direction at the crossover portion.

  The insulation coating means is constituted by, for example, an insulation film in a flat cable configured by integrally covering a plurality of flat conductors arranged in parallel with an insulation film, an insulation holder that holds the cross overlapping portion, and the like. be able to.

According to the present invention, a desired connection path can be configured by accurately and efficiently connecting desired intersections among intersections where conductors intersect in a superposed state.
Specifically, the exposed conductor portions intersecting each other in the intersection overlapping portion formed by overlapping and overlapping exposed conductor groups arranged in a predetermined direction so that the exposed conductor portions are parallel to each other, If it is as it is, the exposed conductors come into contact with each other at all the intersections and can conduct electricity. On the contrary, when the insulating means is disposed between the exposed conductor groups in the crossover portion, the exposed conductors are in an insulated state because the insulating means is interposed between the exposed conductors at all crossing portions. Become.

  Therefore, in the crossing portion in the crossover portion, a window portion that penetrates the exposed conductors in the crossed state so as to face each other is provided in the insulating means corresponding to the conductive crossing portion that conducts the exposed conductor portions. Thus, the exposed conductors at the conductive intersections face each other directly, and the other intersections are in an insulated state because the insulating means is interposed between the exposed conductors. And, by connecting the exposed conductors facing each other through the window portion penetrating the insulating means so as to be conductive, it is possible to accurately and efficiently connect a desired intersection portion among the intersection portions where the conductors intersect in a superposed state. Can do.

  Specifically, an insulating means provided with a window at a location corresponding to a desired conductive intersection according to the vehicle type, grade, and specifications, the first direction exposed conductor group and the second direction exposed in the intersection overlapping portion. Just by placing it between the conductor groups, the exposed conductors of the conductive intersections can be electrically connected to each other through the window that penetrates the insulating means, with the intersections other than the conductive intersections securely insulated. By checking the specifications etc., for example, without searching for and connecting the conductive crossing part, the crossing part to be connected is not mistaken, or the connection of the crimping terminal at the crossing part is not troublesome, Only the conductive intersections can be connected to form a desired connection path.

  Further, an insulating means provided with a window portion at a location corresponding to a conductive intersection portion which is a desired intersection portion according to the vehicle type, grade, and specification, the first direction exposed conductor group and the second direction in the intersection overlapping portion. Since it is only disposed between the exposed conductor groups, the number of parts such as crimp terminals does not increase depending on the number of conductive intersections, and the production efficiency can be improved and the cost can be reduced sufficiently. .

  Furthermore, an insulating means provided with a window portion at a location corresponding to a conductive intersection portion which is a desired intersection portion according to the vehicle type, grade, and specification, the first direction exposed conductor group in the intersection overlapping portion and the second portion. Since it is only placed between the direction-exposed conductor groups, for example, high acceleration vibrations such as 10 G in the engine room and 4 G in the passenger compartment are applied, or there is a temperature difference between high and low temperatures. Even under harsh usage environments such as a large size, there is a problem that, for example, the crimp terminal is detached and dropped due to vibration and the conductivity cannot be maintained, as in the case where the crimp terminal is conductively connected. Therefore, the conductivity at the conductive intersection and the insulation at the other intersection can be stably maintained.

  In this way, all except the insulating means provided with the window at the location corresponding to the conductive intersection, which is the desired intersection according to the vehicle type, grade, and specifications, can be shared, so the cost can be reduced by sharing. .

In addition, by providing an insulating coating means that covers the opposite side of the crossover portion opposite to the polymerization side in an insulating manner , the crossover portion where the desired conductive crossover portion is connected in a conductive manner among the crossover portions is protected in an insulated state. can do. Therefore, there is no fear that the exposed conductor portion is inadvertently short-circuited, and a desired connection path can be reliably configured.
In addition, if the inside is filled with a filler such as a synthetic resin having an insulating property, water-stopping property can be ensured.

Also, the pre-Symbol first direction exposed conductors plurality at intervals in the longitudinal direction, the second direction exposed conductor group, and polymerized for each of the first direction exposed conductors group of a plurality in the longitudinal direction By forming a plurality of cross overlapping portions in the longitudinal direction , various connection paths can be easily configured. More specifically, a plurality of cross-over portions are configured, and desired cross-over portions are connected to each cross-over portion so as to be conductive, so that even if a desired connection path is complicated, it is easy. Can be configured.

Further, it is possible to pre-Symbol plurality of intersecting polymerization unit is more and Orikasaneruko to laminating the polymer direction of the polymerization, to reduce the size of the wire structure can be easily constituted of various connection paths. Therefore, the electric wire structure which comprises the complicated desired connection path | route can be arrange | positioned also in the narrow place where the installation area | region was restrict | limited temporarily, and versatility improves.

Further, the conductor, as well as arranged at a predetermined interval in the width direction, by forming a flat rectangular conductor of the flat cable configured by sandwiching an insulating film having insulating properties, even complex connection routes, more It can be configured efficiently.

  More specifically, since a plurality of flat conductors in a flat cable are arranged in parallel at a predetermined interval, a plurality of conductors arranged in parallel are exposed by peeling off an insulating film at a desired location in the longitudinal direction of the flat cable. Thus, it is possible to easily form the exposed conductor portions spaced apart from each other and arranged in the same direction. Therefore, while crossing flat cables which peeled the insulating film of the predetermined place, it is made to superpose | polymerize and a cross-overpolymerization part can be comprised easily.

Further, the present invention provides a plurality of exposed conductor portions along the first direction that are exposed by removing the insulating coating for a predetermined length in the longitudinal direction of the conductor coated with the insulating coating so that they are parallel to each other. The arranged first direction exposed conductor groups and the second direction exposed conductor groups arranged in a plurality along the second direction so that the exposed conductor portions are parallel to each other intersect and overlap each other. overlapping portion is formed, between the first direction exposes the conductor the second direction exposed conductor group and groups in the cross-polymerization unit, with electrically insulating insulation means is disposed said exposed conductor portions to each other, Insulation coating means for covering the side opposite to the overlapping side in the crossover portion in an insulating manner is provided, and the conductor is composed of a conductor in a covered electric wire covered with an insulation coating for each conductor, and the insulating means includes the Exposed conductor part Among the intersections where the conductors intersect, a window portion is provided at a position corresponding to the conductive intersection portion that conducts the exposed conductor portions so that the exposed conductors in the intersecting state face each other, The exposed conductor portions facing each other are configured to be conductively connected, and the insulating coating means is formed of an insulating holder having a size capable of accommodating and holding the cross-overlapped portion with an insulating synthetic resin. , the accommodating portion for accommodating retaining the cross-overlapped portion in the insulating holder, characterized in that the coated electric wire covering the conductor with an insulating coating is a wire structure groove for fitting holding is formed.
According to the present invention, in addition to the above effects, the wire structure can be configured at low cost, and the cost can be greatly reduced.

Moreover, as an aspect of the present invention, a harness can be connected to the conductors constituting the second direction exposed conductor group in the above-described electric wire structure.
According to the present invention, the harness can be connected through a desired connection route according to the vehicle type, grade, and specifications. Accordingly, the wire harness can be shared, productivity can be improved, and further cost reduction can be achieved.

  According to the present invention, an electric wire structure, an electric connection structure, and an electric wire that can form a desired connection path by accurately and efficiently connecting desired cross portions among cross portions in which conductors intersect in a superposed state. A method for manufacturing a structure can be provided.

The top view of the example of a wiring using the electric wire structure of Example 1. FIG. The perspective view which shows how to superimpose an electric wire structure. The perspective view which has arrange | positioned the cross | intersection insulation film between exposed conductor groups. Explanatory drawing of the resistance welding state which welds the cross | intersection part of a flat conductor. The perspective view which coat | covers a cross-overpolymerization part with a pair of external insulation film. The perspective view of the electric wire structure covered with the external insulation film. The top view of the electric wire structure covered with the external insulation film. The AA arrow directional cross-sectional view of the electric wire structure covered with the external insulation film. The top view of the electric wire structure which arrange | positioned the cross overlap part in multiple numbers in the 1st direction. Explanatory drawing of the folding method which folds the electric wire structure of FIG. The side view of the state which folded the electric wire structure of FIG. 9 in the spelling folded state. The top view of the state which connected the branch harness in the electric wire structure. The top view of the electric wire structure which covered one surface with the external insulation film. The side view of the state which folded the electric wire structure of FIG. 13 in the spelling folded state. The perspective view which shows how to overlap the electric wire structure of Example 2. FIG. The perspective view which has arrange | positioned the cross | intersection insulation film between exposed conductor groups. The perspective view of the electric wire structure which covered one surface with the insulation holder. The top view of the electric wire structure which covered one surface with the insulation holder. Explanatory drawing of the laser welding state which welds the cross | intersection part of a round conductor. The top view of the electric wire structure which arrange | positioned the cross overlap part in multiple numbers in the 1st direction. The side view of the state which folded the electric wire structure in the spelling folded state.

An embodiment of the present invention will be described in detail with reference to the drawings.
Example 1
FIG. 1 is a plan view of a wiring example using the electric wire structure 10 of the first embodiment, FIG. 2 is a perspective view showing how the electric wire structures 10 are overlapped, and FIG. 3 is a cross-section insulating film 40 with an exposed conductor group G1. , G2 is a perspective view arranged between G2 and G2, FIG. 4 is an explanatory view of a resistance welding state in which the intersecting portions of the rectangular conductors 11a and 12a are welded, and FIG. 5 is a perspective view in which the cross overlapping portion GW is covered with a pair of external insulating films 50 6 is a perspective view of the electric wire structure 10 covered with the external insulating film 50, FIG. 7 is a plan view of the electric wire structure 10 covered with the external insulating film 50, and FIG. 8 is an electric wire structure covered with the external insulating film 50. FIG. 10 is a sectional view taken along line AA in FIG.

  9 is a plan view of the electric wire structure 10 in which a plurality of cross overlapping portions GW are arranged in the first direction X, FIG. 10 is an explanatory view of how to fold the electric wire structure 10 in FIG. 9, and FIG. 9 is a side view showing a state where the electric wire structure 10 is folded in a zigzag state, and FIG. 12 is a side view showing a state where the harnesses 3 and 4 are connected in the electric wire structure 10.

  In a vehicle such as an automobile, a wire harness 2 that establishes an electrical connection by mutually connecting a power source, a control device such as an ECU (Engine Control Unit), and an electrical device such as an audio device or a direction indicator is illustrated in FIG. 1, a main harness 3 connected to a power source or a control device, a branch harness 4 that branches from the main harness 3 and has a connector 5 connected to each electric device at the end, and a main harness 3 and a branch It is comprised with the electric wire structure 10 which connects the harness 4. FIG.

The electric wire structure 10 used for the connection of the harnesses 3 and 4 as described above will be described in detail with reference to FIGS.
The electric wire structure 10 of Example 1 includes a first flat cable 11 disposed in the first direction X (longitudinal direction) and a second flat disposed in the second direction Y (width direction) intersecting the first flat cable 11. Flat cable 12, crossover insulating film 40 disposed so as to be sandwiched between the crossing portions of first flat cable 11 and second flat cable 12, and a pair of external insulations covered so as to cover the entire crossing portion It is comprised with the film 50 (refer FIGS. 2-5).

  The first flat cable 11 has five flat conductors 11a arranged in parallel along the first direction X and arranged in parallel in the second direction Y with a predetermined interval. Furthermore, the parallel rectangular conductors 11a are sandwiched from above and below by a pair of insulating coatings 11b and integrally covered.

  At a predetermined location of the first flat cable 11, an exposed conductor portion 11c in which the insulating conductor 11b of a predetermined length in the first direction X of the flat conductor 11a is removed by laser light irradiation to expose the flat conductor 11a. Are formed at a predetermined interval with respect to the first direction X.

  Further, the exposed conductor portion 11c of the flat conductor 11a exposed by removing the insulating coating 11b by a predetermined length includes a plurality of first direction exposed conductor groups G1 arranged along the first direction X so as to be parallel to each other. Forming.

  In the second flat cable 12, the same number of rectangular conductors 12a as the above-described flat conductors 11a are arranged in parallel along the second direction Y, and are arranged in parallel at a predetermined interval in the first direction X. Furthermore, the rectangular conductors 12a arranged in parallel are integrally covered by being sandwiched from above and below by a pair of insulating coatings 12b.

  In the central portion of the second flat cable 12, the insulating coating 12 b corresponding to a predetermined length corresponding to the lateral width of the first flat cable 11 in the second direction Y is removed by laser light irradiation, and the first flat cable 11 An exposed conductor portion 12 c in which the flat conductor 12 a corresponding to the length corresponding to the lateral width is exposed is formed in the central portion of the second flat cable 12.

  Further, the exposed conductor portion 12c of the flat conductor 12a exposed by removing the insulating coating 12b by a predetermined length includes a plurality of second direction exposed conductor groups G2 arranged along the second direction Y so that they are parallel to each other. Forming.

  Furthermore, at both end portions of the second flat cable 12, the insulating coating 12b protruding outside the both ends in the width direction of the first flat cable 11 is removed by laser light irradiation, and both end portions of the flat conductor 12a are removed. A terminal portion 12d that allows the harnesses 3 and 4 to be connected is formed in the exposed portion.

  A first direction exposed conductor group G1 in which a plurality of exposed conductor portions 11c of the first flat cable 11 are arranged along the first direction X so as to be parallel to each other, and an exposed conductor portion 12c of the second flat cable 12 are mutually connected. A plurality of second-direction exposed conductor groups G2 arranged along the second direction Y so as to be parallel to each other intersect with each other in an orthogonal direction and overlap vertically to form a cross-overlapping portion GW.

  Between the first direction exposed conductor group G1 and the second direction exposed conductor group G2 in the cross overlapping portion GW, a cross portion insulating film 40 that electrically insulates the exposed conductor portions 11c and 12c is disposed.

  In the intersection part insulating film 40, the rectangular conductors 11a, 11a, 11c in the intersecting state are formed at positions corresponding to the conductive intersections that conduct the exposed conductor parts 11c, 12c among the intersecting parts where the exposed conductor parts 11c, 12c intersect. A plurality of window portions 40a penetrating in the thickness direction are opened so that 12a face each other (see FIGS. 2 to 4).

The exposed conductor portions 11c and 12c that face each other are connected through the window portion 40a so as to be conductive.
In addition, the window part 40a is arrange | positioned in the location corresponding to the desired conductive cross | intersection part according to a vehicle model, a grade, and a specification.

Then, the manufacturing method which manufactures the electric wire structure 10 mentioned above is demonstrated using FIGS.
First, the insulating coating 11b in the first flat cable 11 is removed by a predetermined length in the first direction X by irradiation with laser light to form an exposed conductor portion 11c in which the flat conductor 11a is exposed.

  Further, the insulation coating 12b at the center portion of the second flat cable 12 is removed by a predetermined length in the second direction Y by irradiation with laser light, and a flat angle corresponding to the width corresponding to the lateral width of the first flat cable 11 is obtained. An exposed conductor portion 12c exposing the conductor 12a is formed. Here, the predetermined length is a width that is slightly larger than the maximum arrangement width of the five flat conductors 11 a arranged in parallel in the other first flat cable 11.

  And the part which exposed both ends of the flat conductor 12a by removing the insulation coating 12b of the both ends which protrude outside the width direction both ends of the 1st flat cable 11 in the 2nd flat cable 12 by irradiation of a laser beam A terminal portion 12d is formed on the substrate (see FIG. 2).

  Subsequently, a first direction exposed conductor group G1 in which a plurality of exposed conductor portions 11c are arranged along the first direction X so as to be parallel to each other, and a second direction Y such that the exposed conductor portions 12c are parallel to each other. When the plurality of second-direction exposed conductor groups G2 arranged along the crossing are perpendicularly overlapped with each other in the orthogonal direction, the cross-section insulating film 40 is replaced with the first-direction exposed conductor group G1 and the second-direction exposed conductor group. It arrange | positions between the cross | intersection parts which G2 cross | intersects, and cross | intersection superposition | polymerization part GW is formed.

  After the exposed conductor portion 11c of the flat conductor 11a and the exposed conductor portion 12c of the flat conductor 12a are opposed to each other through a window portion 40a formed in the intersecting insulating film 40 (see FIG. 3), the resistance welding apparatus 17 The electrodes 17a and 17b are moved into the cross overlapping portion GW where the first direction exposed conductor group G1 and the second direction exposed conductor group G2 intersect, and the electrode 17a is a conductor intersecting the flat conductor 12a of the flat conductor 11a. While pressing against the intersection from below, the electrode 17b is pressed from above onto the conductor intersection that intersects the flat conductor 11a of the flat conductor 12a (see FIG. 4).

  Thereby, only the conductor intersection part of the flat conductor 11a and the flat conductor 12a of the location corresponding to this window part 40a is mutually contacted through the window part 40a of the cross | intersection insulating film 40. FIG. In the portions other than the window portion 40a, the rectangular conductor 11a and the rectangular conductor 12a are kept insulated by the interposition insulating film 40.

  Subsequently, a current supplied from the energization device 10 is energized between the electrode 17a and the electrode 17b, and the conductor intersection where the flat conductor 11a and the flat conductor 12a are in contact with each other is heated to a melting temperature so that the current can be supplied. Resistance welding is performed (see an enlarged view of part a in FIG. 4).

  Thereby, resistance welding of the conductor intersection part of the flat conductor 11a of the 1st direction exposed conductor group G1 and the flat conductor 12a of the 2nd direction exposed conductor group G2 can be carried out reliably and in a favorable state.

  After resistance welding as described above, the electrodes 17a and 17b of the resistance welding apparatus 17 are separated from the flat conductor 11a and the flat conductor 12a, and the electrodes 17a and 17b are moved out of the crossover portion GW. The welding work is completed.

  Next, a pair of external insulating films 50 are covered from above and below so that the entire intersection overlapping portion GW of the first direction exposed conductor group G1 and the second direction exposed conductor group G2 is covered (see FIG. 5), and then crossed. A pair of external insulating films 50 coated on the overlapping portion GW are heated and welded by a heating means (not shown) so as to be in close contact with the cross overlapping portion GW, and opposite edges of the external insulating film 50 are welded to each other. (See FIGS. 6, 7, and 8).

Thereby, since a pair of external insulation film 50 is closely_contact | adhered with respect to the cross polymerization part GW, it can prevent reliably that a water | moisture content penetrate | invades into the inside of the cross polymerization part GW, and can ensure required water stop. .
Furthermore, since the cross overlapping portion GW can be protected in an insulated state, there is no possibility that the exposed conductor portions 11c and 12c are inadvertently short-circuited, and a desired connection path is reliably configured. Can do.

  As described above, after forming a plurality of cross-overlapping portions GW whose front and back surfaces are covered with the external insulating film 50 at a predetermined interval with respect to the first direction X of the first flat cable 11 (see FIG. 9), The cross-over portions GW are folded back at the intermediate portion of the adjacent cross-over portions GW and folded back so that the insulating sides of the cross-over portions GW covered with the external insulating film 50 are overlapped with each other. The electric wire structure 10 formed by superimposing in the overlapping direction Z is configured (see FIGS. 10 and 11).

  When the above-described electric wire structure 10 is used as an electrical connection structure for connecting the backbone harness 3 and the branch harness 4, the backbone harness 3 is connected to the terminal portion 12d protruding to one side and branched to the terminal portion 12d protruding to the other side. If the harness 4 is connected (see FIGS. 1 and 12), the harnesses 3 and 4 can be connected by a desired connection route according to the vehicle type, grade, and specifications. Therefore, the harnesses 3 and 4 in the electrical connection structure can be shared, productivity can be improved, and further cost reduction can be achieved.

In addition, if the electric wire structure 10 is accommodated and held in the imaginary wire insulation case 70 shown in FIGS. 11 and 12, the insulation and water stoppage can be more reliably ensured.
In addition, the desired connection path is complicated by connecting the desired conductive intersections of the first direction exposed conductor group G1 and the second direction exposed conductor group G2 in a plurality of cross overlapping portions GW so as to be conductive. Even in this case, it can be easily configured.

  As described above, the cross-section insulating film 40 provided with the window 40a at the location corresponding to the desired conductive cross-section according to the vehicle type, grade, and specifications, the first direction exposed conductor group G1 in the cross-overlapping portion GW and the first Exposed conductor portion of the conductive intersection portion through the window portion 40a of the intersection insulating film 40 in a state where the intersection portion other than the conductive intersection portion is reliably insulated only by being disposed between the two-way exposed conductor group G2. 11c and 12c can be connected to each other so as to be conductive.

  As a result, for example, while confirming the specifications, etc., without searching for and connecting the conductive crossing part, it is possible to securely connect without crossing the wrong crossing part or connecting the crimping terminal at the crossing part. By connecting only the conductive intersections, a desired connection path can be formed.

Furthermore, since the number of parts such as crimp terminals does not increase depending on the number of conductive intersections, the production efficiency can be improved and the cost can be reduced sufficiently.
As a result, all except the intersection insulating film 40 provided with the window 40a at the location corresponding to the conductive intersection that is a desired intersection according to the vehicle type, grade, and specifications is common, so the cost is reduced by sharing. be able to.

  Furthermore, for example, the conductivity at the conductive intersection portion without causing a problem that the crimp terminal is detached due to vibration and falls off, and the conductivity cannot be maintained, as in the case of connecting in a conductive manner with a crimp terminal, Insulation at other intersections can be stably maintained.

  Furthermore, since a plurality of the flat conductors 11a of the first flat cable 11 and the flat conductors 12a of the second flat cable 12 are arranged in parallel at a predetermined interval, the insulation coating 11b at a desired location in the first direction X, By exposing the plurality of rectangular conductors 11a and 12a arranged in parallel by peeling 12b, the exposed conductor portions 11c and 12c arranged in the same direction can be easily formed at a predetermined interval.

  Therefore, the crossover portions GW can be easily configured by crossing and superposing the flat cables 11 and 12 with the insulating coatings 11b and 12b peeled off at predetermined locations.

  Furthermore, since the electric wire structure 10 is configured so as to overlap with the polymerization direction Z in which the cross-over portions GW are superposed, the electric wire structure that can easily form various connection paths can be miniaturized. Therefore, it is possible to arrange the electric wire structure 10 constituting a complicated connection path in a narrow place where the installation area is limited, and versatility is improved.

In Example 1 described above, the example in which the electric wire structure 10 is configured by overlapping the cross overlapping portions GW whose front and back surfaces are covered with the external insulating film 50 in a zigzag folded state has been described, but the crossing arranged in the first direction X Another example in which the electric wire structure 10 is configured by overlapping the insulating side and the non-insulating side of the overlapping portion GW will be described with reference to FIGS. 13 and 14.
FIG. 13 is a plan view of the electric wire structure 10 having one surface covered with the external insulating film 50, and FIG. 14 is a side view of the electric wire structure 10 shown in FIG.

  The insulating side of the cross-overlapping portion GW covered with the external insulating film 50 and the non-insulating side of the cross-overlapping portion GW not covered with the external insulating film 50 are folded back in a zigzag state so as to overlap each other. A three-dimensional electric wire structure 10 is formed by superposing the cross-over portions GW in the polymerization direction Z to be polymerized with each other.

  That is, the insulating side of the cross-overlapping portion GW covered with the external insulating film 50 and the non-insulating side of the cross-overlapping portion GW not covered with the second insulating film are overlapped and insulated from each other. Can be reduced compared to the case where both the front and back surfaces of the crossover portion GW are coated. Furthermore, since it is only necessary to coat the outer insulating film 50 on either one of the front and back surfaces of the crossover portion GW, it is possible to reduce the weight and thickness as the number of coatings is small.

(Example 2)
Next, with respect to the first embodiment using the first flat cable 11 and the second flat cable 12, the first covered electric wire 21 in which the round conductor 21a is covered with the insulating cover 21b and the round conductor 22a are covered with the insulation. The electric wire structure 20 of Example 2 using the 2nd covered electric wire 22 coat | covered with 22b is demonstrated using FIGS. 15-21.

  15 is a perspective view showing how the electric wire structure 20 of Example 2 is superposed, FIG. 16 is a perspective view in which the insulating film 40 is disposed between the exposed conductor groups G1 and G2, and FIG. FIG. 18 is a plan view of the electric wire structure 20 having one surface covered with an insulating holder 60, and FIG. 19 is a laser welding state in which the intersecting portions of the round conductors 21a and 22a are welded. FIG. 20 is a plan view of the electric wire structure 20 in which a plurality of cross overlapping portions GW are arranged in the first direction X, and FIG. 21 is a side view of the electric wire structure 20 folded in a zigzag state.

  The electric wire structure 20 according to the second embodiment includes five first covered electric wires 21 arranged in parallel along the first direction X, and arranged in parallel along the second direction Y across the first covered electric wires 21. The five second covered electric wires 22, the intersection insulating film 40 arranged so as to be sandwiched between the intersections of the first covered electric wires 21 and the second covered electric wires 22, and so as to cover one surface of the intersections And an insulating holder 60 coated on the surface (see FIGS. 15 to 18).

  The first covered electric wire 21 is configured by covering the entire length of the round conductor 21a with an insulating coating 21b. The first covered electric wires 21 are arranged in parallel along the first direction X, and five wires are arranged in parallel in the second direction Y with a predetermined interval.

  At a predetermined location of the first covered electric wire 21, an exposed conductor in which the round conductor 21 a is exposed by removing the insulating coating 21 b of a predetermined length in the first direction X by laser light irradiation. A plurality of portions 21c are formed at a predetermined interval with respect to the first direction X.

  Further, a plurality of exposed conductor portions 21c of the round conductor 21a exposed by removing the insulating coating 21b by a predetermined length are arranged in the first direction X so as to be parallel to each other. Is forming.

  The second covered electric wire 22 is configured by covering the entire length of the round conductor 22a with an insulating coating 22b. The same number of round conductors 22a as the round conductors 21a described above are arranged in parallel along the second direction Y, and five are arranged in parallel in the first direction X at a predetermined interval.

  At the central portion of the second covered electric wire 22, an insulating coating 22 b corresponding to a predetermined length corresponding to the arrangement width of the first covered electric wires 21 arranged in parallel in the second direction Y with a predetermined interval is provided. An exposed conductor portion 22 c that is removed by irradiation and exposes the round conductor 22 a corresponding to the arrangement width of the first covered wire 21 is formed in the center portion of the second covered wire 22.

  Further, a second direction exposed conductor group G2 in which a plurality of exposed conductor portions 22c of the round conductor 22a exposed by removing the insulating coating 22b by a predetermined length are arranged along the second direction Y so as to be parallel to each other. Is forming.

  Furthermore, at both ends of the second covered electric wire 22, portions of the insulating coating 22 b that protrude outward from both ends in the width direction of the first covered electric wire 21 are removed by laser light irradiation, and both ends of the round conductor 22 a are removed. A terminal portion 22d that allows the harnesses 3 and 4 to be connected is formed in a portion where the portion is exposed.

  A first direction exposed conductor group G1 in which a plurality of exposed conductor portions 21c of the first covered electric wire 21 are arranged along the first direction X so as to be parallel to each other, and an exposed conductor portion 22c of the second covered electric wire 22 are mutually connected. A plurality of second-direction exposed conductor groups G2 arranged along the second direction Y so as to be parallel to each other intersect with each other in an orthogonal direction and overlap vertically to form a cross-overlapping portion GW.

  Between the first direction exposed conductor group G1 and the second direction exposed conductor group G2 in the cross overlap portion GW, a cross portion insulating film 40 that electrically insulates the exposed conductor portions 21c and 22c is disposed. The exposed conductor portions 21c and 22c of the round conductors 22a and 22b that face each other through the window portion 40a provided in the intersecting insulating film 40 are connected to each other so as to be conductive, thereby constituting the electric wire structure 20.

  The insulating holder 60 is formed of a synthetic resin having an insulating property and has a size capable of accommodating and holding the intersecting overlapping portion GW where the first direction exposed conductor group G1 and the second direction exposed conductor group G2 intersect. In addition, groove portions 60a and 60b for fitting and holding the first covered electric wire 21 and the second covered electric wire 22 are formed in the accommodating portion 61 that accommodates and holds the cross overlapping portion GW.

  The groove portions 60 a are formed at both end portions in the first direction X of the insulating holder 60, and are disposed at five locations in the second direction Y with a predetermined interval corresponding to the number of the first covered electric wires 21. Moreover, the groove part 60a is formed in the magnitude | size which fits and holds the exposed side edge part of the insulation coating 21b corresponding to the exposed conductor part 21c of the round conductor 21a in the covered electric wire 21. FIG.

  The groove portions 60b are formed at both end portions in the second direction Y of the insulating holder 60, and are arranged at five locations in the first direction X with a predetermined interval corresponding to the number of the second covered electric wires 22. Further, the groove 60b is formed to have a size that fits and holds the exposed end portion of the insulating coating 22b corresponding to the exposed conductor portion 22c of the round conductor 22a in the second covered electric wire 22.

Then, the manufacturing method which manufactures the electric wire structure 20 mentioned above is demonstrated using FIGS. 15-21.
First, an exposed conductor portion 21c in which the insulating coating 21b in the first covered electric wire 21 is removed by a predetermined length in the first direction X (longitudinal direction) by laser light irradiation to expose the first round conductor 21a. Form.

  Further, the insulating coating 22b at the center portion of the second covered electric wire 22 is removed by a predetermined length in the second direction Y (width direction) by laser light irradiation, and the five first covered electric wires 21 are arranged in parallel. An exposed conductor portion 22c in which the second round conductor 22a is exposed is formed by removing the length corresponding to the arrangement width. Here, the predetermined length is a width that is slightly larger than the maximum arrangement width of the five first round conductors 21 a arranged in parallel in the other first covered electric wire 21.

  And the insulation coating 22b of the both ends which protrude outside rather than the width direction both ends which arranged the five 1st covered electric wires 21 in the 2nd covered electric wire 22 in parallel is removed, and the both ends of the 2nd round conductor 22a are removed. Terminal portions 22d are formed in the exposed portions.

  Subsequently, a first direction exposed conductor group G1 in which a plurality of exposed conductor portions 21c are arranged along the first direction X so as to be parallel to each other, and a second direction Y such that the exposed conductor portions 22c are parallel to each other. When the plurality of second-direction exposed conductor groups G2 arranged along the crossing are perpendicularly overlapped with each other in the orthogonal direction, the cross-section insulating film 40 is replaced with the first-direction exposed conductor group G1 and the second-direction exposed conductor group. It arrange | positions between the cross | intersection parts which G2 cross | intersects, and cross | intersection superposition | polymerization part GW is formed (refer FIG. 15, FIG. 16).

  After the exposed conductor portion 21c of the first round conductor 21a and the exposed conductor portion 22c of the second round conductor 22a are opposed to each other through the window portion 40a formed in the intersecting insulating film 40 (FIG. 17, 18), the laser irradiator 27 is moved to a position facing the conductor intersection of the first round conductor 21a and the second round conductor 22a, and the laser emitted from the laser irradiator 27 is moved to the intersection. Irradiation is performed toward the conductor intersection between the first round conductor 21a and the second round conductor 22a through the window 40a of the insulating film 40, and spot welding is performed so that energization is possible (refer to the enlarged view of part c in FIG. 19). .

Thereby, spot welding of the conductor crossing part of the 1st round conductor 21a of the 1st direction exposed conductor group G1 and the 2nd round conductor 22a of the 2nd direction exposed conductor group G2 to a reliable and favorable state can be carried out. it can.
After spot welding as described above, the welding operation is completed if the laser irradiator 27 is retracted from the conductor intersection and moved to the upper side or the side of the intersection overlap portion GW.

Next, the insulating holder 60 is covered from below so that the back surface side of the crossover portion GW is covered, and the crossover portion GW is housed and held in the housing portion 61 of the insulating holder 60. Thereafter, the cross-over portion GW can be fixed to the insulating holder 60 by filling the accommodating portion 61 with an insulating synthetic resin as a filler.
As a result, the conductive state between the first round conductor 21a and the second round conductor 22a can be obtained stably over a long period of time, and water-stopping can be ensured.

  As described above, after forming a plurality of cross-overlapping portions GW whose back side is covered with the insulating holder 60 at a predetermined interval with respect to the first direction X, when folded back at an intermediate portion between adjacent cross-overlapping portions GW. In addition, the insulating side of the crossover portion GW covered with the insulating holder 60 and the non-insulating side of the crossover portion GW not covered with the insulating holder 60 are folded back in a zigzag state so as to overlap each other, The electric wire structure 20 formed by superposing the cross-over portions GW in the polymerization direction Z to be superposed on each other is configured (see FIGS. 20 and 21).

  By using the above-described electric wire structure 20 as an electrical connection structure for connecting the backbone harness 3 and the branch harness 4 (see FIGS. 1 and 12), the harness 3 can be connected with a desired connection route according to the vehicle type, grade, and specifications. , 4 can be connected. As a result, operations and effects substantially equivalent to those of the first embodiment can be achieved.

  Furthermore, the first round conductor 21a is constituted by a first covered electric wire 21 in which the first round conductor 21a is covered with an insulating coating 21b, and the second round conductor 22a is provided for each second round conductor 22a. Compared to the flat cables 11 and 12 of the first embodiment, the electric wire structure 20 can be configured at a lower cost than the flat cables 11 and 12 of the first embodiment because the second covered electric wire 22 is covered with the insulating coating 22b. Can be achieved.

  The electric wire structure 20 may be accommodated and held in an imaginary wire insulating case 70 shown in FIG. 21 or the external insulating film 50 may be covered so that the entire accommodating portion 61 of the insulating holder 60 is covered. Insulating properties and water-stopping properties can be ensured more reliably.

In the correspondence between the configuration of the present invention and the embodiment,
The conductor of the present invention corresponds to the flat conductors 11a and 12a and the round conductors 21a and 22a,
Similarly,
The insulating means corresponds to the intersection insulating film 40,
The insulating covering means corresponds to the external insulating film 50 and the insulating holder 60,
The present invention is not limited to the configuration of the above-described embodiment, but can be applied based on the technical idea shown in the claims, and many embodiments can be obtained.

In Example 1, the strip-shaped insulating coating 12b is formed in the first direction X on both end portions of the flat conductors 12a arranged in parallel without removing the insulating coating 12b covering the both end portions of the second flat cable 12. May be integrated.
Further, instead of the external insulating film 50, the insulating holder 60 of Example 2 may be covered on both the front and back surfaces or one surface of the cross-overlapping portion GW in the electric wire structure 10.

  In the second embodiment, the first covered electric wire 21 and the second covered electric wire 22 are configured by the round conductors 21a and 22a and the insulating coatings 21b and 22b. However, the present invention is not limited thereto. The core wire may be covered with a shield member such as an aluminum member, and then covered with an insulating coating. Or you may comprise with the twisted pair cable which twisted together several covered electric wires. Or you may comprise the conductor of the 1st covered electric wire 21 and the 2nd covered electric wire 22 with the twisted wire which twisted the electroconductive single wire or the some strand, for example.

  Further, instead of using the second covered electric wire 22 in which the peripheral surface of the round conductor 22a is covered with the insulating coating 22b, five bare electric wires not covered with the insulating coating 22b are arranged in parallel, and the second direction exposed conductor You may comprise the group G2.

  Furthermore, the cross overlapping portion GW of the electric wire structure 20 is accommodated and held in the insulating holder 60. However, the present invention is not limited to this. For example, a cover that covers the insulating holder 60 is provided, and the cross polymerization is performed in cooperation with the insulating holder 60. The part GW may be covered and held.

  Furthermore, the exposed conductor portion 22c and the terminal portion 22d are covered with a pair of insulating coatings 21b on a part of the round conductor 22a that protrudes outward from both ends in the width direction of the first covered wire 21 in the second covered wire 22. You may comprise.

  In addition, the cross overlap portion GW between the first flat cable 11 and the second flat cable 12 is covered with an insulating holder 60, or the cross overlap portion GW between the first covered electric wire 21 and the second covered electric wire 22 is paired with external insulation. The film 50 may be covered. Moreover, you may block | close the open side of this insulation holder 60 with the cover member which has insulation for every insulation holder 60 which covers the cross | overlapping superposition | polymerization part GW.

  Furthermore, the intersection of the flat conductor 11a of the first flat cable 11 and the flat conductor 12a of the second flat cable 12 is laser-welded so that the round conductor 22a of the first covered electric wire 21 and the round shape of the second covered electric wire 22 are formed. The intersection with the conductor 22b may be resistance welded or ultrasonic vibration welded.

X ... 1st direction Y ... 2nd direction Z ... Overlapping direction G1 ... 1st direction exposed conductor group G2 ... 2nd direction exposed conductor group GW ... Cross overlap part 3 ... Core harness 4 ... Branch harness 10 ... Electric wire structure 11 ... 1st flat cable 12 ... 2nd flat cable 11a, 12a ... Flat conductor 11b, 12b ... Insulation coating 11c, 12c ... Exposed conductor part 12d ... Terminal part 20 ... Electric wire structure 21 ... First covered electric wire 22 ... Second covered electric wire 21a, 22a ... Round conductors 21b, 22b ... Insulation coating 21c, 22c ... Exposed conductor portion 22d ... Terminal part 40 ... Intersection insulation film 40a ... Window part 50 ... External insulation film 60 ... Insulation holder

Claims (4)

A first direction exposed conductors portions exposed by removing the insulating coating of predetermined length fraction in the longitudinal direction of the conductor coated with an insulating coating, which is more disposed along the first direction so that their is parallel Exposed conductor group;
The exposed conductor portion, and a second direction exposed conductors group of a plurality of arranged in the second direction so that their are parallel,
Crossing overlapping portion is formed by polymerizing together crossing,
Wherein during said first direction exposed conductors at the intersection overlapping portion and said second direction exposed conductor group, together with the insulating means for electrically insulating said exposed conductor portions to each other are arranged,
Insulation coating means for covering the side opposite to the overlapping side in the crossover portion so as to be insulated is provided,
The conductor is
It is arranged with a predetermined interval in the width direction, and is composed of a flat rectangular conductor in a flat cable configured by being sandwiched between insulating films having insulating properties,
In the insulation means,
Of the intersecting portions where the exposed conductor portions cross each other, a window portion penetrating so that the exposed conductors in the intersecting state face each other is provided at a position corresponding to a conductive intersection portion that conducts the exposed conductor portions,
The exposed conductor portions to each other directly facing is constructed by connecting the conductively through the window portion,
A plurality of the first direction exposed conductor groups are provided at intervals in the longitudinal direction,
The second direction exposed conductor group is polymerized with respect to each of the first direction exposed conductor groups provided in the longitudinal direction, and a plurality of cross overlapping portions are formed in the longitudinal direction.
The insulating coating means comprises:
In the cross polymerization portion adjacent among the plurality of cross polymerization portions, provided on different opposite sides,
The electric wire structure folded so that the plurality of cross-over portions are stacked in the superposition direction of polymerization . A first direction exposed conductors portions exposed by removing the insulating coating of predetermined length fraction in the longitudinal direction of the conductor coated with an insulating coating, which is more disposed along the first direction so that their is parallel Exposed conductor group;
The exposed conductor portion, and a second direction exposed conductors group of a plurality of arranged in the second direction so that their are parallel,
Crossing overlapping portion is formed by polymerizing together crossing,
Wherein during said first direction exposed conductors at the intersection overlapping portion and said second direction exposed conductor group, together with the insulating means for electrically insulating said exposed conductor portions to each other are arranged,
Insulation coating means for covering the side opposite to the overlapping side in the crossover portion so as to be insulated is provided,
The conductor is
Each conductor is composed of a conductor in a covered electric wire covered with an insulating coating,
In the insulation means,
Of the intersecting portions where the exposed conductor portions intersect, a window portion penetrating so that the exposed conductors in the intersecting state face each other is provided at a location corresponding to a conductive intersection portion that conducts the exposed conductor portions,
The exposed conductor portions to each other directly facing is constructed by connecting the conductively through the window portion,
The insulating coating means includes
The insulating synthetic resin is composed of an insulating holder having a size capable of accommodating and holding the crossover portion.
A wire structure for fitting and holding a covered electric wire in which the conductor is covered with an insulating coating is formed in the accommodating portion that accommodates and holds the cross overlapping portion in the insulating holder . The electrical connection structure which connected the harness to the said conductor which comprises the said 2nd direction exposed conductor group in the electric wire structure of Claim 1 or 2 . Removing the insulation coating for a predetermined length in the longitudinal direction of the conductor coated with the insulation coating to form an exposed conductor portion exposing the conductor;
A first direction exposed conductor group in which a plurality of the exposed conductor portions are arranged along the first direction so as to be parallel to each other;
A second direction exposed conductor group in which a plurality of the exposed conductor portions are arranged along the second direction so as to be parallel to each other;
It is arranged so as to cross and polymerize to form a cross-over part,
Among the intersection portions where the exposed conductor portions intersect between the first direction exposed conductor group and the second direction exposed conductor group in the intersecting overlapping portion, a conductive intersection portion that conducts the exposed conductor portions to each other Insulating means for electrically insulating the exposed conductor portions provided with windows at corresponding locations is disposed,
The exposed conductor parts facing each other through the window part of the insulating means are connected so as to be conductive,
A plurality of the first direction exposed conductor groups are provided at intervals in the longitudinal direction,
The second direction exposed conductor group is superposed on each of the first direction exposed conductor groups provided in the longitudinal direction to form a plurality of cross-overlapping portions in the longitudinal direction,
Insulation coating means for covering the side opposite to the overlapping side in the crossover portion so as to be insulated is provided,
In the cross-overlapping part adjacent among the plurality of cross-overlapping parts, the insulating coating means is provided on a different opposite side,
The method for manufacturing an electric wire structure in which the plurality of cross-over portions are folded so as to be stacked in the polymerization direction to be polymerized .

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