JP5900223B2 - Manufacturing method of wire harness - Google Patents

Description

  The present invention relates to a wire harness in which a terminal connected to an end of an electric wire is accommodated in a housing made of resin, and a method for manufacturing the same.

  Conventionally, in a wire harness, as one method for ensuring airtightness between a housing for housing a terminal and a cable (electric wire), the resin of the housing is melted by ultrasonic vibration, and the molten resin is melted. There is an ultrasonic method in which the periphery of a cable is covered with resin without a gap and a molten resin layer is formed (see, for example, Patent Document 1).

  The wire harness described in Patent Document 1 is manufactured using the above ultrasonic method. Specifically, after the end of the cable is inserted into the cable insertion hole of the housing, a welding member made of resin is fitted into the recess formed on the insertion side of the cable insertion hole, and the fitted welding member is By ultrasonically oscillating, the welding member is welded to the housing, and the gap between the welding member and the cable is sealed with a molten resin melted by the welding member, so that the space between the housing of the wire harness and the cable is hermetically sealed. Stop.

JP 2011-100582 A

  By the way, in the manufacturing method of the wire harness using the ultrasonic method disclosed in Patent Document 1, the cable insertion hole of the housing is formed smaller than the size of the terminal connected to the tip of the cable. If a terminal is connected to the tip of the cable, the cable cannot be inserted into the cable insertion hole from the side where the terminal is connected. However, in the wire harness manufacturing line, there is a need to connect a terminal to the tip of the cable before inserting the end of the cable into the cable insertion hole from the viewpoint of work efficiency.

  In other words, if the end of the cable is inserted into the cable insertion hole of the housing that accommodates the terminal before connecting the terminal to the tip of the cable, the housing becomes an obstacle in the subsequent process such as crimping the terminal. Therefore, there is a problem that workability is deteriorated.

  Therefore, the present inventors have considered that a cable insertion hole is formed in such a size that a terminal can be inserted, and a terminal connected in advance to the tip of the cable is inserted into the cable insertion hole. However, when the cable insertion hole is enlarged, the gap between the inner surface of the cable insertion hole and the cable increases, so that the molten resin easily flows from the cable insertion hole into the housing. For this reason, in order to ensure airtightness, more molten resin is needed. In order to generate a lot of molten resin, for example, it is necessary to lengthen the time of ultrasonic vibration, but if the time of ultrasonic vibration becomes long, an unintended part of the housing generates heat due to ultrasonic vibration and melts. Another problem occurs. That is, there has been a demand for a manufacturing method capable of suppressing an increase in time for ultrasonic vibration while increasing the cable insertion hole.

  Therefore, the present invention provides a wire harness capable of suppressing an increase in the time of ultrasonic vibration while forming a terminal insertion hole through which a terminal can be inserted, and a method for manufacturing the same. With the goal.

The present invention has an electric wire, a terminal connected to an end portion of the electric wire, and a housing made of a resin that accommodates the terminal, and the housing accommodates the terminal. Ultrasonic excitation of a first member, a second member including a lead-out portion from which the electric wire is led out on the side opposite to the terminal, and a third member interposed between the first member and the second member A method of manufacturing a wire harness that is integrated by ultrasonic welding that is welded by the first member, wherein a terminal insertion hole through which the terminal is inserted is formed in the first member, and the electric wire is inserted through the second member. A first electric wire insertion hole is formed, and the first member and the third member are solidified so that at least the third member is melted by the ultrasonic vibration so as to cover an outer peripheral side of the terminal insertion hole. The weld formed Welded, between the second member in the said wire first wire insertion hole, the wire harness is solidified by flowing at least a molten resin in which the second member is melted by shaking the ultrasonic pressure A manufacturing method is provided.

  The third member is formed with a cover surface that covers at least a part of the terminal insertion hole, and an accommodation hole that accommodates at least a part of the outer periphery of the first wire insertion hole of the second member. It is good to be.

  In addition, the third member is formed by combining a plurality of resin members having arc grooves that form the accommodation hole, and the second member sandwiches the electric wire and at least a part thereof is accommodated in the accommodation hole. A plurality of resin members may be combined.

  The third member is formed with a second wire insertion hole that allows the wire to pass therethrough and communicates with the first wire insertion hole, and between the wire and the third member in the second wire insertion hole. Preferably, at least the second member is solidified by flowing a molten resin melted by the ultrasonic vibration.

Moreover, this invention has the housing which consists of resin which accommodates the electric wire, the terminal connected to the edge part of the said electric wire, and the said terminal for the purpose of solving the said subject, The said housing is the said terminal. Ultrasound a first member to be accommodated, a second member including a lead-out portion from which the electric wire is led out on the side opposite to the terminal, and a third member interposed between the first member and the second member A wire harness manufacturing method integrated by ultrasonic welding that is welded by vibration, the wire insertion step of inserting the wire into a wire insertion hole for inserting the wire formed in the second member, and After the wire insertion step, a terminal insertion step of inserting the terminal into a terminal insertion hole for inserting the terminal formed in the first member, the first member, the second member, and the third member. Axis of the wire An arrangement step of arranging along the direction, and a welding step of welding the first member and the third member by ultrasonic vibration and welding the third member and the second member, In the welding step, the first member and the third member are formed by a welding portion formed by solidifying at least the third member melted by the ultrasonic vibration so as to cover the outer peripheral side of the terminal insertion hole. A wire harness that is a step of causing a molten resin obtained by melting at least the second member by ultrasonic vibration to flow between the electric wire and the second member in the electric wire insertion hole to be solidified. A manufacturing method is provided.

  In addition, the third member is formed by combining a plurality of resin members having arc grooves that form the accommodation hole, and the second member sandwiches the electric wire and at least a part thereof is accommodated in the accommodation hole. A plurality of resin members are combined, and the arranging step includes the plurality of resin members constituting the second member facing each other across the electric wire, and the plurality of resin members constituting the third member are It is good to include the process of facing each other across the electric wire.

  The first member has an end surface in which an opening of the terminal insertion hole is formed, and the third member is formed to protrude from the lid surface at a peripheral edge of the lid surface, and the tip of the third member is formed in the arranging step. The portion may have a protrusion that contacts the end surface, and the welding step may be a step of melting the protrusion and welding the first member and the third member.

  According to the present invention, it is possible to suppress an increase in time required for welding while forming a terminal insertion hole through which a terminal can be inserted into the housing.

The wire harness manufactured by the manufacturing method which concerns on embodiment of this invention is shown, (a) is a side view which shows the state before the fitting of a female connector and a male connector, (b) is a female connector and a male connector. It is a perspective view which shows the state fitted. A female connector is shown, (a) is a front view, (b) is sectional drawing in the cross section containing the axial line of a some electric wire. A main body member is shown, (a) is an external appearance perspective view, (b) is a cross-sectional perspective view in the AA cross section of (a), (c) is a B arrow view of (a). The 2nd welding member is shown, (a) is a perspective view, (b) is a perspective view seen from a different direction from (a), (c) is a CC line sectional view of (a). The 1st welding member is shown, (a) is a perspective view, (b) is the DD sectional view taken on the line of (a). (A) And (b) is a schematic diagram which shows the manufacturing process of a wire harness. (C) is a schematic diagram which shows the support stand used for the manufacturing process of a wire harness. It is sectional drawing which shows the state which arranged the 2nd welding member and the 1st fusion member along with the main body member along the axial direction of an electric wire. It is the elements on larger scale of FIG. 7 which shows the flow of a fusion | melting member. (A) is a top view which shows the 2nd welding member which concerns on the modification of embodiment. (B) is a top view which shows the 1st welding member which concerns on the modification of embodiment.

[Embodiment]
FIG. 1 shows a wire harness 100 manufactured by a manufacturing method according to an embodiment of the present invention, and a male connector 9 fitted to the female connector 1 of the wire harness 100. FIG. The side view which shows the state before fitting of the male connector 9, (b) is a perspective view which shows the state by which the female connector 1 and the male connector 9 were fitted. 2A and 2B show the female connector 1, in which FIG. 2A is a front view, and FIG. 2B is a cross-sectional view in a cross section including the axes of a plurality of electric wires 11. In addition, in FIG. 2A, illustration of a terminal support member 40 described later is omitted, and the back side thereof is shown.

  This wire harness 100 is used, for example, to supply a three-phase alternating current as a drive current to an electric motor as a drive source that generates a driving force for running the vehicle. In this case, the wire harness 100 electrically connects the electric motor and the inverter. In FIG. 1, one end of the wire harness 100 is shown.

  The wire harness 100 includes a plurality (three in the present embodiment) of electric wires 11, a plurality of terminals 12 (shown in FIG. 2) connected to respective end portions of the plurality of electric wires 11, and a plurality of terminals 12. And a female connector 1 having a female housing 10 made of a resin to be accommodated. The female housing 10 is formed by integrating a main body member 2 made of resin and a welding member 3 made of resin.

  The male connector 9 has a male housing 90 fitted into the female housing 10, and one end of a plurality (three in this embodiment) of electric wires 91 is accommodated in the male housing 90. The male housing 90 includes, for example, a flange portion 901 for fixing the male housing 90 to a case (not shown) of a device such as an inverter or a motor, and a cylindrical portion 902 protruding in a direction orthogonal to the flange portion 901. A cylindrical portion 903 formed with a through-hole that communicates the inside and outside of the cylindrical portion 902, an engaging projection 904 that protrudes outward from the cylindrical portion 902, and the other side of the flange portion 901 (the opposite side of the cylindrical portion 902) The electric wire 91 has a lead-out portion 905 that is led out to the opposite side of the terminal 12.

  A plurality of terminals (not shown) connected to the respective ends of the plurality of electric wires 91 are accommodated in the cylindrical portion 902. This terminal is electrically connected to the terminal 12 of the female connector 1 when the female connector 1 and the male connector 9 are fitted. The terminals of the female connector 1 and the terminals 12 of the female connector 1 are pressed through an insulating member (not shown) by a pressing member 906 (shown in FIG. 1B) screwed into the inner surface of the cylindrical portion 903.

  As shown in FIG. 2, the main body member 2 includes a cylindrical portion 21 having openings 210 that allow the plurality of terminals 12 to face the outside of the female housing 10, and the cylindrical portion 21. A small tube portion 22 having a width in the arrangement direction (vertical direction in FIG. 2) smaller than the tubular portion 21, and an electric wire holding portion 23 that holds one end of the plurality of electric wires 11 inside the small tube portion 22. Are integrated.

  Between the small cylinder part 22 and the electric wire holding | maintenance part 23, the cyclic | annular space which accommodates the cylinder part 902 (it shows to Fig.1 (a)) of the male side housing 90 is formed. The small tube portion 22 and the electric wire holding portion 23 are connected by a rib 24 described later. In addition, an annular seal member 41 that seals between the outer surface of the wire holding portion 23 and the inner surface of the cylindrical portion 902 of the male housing 90 is disposed.

  The cylindrical portion 21 is formed with a round hole 211 that allows the pressing member 906 to be rotated from the outside of the female housing 10. Further, the tubular portion 21 is formed with an engaging portion 212 that engages with the engaging protrusion 904 of the male housing 90 to prevent inadvertent detachment of the male housing 90 from the female housing 10. .

  The electric wire 11 includes a center conductor 110 and a sheath 111 made of an insulator that covers the center conductor 110. The terminal 12 integrally includes a caulking portion 120 and a plate-like connection portion 121 that is in surface contact with the terminal of the male connector 9. At the distal end portion of the electric wire 11, the sheath 111 is removed to expose the central conductor 110, and the crimped portion 120 is crimped to the exposed central conductor 110.

  A terminal support member 40 that supports the terminals 12 by inserting the connection portions 121 of the plurality of (three) terminals 12 is fixed to one end of the wire holding portion 23 in the axial direction of the plurality of wires 11. The terminal support member 40 is fixed to the electric wire holding part 23 by an unillustrated locking mechanism.

  The welding member 3 includes a first welding member 5 from which a plurality of electric wires 11 are led out, and a second welding member 6 interposed between the main body member 2 and the first welding member 5. An annular flange 233 formed so as to surround the second welding member 6 is formed at the other end of the wire holding portion 23 (the end opposite to the side on which the terminal support member 40 is fixed). Yes. A plurality of first wire insertion holes 510 (the same number as the wires 11) through which the plurality of wires 11 are inserted are formed in the first welding member 5.

  In FIG. 2, a boundary line where the first welding member 5 and the second welding member 6 are fused and a boundary line where the second welding member 6 and the main body member 2 are fused are indicated by broken lines. The main body member 2, the first welding member 5, and the second welding member 6 are integrated by ultrasonic welding in which these members are welded by ultrasonic vibration.

  More specifically, the main body member 2 and the second welding member 6 are formed by solidifying a molten resin obtained by melting the second welding member 6 by ultrasonic vibration so as to cover the outer peripheral side of the terminal insertion hole 232. The first welded portion 31 and this molten resin are welded by the second welded portion 32 formed by solidifying between the flange portion 233 and the second welded member 6. The first welded portion 31 is formed to collectively surround the three terminal insertion holes 232. In addition, the molten resin which the 1st welding member 5 fuse | melted may flow into the 1st welding part 31 and the 2nd welding part 32, and may be solidified.

  Further, the first welding member 5 and the second welding member 6 are formed by a third welding portion 33 and a fourth welding portion 34 formed by solidifying a molten resin obtained by melting the first welding member 5 by ultrasonic vibration. It is welded. In addition, the molten resin which the 2nd welding member 6 fuse | melted may flow into the 3rd welding part 33, and may be solidified.

  Further, between the plurality of electric wires 11 and the first welding member 5 in the first electric wire insertion hole 510, a molten resin in which the first welding member 5 is melted by ultrasonic vibration flows and is solidified. In addition, the molten resin which the 2nd welding member 6 fuse | melted may flow between the electric wire 11 and the 1st welding member 5, and may be solidified.

  The main body member 2 is an example of the “first member” of the present invention that houses the terminal 12. The 1st welding member 5 is an example of the "2nd member" of this invention containing the base 50 (after-mentioned) as a derivation | leading-out part from which the electric wire 11 is derived | led-out. The second welding member 6 is an example of the “third member” in the present invention.

  In the present embodiment, the main body member 2, the first welding member 5, and the second welding member 6 are made of the same resin material. As this resin material, for example, PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), PA (polyamide) or the like can be used.

  3A and 3B show the main body member 2 according to the present embodiment, wherein FIG. 3A is an external perspective view, FIG. 3B is a cross-sectional perspective view taken along the line AA in FIG. 3A, and FIG. FIG. In addition, in FIG. 3, the state before the 1st welding member 5 and the 2nd welding member 6 is welded is shown.

  As shown in FIG. 3 (c), the electric wire holding part 23 and the small cylinder part 22 of the main body member 2 are radially formed between the outer surface of the electric wire holding part 23 and the inner surface of the small cylinder part 22. In the embodiment, four ribs 24 are connected. The electric wire holding part 23 is formed with three rectangular parallelepiped accommodation spaces 231 for accommodating one end of the electric wire 11 and the crimping part 120 of the terminal 12, respectively. One end of the accommodation space 231 communicates with the outside through the terminal insertion hole 232. The terminal insertion hole 232 has an opening on the end surface 23 a of the wire holding portion 23.

  In the present embodiment, the terminal insertion hole 232 is formed in a rectangular shape having a long side in the width direction of the connection portion 121 of the terminal 12, and the terminal 12 can be inserted through the terminal insertion hole 232. More specifically, the long side of the terminal insertion hole 232 is larger than the width dimension of the connection portion 121 of the terminal 12 (the horizontal dimension in FIG. 2A), and the short side of the terminal insertion hole 232 is the terminal 12 It is formed larger than the height dimension of the crimped portion 120 (the vertical dimension in FIG. 2A). Accordingly, the terminal 12 can pass through the terminal insertion hole 232.

  Further, the flange portion 233 of the electric wire holding portion 23 is formed so as to protrude in a direction orthogonal to the end surface 23a. The second welding member 6 is accommodated in the space formed by the inner surface 233a and the end surface 23a of the flange portion 233.

  FIG. 4 shows the second welding member 6, (a) is a perspective view, (b) is a perspective view seen from a different direction from (a), and (c) is a sectional view taken along the line CC of (a). is there.

  The second welding member 6 integrally includes a track-shaped plate portion 60 and an annular protrusion 61 formed along the peripheral edge of one flat surface 60 a of the plate portion 60. The protrusion 61 is formed on the periphery of the flat surface 60a so as to protrude from the flat surface 60a. The protrusion 61 is an example of the “protrusion” in the present invention.

  The plate portion 60 is formed with an accommodation hole 601 and a second electric wire insertion hole 602 that communicate with each other along the thickness direction. The accommodation hole 601 opens to the other flat surface 60b side on the back side of the flat surface 60a, and the second electric wire insertion hole 602 opens to the flat surface 60a side. In the present embodiment, three accommodation holes 601 and three second electric wire insertion holes 602 are formed. The accommodating hole 601 accommodates a cylindrical portion 51 of the first welding member 5 described later. The second electric wire insertion hole 602 communicates with the first electric wire insertion hole 510 of the first welding member 5 and allows the electric wire 11 to pass therethrough.

  The inner surface of the accommodation hole 601 includes a large-diameter cylindrical surface 601a that opens to the flat surface 60b, and a tapered surface 601b that is formed continuously with the cylindrical surface 601a and has an inner diameter that decreases toward the second wire insertion hole 602 side. It is out. The inner surface 602a of the second electric wire insertion hole 602 is formed as a cylindrical surface having an inner diameter smaller than the inner diameter of the end portion of the tapered surface 601b on the second electric wire insertion hole 602 side. A step surface 601c parallel to the flat surface 60a is formed between the tapered surface 601b and the inner surface 602a.

  In the flat surface 60 a, the peripheral portion of the opening of the accommodation hole 601 is recessed in the thickness direction of the plate portion 60. The flat surface 60 a is an example of the “lid surface” in the present invention that closes a part of the terminal insertion hole 232.

  5A and 5B show the first welding member 5, where FIG. 5A is a perspective view and FIG. 5B is a cross-sectional view taken along the line DD in FIG.

  The first welding member 5 integrally includes a base portion 50 and three cylindrical portions 51. The first welding member 5 has three first electric wire insertion holes that penetrate the three cylindrical portions 51 along the central axis thereof, penetrate the base portion 50 in the thickness direction, and are respectively inserted with the three electric wires 11. 510 is provided. The inner surface 510a of the first electric wire insertion hole 510 is formed as a cylindrical surface having a uniform inner diameter.

  The base portion 50 includes a plate portion 500 having a track shape on the periphery, an annular outer peripheral protrusion portion 501 formed along the peripheral edge of one flat surface 500 a of the plate portion 500, and an outer peripheral protrusion portion 501 adjacent to the outer peripheral protrusion portion 501. And an annular inner peripheral projection 502 formed on the inner side.

  The outer peripheral protrusion 501 and the inner peripheral protrusion 502 protrude along the central axis of the first electric wire insertion hole 510, that is, along the axial direction of the electric wire 11, and the tip portion thereof is in a cross section orthogonal to the axial direction of the electric wire 11. The cross-sectional area is formed to be small. In addition, the inner circumferential protrusion 502 is formed to be higher than the outer circumferential protrusion 501 from the plane 500a.

  The three cylinder portions 51 are formed so as to extend from the plane 500a of the plate portion 500 in a direction orthogonal to the plane 500a. The cylindrical portion 51 is integrally formed with a cylindrical portion 511 on the base side (base 50 side) and a tapered portion 512 that is formed at one end of the cylindrical portion 511 and whose outer diameter decreases toward the distal end side of the cylindrical portion 51. It is comprised.

  The cylinder part 51 is accommodated in the accommodation hole 601 of the second welding member 6. That is, at least a part of the outer peripheral side of the first wire insertion hole 510 in the first welding member 5 is accommodated in the accommodation hole 601.

(Method for manufacturing wire harness 100)
Next, a method for manufacturing the wire harness 100 will be described with reference to FIGS.

  FIGS. 6A and 6B are schematic views showing the manufacturing process of the wire harness 100. FIG. FIG. 6C is a schematic diagram showing a state in which the support base 80 is viewed from the front (front) surface 80a side in the manufacturing process of the wire harness 100. FIG. FIG. 7 is a cross-sectional view showing a state in which the second welding member 6 and the first fusion member 5 are arranged side by side with the main body member 2 along the axial direction of the electric wire 11. FIG. 8 is a partially enlarged view of FIG. 7 showing the flow of the molten resin in the welding process.

  The manufacturing process of the wire harness 100 includes an electric wire insertion step of inserting the electric wire 11 into the first electric wire insertion hole 510 of the first fusion member 5 and the second electric wire insertion hole 602 of the second fusion member 6, and one end of the electric wire 11. A terminal connection step of connecting the terminal 12 to the terminal, a terminal insertion step of inserting the terminal 12 connected to one end of the electric wire 11 through the terminal insertion hole 232 of the main body member 2, the main body member 2, the second welding member 6, and the second The first welding member 5 is disposed along the axial direction of the electric wire 11, and the main body member 2 and the second welding member 6 are welded by ultrasonic vibration, and the second welding member 6 and the first welding member 5 And a welding step for welding. Hereinafter, each step will be described in more detail. In addition, the work procedure in each process is shown as an example, and is not limited to this work procedure.

(Wire insertion process)
In the electric wire insertion step, the three electric wires 11 are inserted into the three first electric wire insertion holes 510 of the first fusion member 5 and the three second electric wire insertion holes 602 of the second fusion member 6. At this time, one end of the electric wire 11 to which the terminal 12 is fixed is first inserted into the first electric wire insertion hole 510 of the first fusion member 5, and one end of the electric wire 11 that has passed through the first electric wire insertion hole 510 is inserted into the second electric wire. It is inserted through the insertion hole 602.

(Terminal connection process)
In the terminal connection step, the sheath 111 at one end of the electric wire 11 is removed to expose the center conductor 110, and the crimped portion 120 of the terminal 12 is crimped and fixed to the exposed center conductor 110. Thereby, the terminal 12 is connected to the electric wire 11.

(Terminal insertion process)
In the terminal insertion step, the terminal 12 connected to the electric wire 11 is inserted into the terminal insertion hole 232 from the end surface 23 a side of the electric wire holding portion 23 and accommodated in the accommodating space 231. The terminal 12 passes through the terminal insertion hole 232, and the inner surface of the terminal insertion hole 232 faces the outer peripheral surface of the electric wire 11. The terminal 12 is supported in the main body member 2 by a terminal support member 40 fixed to one end portion of the electric wire holding portion 23.

(Arrangement process)
In the arrangement step, as shown in FIG. 6A, the main body member 2, the second welding member 6, and the first fusion member 5 are arranged along the axial direction of the electric wires 11. When this arrangement is completed, as shown in FIG. 7, the end surface 23a of the electric wire holding portion 23 of the main body member 2 and the flat surface 60a of the second welding member 6 face each other, and the tip portion of the protrusion 61 contacts the end surface 23a. To do. In addition, the cylindrical portion 51 is accommodated in the accommodation hole 601 of the second welding member 6, and the tip end portion of the tapered portion 512 of the cylindrical portion 51 contacts the step surface 601 c of the second welding member 6.

  The outer peripheral surface of the electric wire 11 faces the inner surface 510 a of the first electric wire insertion hole 510 of the first fusion member 5 and the inner surface 602 a of the second electric wire insertion hole 602 of the second fusion member 6. Between the outer peripheral surface of the taper part 512 of the cylinder part 51 and the taper surface 601b of the accommodation hole 601, between the sheath 111 of the electric wire 11 and the inner surface 510a of the first electric wire insertion hole 510, and between the sheath 111 and the second of the electric wire 11. Between the inner surface 602a of the electric wire insertion hole 602, a gap into which molten resin can flow is formed.

  Note that the first welding member 5 and the second welding member 6 have one end of the electric wire 11 inserted in advance into the first electric wire insertion hole 510 and the accommodation hole 601 before connecting the terminal 12 to one end of the electric wire 11. After connecting the terminal 12 to one end of the electric wire 11, the other end of the electric wire 11 is inserted into the first electric wire insertion hole 510 and the accommodation hole 601, and the first welding member 5 and the second welding are connected along the electric wire 11. The member 6 may be moved.

  Further, in the arranging step, the three electric wires 11 are introduced into a slit portion 801 (shown in FIG. 6C) provided on the support base 80, and the first welding member 5 is placed on the lower side (support base). 80 on the surface 80a side). As a result, the other flat surface 500 b opposite to the one flat surface 500 a in the plate portion 500 of the base 50 comes into contact with the surface 80 a of the support base 80.

(Welding process)
In the welding step, the ultrasonic horn 81 is moved toward the main body member 2, and the end face 81 a of the ultrasonic horn 81 is brought into contact with the opening-side end face 21 a of the opening 210 in the main body member 2. The ultrasonic horn 81 is mechanically connected to an ultrasonic transducer (not shown) and can transmit vibration (ultrasonic vibration) of the ultrasonic transducer to the main body member 2. When the end surface 81a of the ultrasonic horn 81 that vibrates ultrasonically contacts the opening-side end surface 21a, the main body member 2 is vibrated. The ultrasonic horn 81 presses the main body member 2 toward the support base 80 while vibrating. FIG. 6C shows a state where the welding process is completed.

  In this welding step, as shown in FIG. 8, a part of the tapered part 512 of the cylindrical part 51 is melted to become a molten resin, and a part of the molten resin is formed between the outer peripheral surface of the electric wire 11 and the first electric wire insertion hole 510. It flows between the inner surface 510a and the inner surface 602a of the second electric wire insertion hole 602 and solidifies. Further, another part of the molten resin flows between the outer peripheral surfaces of the tapered portion 512 and the cylindrical portion 511 and the tapered surface 601b and the cylindrical surface 601a, so that the second welding member 6 and the first welding member 5 are connected to each other. The four welds 34 are welded. Thereby, between the electric wire 11 and the 1st welding member 5 in the 1st electric wire insertion hole 510, between the electric wire 11 and the 2nd welding member 6 in the 2nd electric wire insertion hole 602, and the 1st welding member 5 The space between the cylindrical portion 51 and the second welding member 6 in the accommodation hole 601 is hermetically sealed.

  Further, in the welding step, as shown in FIG. 8, the protrusion 61 of the second welding member 6 is melted to become a molten resin, and this molten resin is used as the flat surface 60 a of the plate portion 60 of the second welding member 6 and the main body member 2. The main body member 2 and the second welding member 6 are welded to each other at the first welding portion 31. The molten resin also flows between the peripheral surface of the plate portion 60 and the inner surface 233 a of the flange portion 223, and the main body member 2 and the second welding member 6 are welded at the second welding portion 32.

  Further, in the welding process, as shown in FIG. 8, the outer peripheral projection 501 and the inner peripheral projection 502 of the first welding member 5 are melted to become a molten resin, and this molten resin is the plate portion 60 of the second welding member 6. The second welding member 6 and the first welding member 5 are welded to each other at the third welding portion 33. The second welding member 6 and the first welding member 5 are welded at the third welding portion 33.

  Furthermore, in the welding process, as shown in FIG. 8, molten resin in which the tapered portion 512 of the first welding member 5 is melted flows between the electric wire 11 and the second welding member 6 in the second electric wire insertion hole 602. And solidify.

  The molten resin that has flowed into these parts is solidified by natural cooling, and the main body member 2, the first welding member 5, and the second welding member 6 are integrated by welding. As a result, the wire harness 100 shown in FIGS. 1 and 2 is obtained.

(Operation and effect of the embodiment)
According to the embodiment described above, the following operations and effects can be obtained.

(1) Since the terminal insertion hole 232 allows the terminal 12 to be inserted, after connecting the terminal 12 to the electric wire 11, the terminal 12 is inserted into the housing space 231 of the main body member 2 through the terminal insertion hole 232. Can be accommodated. Thereby, it is possible to facilitate the work in the arrangement process. That is, if the terminal insertion hole 232 has a size that prevents the terminal 12 from being inserted, one end of the electric wire 11 is inserted into the terminal insertion hole 232 before the terminal 12 is connected, and the body member 2 is opened. It is necessary to connect the terminal 12 to one end of the drawn electric wire 11 and pull the electric wire 11 back to accommodate the terminal 12 in the accommodation space 231. According to the present embodiment, Such work becomes unnecessary.

(2) The terminal insertion hole 232 is blocked by the flat surface 60a of the second welding member 6, and the protrusion 61 protruding from the flat surface 60a is melted and welded to the end surface 23a of the electric wire holding portion 23. An increase in time can be suppressed. In other words, if the terminal insertion hole 232 is closed by pouring the molten resin between the terminal insertion hole 232 and the electric wire 11, a lot of molten resin is required, so the vibration time in the welding process becomes longer. Unintentional melting is likely to occur at a contact portion between the main body member 2 and the ultrasonic horn 81, a boundary portion between the tubular portion 21 and the small tubular portion 22, or the like. However, according to the present embodiment, the terminal insertion hole 232 is closed by melting the protrusion 61 and welding the second welding member 6 to the main body member 2, so that the amount of necessary molten resin can be reduced. It is possible to reduce the vibration time in the welding process and to avoid the main body member 2 from being damaged. Further, the time required for manufacturing the wire harness 100 can be shortened by reducing the vibration time.

(3) The main body member 2 and the second welding member 6 are in contact with the front end portion of the protrusion 61 and the end surface 23a, and the resin material is melted by vibration. That is, the contact area between the tip of the protrusion 61 and the end face 23a is narrow at the beginning of the welding process and gradually increases as the resin material melts. As a result, heat generated by vibration is concentrated on these contact parts to prevent damage to the main body member 2 or the welding member 3 in other parts, and the amount of molten resin generated by vibration is secured and sealed. It is possible to ensure.

(4) The main body member 2 and the second welding member 6 are welded at least at the first welding portion 31, and between the electric wire 11 and the inner surface 510a of the first electric wire insertion hole 510 and the inner surface 602a of the second electric wire insertion hole 602. Since the molten resin flows in and solidifies, the waterproofness and airtightness of the wire harness 100 are ensured.

(5) The terminal insertion hole 232 is mainly sealed with a molten resin in which the second welding member 6 (projection portion 61) is melted, and the electric wire 11 and the inner surface 510a of the first electric wire insertion hole 510 and the second electric wire insertion hole 602. The gap with the inner surface 602a is mainly sealed with a molten resin in which the first welding member 5 (cylinder portion 51) is melted. That is, since these parts are sealed by the first welding member 5 and the second welding member 6, the time for ultrasonic vibration can be shortened.

(Modification of the embodiment)
Fig.9 (a) is a top view which shows the 2nd welding member 6 which concerns on the modification of embodiment. FIG.9 (b) is a top view which shows the 1st welding member 5 which concerns on the modification of embodiment.

  The second welding member 6 according to this modification is a combination of the first member 6A and the second member 6B. When the first member 6A and the second member 6B are combined, the second member 6A according to the first embodiment is combined. 2 It is comprised so that it may become the same shape as the welding member 6. FIG. In the state where the first member 6A and the second member 6B are coupled, the constituent elements having the same functions as those described in the first embodiment are denoted by the same reference numerals, and the duplicate description thereof. Is omitted.

  The first member 6 </ b> A and the second member 6 </ b> B are formed symmetrically with respect to a virtual plane including the central axis of the three electric wires 11. Three arc grooves 601A having an inner diameter corresponding to the outer diameter of the three electric wires 11 are formed in the first member 6A, and three arc grooves having the same inner diameter as the arc groove 601A are formed in the second member 6B. 601B is formed. The arc groove 601A and the arc groove 601B constitute an accommodation hole 601 (shown in FIG. 4) by the coupling of the first member 6A and the second member 6B.

  Moreover, the 1st welding member 5 which concerns on this modification combines 1st member 5A and 2nd member 5B, and if 1st member 5A and 2nd member 5B are couple | bonded, it will become 1st Embodiment. It is comprised so that it may become the same shape as the 1st welding member 5 which concerns. In the state in which the first member 5A and the second member 5B are coupled, the constituent elements having the same functions as those described in the first embodiment are denoted by the same reference numerals, and the redundant description is given. Is omitted.

  The first member 5 </ b> A and the second member 5 </ b> B are formed symmetrically with respect to a virtual plane including the central axis of the three electric wires 11. Three arc grooves 510A having an inner diameter corresponding to the outer diameters of the three electric wires 11 are formed in the first member 5A, and three arc shapes having the same inner diameter as the arc groove 510A are formed in the second member 5B. The groove portion 510B is formed. The arc groove 510A and the arc groove 510B constitute a first electric wire insertion hole 510 (shown in FIG. 5) by the combination of the first member 5A and the second member 5B.

  In the manufacturing process of the wire harness 100 according to this modification, in the arranging process, the first member 5A and the second member 5B face each other with the three electric wires 11 therebetween, and the first member 6A and the second member 6B are 3 Face each other across the wire 11 of the book. In the welding process, the main body member 2, the first member 5A and the second member 5B constituting the first welding member 5, and the first member 6A and the second member 6B constituting the second welding member 6 are integrated by welding. The Other than this, the wire harness 100 is manufactured by the same manufacturing process as described above.

  According to this modification, since the three electric wires 11 are sandwiched between the first member 5A and the second member 5B, and the first member 6A and the second member 6B, the electric wire 11 is inserted into the accommodation hole 601 and the first electric wire insertion hole 510. There is no need to insert the cable. Thereby, the manufacturing process of the wire harness 100 can be further simplified.

  While the embodiments of the present invention have been described above, the embodiments described above do not limit the invention according to the claims. In addition, it should be noted that not all the combinations of features described in the embodiments are essential to the means for solving the problems of the invention.

  Further, the present invention can be appropriately modified and implemented without departing from the spirit of the present invention. For example, in the above-described embodiment, the first welding member 5 and the second welding member 6 are provided with protrusions. However, the present invention is not limited to this, and the main body member 2 is provided with a protrusion protruding toward the second welding member 6. The second welding member 6 may be provided with a protrusion that protrudes toward the first welding member 5.

  Moreover, although the said embodiment demonstrated the case where the resin material of the main body member 2, the 1st welding member 5, and the 2nd welding member 6 was the same, the resin material of each member may differ. Furthermore, there is no restriction | limiting in particular also about the use of the wire harness 100, the number of the electric wires 11, etc. Moreover, in the said embodiment, although the main body member 2 and the 2nd welding member 6 were welded by the 1st welding part 31 and the 2nd welding part 32, the main body member 2 and the 2nd welding member 6 are the 1st. It may be welded only by the welding part 31.

DESCRIPTION OF SYMBOLS 1 ... Female connector, 2 ... Main body member (1st member), 3 ... Welding member, 5 ... 1st welding member (2nd member), 5A ... 1st member, 5B ... 2nd member, 6 ... 2nd welding member (3rd member), 6A ... 1st member, 6B ... 2nd member, 9 ... Male connector, 10 ... Female side housing, 11 ... Electric wire, 12 ... Terminal, 21 ... Cylindrical part, 21a ... Opening side end surface, 22 ... Small tube part, 23 ... Electric wire holding part, 23a ... End face, 24 ... Rib, 31 ... First welding part, 32 ... Second welding part, 33 ... Third welding part, 34 ... Fourth welding part, 40 ... Terminal Support member 41 ... Sealing member 50 ... Base part 51 ... Tube part 60 ... Plate part 60a, 60b ... Flat surface 61 ... Projection part 80 ... Support base 80a ... Surface 81 ... Ultrasonic horn 81a ... End face, 90 ... male housing, 91 ... electric wire, 100 ... wire harness, 110 ... center conductor, 111 ... sea , 120 ... caulking part, 121 ... connection part, 210 ... opening, 211 ... round hole, 212 ... engagement part, 223 ... collar part, 231 ... housing space, 232 ... terminal insertion hole, 233 ... collar part, 233a ... Inner surface, 233b ... end face, 500 ... plate portion, 500a, 500b ... flat surface, 501 ... outer peripheral projection portion, 502 ... inner peripheral projection portion, 510 ... first wire insertion hole, 510A, 510B ... arc groove, 510a ... inner surface, 511 ... Cylindrical part, 512 ... Tapered part, 601 ... Accommodating hole, 601A, 601B ... Arc groove, 601a ... Cylinder surface, 601b ... Tapered surface, 601c ... Step surface, 602 ... Second electric wire insertion hole, 602a ... Inner face, 801 ... Slit part, 901 ... Flange part, 902 ... Cylinder part, 903 ... Cylindrical part, 904 ... Engagement projection, 905 ... Deriving part, 906 ... Pushing member

Claims (7)

An electric wire, a terminal connected to an end of the electric wire, and a housing made of a resin that accommodates the terminal;
The housing is interposed between a first member that accommodates the terminal, a second member that includes a lead-out portion from which the electric wire is led out to the opposite side of the terminal, and the first member and the second member. A method of manufacturing a wire harness that is integrated by ultrasonic welding for welding a third member by ultrasonic vibration,
A terminal insertion hole for inserting the terminal is formed in the first member,
The second member is formed with a first electric wire insertion hole for inserting the electric wire,
The first member and the third member are welded by a welded portion formed by solidifying at least the third member melted by the ultrasonic vibration so as to cover the outer peripheral side of the terminal insertion hole. ,
A method for manufacturing a wire harness , wherein at least the second member is melted and melted by the ultrasonic vibration between the electric wire and the second member in the first electric wire insertion hole. In the third member, a cover surface that covers at least a part of the terminal insertion hole, and an accommodation hole that accommodates at least a part of the outer peripheral side of the first wire insertion hole of the second member are formed.
The manufacturing method of the wire harness of Claim 1. The third member is a combination of a plurality of resin members each having an arc groove that constitutes the accommodation hole.
The second member is a combination of a plurality of resin members that sandwich the electric wire and at least a part of which is accommodated in the accommodation hole.
The manufacturing method of the wire harness of Claim 1 or 2. The third member is formed with a second electric wire insertion hole that allows the electric wire to pass therethrough and communicates with the first electric wire insertion hole.
The molten resin in which at least the second member is melted by the ultrasonic vibration flows into and solidifies between the electric wire and the third member in the second electric wire insertion hole. The manufacturing method of the wire harness in any one. An electric wire, a terminal connected to an end of the electric wire, and a housing made of a resin that accommodates the terminal; the housing includes a first member that accommodates the terminal; and the electric wire is opposite to the terminal. A wire harness in which a second member including a lead-out portion to be led out and a third member interposed between the first member and the second member are integrated by ultrasonic welding for welding by ultrasonic vibration. A manufacturing method comprising:
An electric wire insertion step of inserting the electric wire into an electric wire insertion hole for inserting the electric wire formed in the second member;
After the wire insertion step, a terminal insertion step of inserting the terminal into a terminal insertion hole for inserting the terminal formed in the first member;
An arrangement step of arranging the first member, the second member, and the third member along the axial direction of the electric wire;
A welding step of welding the first member and the third member by ultrasonic vibration and welding the third member and the second member;
In the welding step, the first member and the third member are formed by a welded portion formed by solidifying at least the third member melted by the ultrasonic vibration so as to cover the outer peripheral side of the terminal insertion hole. A molten resin in which at least the second member is melted by the ultrasonic vibration is caused to flow between the electric wire and the second member in the electric wire insertion hole to be solidified. Manufacturing method. The third member is a combination of a plurality of resin members each having an arc groove that constitutes the accommodation hole.
The second member is a combination of a plurality of resin members that sandwich the electric wire and at least a part of which is accommodated in the accommodation hole,
The arranging step includes a step of facing the plurality of resin members constituting the second member across the electric wire and facing the plurality of resin members constituting the third member across the electric wire. The manufacturing method of the wire harness of Claim 5. The first member has an end surface in which an opening of the terminal insertion hole is formed,
The third member is formed to protrude from the lid surface at a peripheral edge of the lid surface, and has a protrusion whose tip is in contact with the end surface in the arranging step,
The welding step is a step of melting the protrusion and welding the first member and the third member.
The manufacturing method of the wire harness of Claim 5 or 6.

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