JPH02278615A - Manufacture of flat wire harness - Google Patents
Manufacture of flat wire harnessInfo
- Publication number
- JPH02278615A JPH02278615A JP1098696A JP9869689A JPH02278615A JP H02278615 A JPH02278615 A JP H02278615A JP 1098696 A JP1098696 A JP 1098696A JP 9869689 A JP9869689 A JP 9869689A JP H02278615 A JPH02278615 A JP H02278615A
- Authority
- JP
- Japan
- Prior art keywords
- wire harness
- wire
- flat
- manufacturing
- electric wires
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 22
- 238000000034 method Methods 0.000 claims abstract description 16
- 239000004831 Hot glue Substances 0.000 claims description 5
- 238000005452 bending Methods 0.000 claims description 2
- 238000000465 moulding Methods 0.000 claims 1
- 239000000853 adhesive Substances 0.000 abstract description 4
- 230000001070 adhesive effect Effects 0.000 abstract description 4
- 238000002844 melting Methods 0.000 abstract 2
- 230000008018 melting Effects 0.000 abstract 1
- 238000009413 insulation Methods 0.000 description 5
- 238000009434 installation Methods 0.000 description 4
- 239000011265 semifinished product Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000002788 crimping Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 238000005219 brazing Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000001012 protector Effects 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
Landscapes
- Insulated Conductors (AREA)
Abstract
Description
【発明の詳細な説明】
〔産業上の利用分野〕
本発明は、車輌の配線に使用されるフラットワイヤーハ
ーネスの製造方法に関する。DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method of manufacturing a flat wire harness used for wiring a vehicle.
現在のワイヤーハーネスの多くは、絶縁被覆電線を集束
し、これをテープ巻き、チューブなどで結束させたもの
である。そして、車輌への配設に際しては、第４図に示
すように、ワイヤーハーネスＷを車体構造に合わせたプ
ロテクタｂで保持し、テープ巻きａされた部分にクラン
プＣを取り付＆Ｊて車体に固定している。そのために、
ワイヤーハーネスの製造には非常に多くの工程を要する
。Most current wire harnesses are made by collecting insulated wires and binding them with tape, tubes, etc. When installing it on the vehicle, as shown in Figure 4, the wire harness W is held with a protector b that matches the vehicle body structure, and a clamp C is attached to the tape-wrapped part a and fixed to the vehicle body. are doing. for that,
Manufacturing a wire harness requires numerous steps.
すなわち、ワイヤーハーネスの製造工程は、電線の切断
、皮ムキ（絶縁被覆の剥離）、端子金具の圧着などの前
工程と、端子付電線の配索、集束、仕上げテープ巻き、
コネクタハウジングの装着などの後工程とに分かれてい
る。また、車体と各種電装品との隙間をぬって配設しな
ければならないために複雑な形状となっている。In other words, the manufacturing process for wire harnesses includes pre-processes such as cutting the wires, stripping the insulation coating, and crimping the terminal fittings, as well as routing the wires with terminals, converging them, wrapping them with finishing tape, and finishing them with tape.
This process is divided into post-processes such as attaching the connector housing. Furthermore, it has a complicated shape because it must be installed through gaps between the vehicle body and various electrical components.
従来の電線集束型のワイヤーハーネスは、その製造工程
が多く、形状が複雑で機械による自動化が困難であり、
生産性の向」二が望めず、集束径の肥大化により車体へ
の配設にも非常な困難を伴う。Conventional wire harnesses require many manufacturing steps, have complex shapes, and are difficult to automate with machines.
No improvement in productivity can be expected, and the enlarged focusing diameter makes installation on the vehicle body extremely difficult.
本発明の課題は、製造工程が少なく、自動化が容易で、
しかも軽量で狭いスペースに配設することができるフラ
ットワイヤーハーネスの製造方法を提供することにある
。The object of the present invention is to have fewer manufacturing steps, easy automation,
Moreover, it is an object of the present invention to provide a method for manufacturing a flat wire harness that is lightweight and can be installed in a narrow space.
〔課題を解決するだめの手段］
前記の課題は、請求項（１）に記載のように、塑性変形
可能な複数の電線を絶縁間隔を置いてフラット状に配線
し、これらをホットメルト接着剤により仮固定し、その
両面に絶縁シートを融着して電線を固定することにより
達成される。[Means for Solving the Problem] The above problem is achieved by wiring a plurality of plastically deformable electric wires in a flat shape with insulating intervals, and bonding them with a hot melt adhesive, as described in claim (1). This is achieved by temporarily fixing the wire with a wire and fusing an insulating sheet to both sides of the wire.
配線に使用する電線は、単線または撚線の裸線を用いる
のが、所望のパターンに配線するうえて有利である。配
線は、複数の電線を直線状に並べるか、或いは予めワイ
ヤーハーネスの車体への配設経路に沿って並べることが
でき、途中から枝線を引き出すようにしてもよい。It is advantageous to use single or twisted bare wires for wiring in a desired pattern. For the wiring, a plurality of electric wires may be arranged in a straight line, or they may be arranged in advance along the installation route of the wire harness to the vehicle body, and branch wires may be drawn out from the middle.
また１、請求項（３）に記載の方法に従うことにより、
車体の凹凸や屈曲に適合する立体形状のフラットワイヤ
ーハーネスが得られる。In addition, 1. By following the method described in claim (3),
A flat wire harness with a three-dimensional shape that conforms to the unevenness and bends of the vehicle body can be obtained.
本発明方法により得られるワイヤーハーネスはフラット
状であり、軽量で車体と各種電装品との狭いスペースに
も容易に配設することができる。The wire harness obtained by the method of the present invention has a flat shape, is lightweight, and can be easily installed in a narrow space between the vehicle body and various electrical components.
このフラットワイヤーハーネスの製造工程は、極めて少
なく、自動化が容易であり、従来の電線集束型のワイヤ
ーハーネスの製造に要求される後工程をほとんど省くこ
とができ、生産性の大幅な向上が期待される。The manufacturing process for this flat wire harness is extremely small and easy to automate, and it is possible to eliminate most of the post-processes required for manufacturing conventional wire bundled wire harnesses, which is expected to significantly improve productivity. Ru.
以下、本発明方法を実施例を示す図面に基づいて具体的
に説明する。Hereinafter, the method of the present invention will be specifically explained based on drawings showing examples.
第１図（ａ）〜（Ｃ）はフラットワイヤーハーネスの製
造工程を示す。FIGS. 1(a) to 1(C) show the manufacturing process of a flat wire harness.
第１図（ａ）のように、最初に複数の裸電線１を絶縁間
隔を置いて平行に配線する。配線は直線状に限定されず
、途中に折り曲げ部を有してもよく、第２回に示すよう
に分岐線１ａを取り出すこともでき、車体への配設経路
に沿うように所望のパターンで配線する。As shown in FIG. 1(a), first, a plurality of bare electric wires 1 are wired in parallel with insulation intervals. The wiring is not limited to a straight line, and may have a bent part in the middle. As shown in Part 2, the branch line 1a can be taken out, and the wiring can be wired in a desired pattern along the installation route to the vehicle body. Wire.
次いで、所望のパターンに配線された裸電線１群に対し
てホントメルト接着剤２をデイスペンサスクリーン印刷
などの既知の手段を用いて塗布し、裸電線１群を仮固定
した半製品Ｗ。を製造する。Next, a true melt adhesive 2 is applied to a group of bare electric wires wired in a desired pattern using a known method such as dispenser screen printing, thereby creating a semi-finished product W in which the group of bare electric wires is temporarily fixed. Manufacture.
次に、第１図（ｂ）のように、半製品Ｗ０の両面に絶縁
シート３を融着し、裸電線１群を固定することにより、
第１図（Ｃ）のような半製品であるフラットワイヤーハ
ーネスＷが得られる。Next, as shown in FIG. 1(b), insulating sheets 3 are fused to both sides of the semi-finished product W0 and a group of bare electric wires are fixed.
A semi-finished flat wire harness W as shown in FIG. 1(C) is obtained.
図中、４は絶縁シート３の繰出しロール、５はホットロ
ールを示す。絶縁シート３としては、ポリ塩化ビニール
、ポリエステルなどのフィルムであって、Ｗ性変形させ
た裸電線１の形状をそのまま保持できる性質のものが好
ましい。In the figure, 4 indicates a feed roll of the insulating sheet 3, and 5 indicates a hot roll. The insulating sheet 3 is preferably a film made of polyvinyl chloride, polyester, or the like, which can maintain the shape of the bare electric wire 1 that has been deformed by W.
絶縁シート３の半製品Ｗ。への融着は、上記のホットロ
ール５に限らず、ホントプレス、温風等の手段を用いて
行うこともできる。Half-finished product W of insulation sheet 3. The fusion can be performed not only by using the hot roll 5 described above, but also by using a real press, hot air, or other means.
得られたフラットワイヤーハーネスＷに端末処理を施す
ことにより完成品が得られる。A finished product is obtained by subjecting the obtained flat wire harness W to terminal treatment.
すなわち、各裸電線１の端末に、図示しない端子金具を
溶接、圧着、ろう付、圧接などにより接続し、或いはプ
レス加］二によりタブ状の端子を形成し、これらの端子
金具または端子にコネクタハウジング（第２図参照）を
装着することにより、完成品が得られる。なお、第１図
（ａ）において、裸電線１として予めその端末に端子金
具を接続したものを用いることも可能である。That is, a terminal fitting (not shown) is connected to the end of each bare electric wire 1 by welding, crimping, brazing, pressure welding, etc., or by pressing to form a tab-shaped terminal, and a connector is attached to these terminal fittings or terminals. A finished product is obtained by attaching the housing (see Figure 2). In addition, in FIG. 1(a), it is also possible to use, as the bare electric wire 1, a wire with a terminal fitting connected to its terminal in advance.
第２図は立体形状をもつフラットワイヤーハーネスＷ′
の製造方法を示す。Figure 2 shows a flat wire harness W' with a three-dimensional shape.
The manufacturing method is shown below.
図において、６および７はそれぞれ車体構造に対する凹
部６ａと凸部７ａを有するホットプレスを示す。また、
第１図（ａ）と同様にして製造された半製品Ｗ。′ば、
直線状の裸電線１群の途中から一部がＬ形に折り曲げら
れて外部に引き出された分岐線部分１ａを持つ。In the figure, 6 and 7 indicate hot presses having recesses 6a and protrusions 7a, respectively, for the vehicle body structure. Also,
A semi-finished product W manufactured in the same manner as in FIG. 1(a). 'Ba,
A branch line part 1a is formed by bending a part of a group of linear bare electric wires into an L shape and drawing them out to the outside.
この場合には、半製品Ｗ。′の両面を分岐部分３ａをも
つ絶縁シート３で挟み、ホットプレス６．７で加熱加圧
処理することにより、立体形状のフラットワイヤーハー
ネスＷ′が得られる。In this case, the semi-finished product W. A three-dimensional flat wire harness W' is obtained by sandwiching both sides of the wiring harness W' between insulating sheets 3 having branched portions 3a and subjecting them to heat and pressure treatment using a hot press 6.7.
このハーネスＷ′は、車体への配設経路に沿う分岐線Ｗ
ａと、車体構造に合致する凹凸部ｗｂを備えているから
、その端末にコネクタ８を装着することにより、直ちに
車体へ配設することができる。This harness W' is connected to a branch line W along the installation route to the vehicle body.
a and a concavo-convex portion wb that matches the vehicle body structure, the connector 8 can be installed on the vehicle body immediately by attaching the connector 8 to its terminal.
第３図はフラットワイヤーハーネスの他の製造方法を示
す。FIG. 3 shows another method of manufacturing a flat wire harness.
すなわち、前記の裸電線１に代えて絶縁被覆電線９を用
いたもので、本実施では、ホットメルト接着剤による電
線の仮固定工程を省き、直ちに接着剤１０および基材シ
ート１１により第１図（Ｃ）と同等のフラットワイヤー
ハーネスＷ“を製造することができる。この場合、絶縁
被覆９ａおよび基材シート１１としては、前記と同様に
塑性変形させた導体９ｂの形状をそのまま保持できる性
状のものを使用するのが好ましい。That is, an insulated wire 9 is used in place of the bare wire 1, and in this implementation, the step of temporarily fixing the wire with a hot melt adhesive is omitted, and the adhesive 10 and the base sheet 11 are immediately attached to the wire as shown in FIG. A flat wire harness W" equivalent to (C) can be manufactured. In this case, the insulation coating 9a and the base sheet 11 are made of a material that can maintain the shape of the conductor 9b which has been plastically deformed in the same manner as described above. It is preferable to use
以上説明したように、本発明のフラットワイヤーハーネ
スの製造方法は、製造工程が極めて短く、自動化も容易
であり、軽量であって車体への狭いスペースにそのまま
配設できるワイヤーハーネスが得られるから、生産性の
大幅な向上が期待される。As explained above, the method for manufacturing a flat wire harness of the present invention has an extremely short manufacturing process, can be easily automated, and can provide a wire harness that is lightweight and can be installed as is in a narrow space in a vehicle body. A significant improvement in productivity is expected.
第１図（ａ）〜（Ｃ）はそれぞれ本発明方法の一実施例
を示す製造工程の説明図、
第２図および第３図はそれぞれ本発明方法の他の実施例
を示す説明図、
第４図は従来のワイヤーハーネスの説明図である。
ｗ、ｗ’、ｗ“・・・フラットワイヤーハーネス、Ｗ、
、Ｗ、 ・・・（半製品の）フラットワイヤーハーネ
ス、Ｗａ・・・分岐線、ｗｂ・・・凹凸部、■・・・裸
線、２・・・ホットメルト接着剤、３・・・絶縁シート
、６゜７・・・ホットプレス、６ａ・・・凹部、７ａ・
・・凸部。
（ｂ）
第１図FIGS. 1(a) to (C) are explanatory diagrams of the manufacturing process showing one embodiment of the method of the present invention, respectively. FIGS. 2 and 3 are explanatory diagrams of other embodiments of the method of the present invention, respectively. FIG. 4 is an explanatory diagram of a conventional wire harness. w, w', w"...Flat wire harness, W,
, W, ...(semi-finished) flat wire harness, Wa...branch line, wb...irregularity, ■...bare wire, 2...hot melt adhesive, 3...insulation Sheet, 6°7... Hot press, 6a... Concave part, 7a.
...Protrusion. (b) Figure 1
Claims (3)
ラット状に配線し、これらをホットメルト接着剤により
仮固定し、その両面に絶縁シートを融着して電線を固定
することを特徴とするフラットワイヤーハーネスの製造
方法。(1) A plurality of plastically deformable electric wires are wired in a flat shape with insulated intervals, temporarily fixed with hot melt adhesive, and an insulating sheet is fused on both sides to fix the electric wires. A method for manufacturing a flat wire harness.
ら成る裸線またはその絶縁被覆電線を用いる請求項（１
）の製造方法。(2) Claim (1) in which the plastically deformable electric wire is a bare wire consisting of a single wire or a stranded wire, or an insulated wire thereof.
) manufacturing method.
ラット状に配線し、これらをホットメルト接着剤により
仮固定し、その両面を絶縁シートで挟んだ状態で車体構
造に合わせた凹凸または屈曲を有するホットプレスで成
型し、絶縁シートの融着により電線を固定することを特
徴とする立体形状をもつフラットワイヤーハーネスの製
造方法。(3) A plurality of plastically deformable electric wires are wired in a flat shape with insulated intervals, temporarily fixed with hot melt adhesive, and with both sides sandwiched between insulating sheets, the unevenness or convexity or A method for manufacturing a flat wire harness having a three-dimensional shape, which is characterized by molding with a bending hot press and fixing electric wires by fusing an insulating sheet.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1098696A JPH02278615A (en) | 1989-04-20 | 1989-04-20 | Manufacture of flat wire harness |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1098696A JPH02278615A (en) | 1989-04-20 | 1989-04-20 | Manufacture of flat wire harness |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH02278615A true JPH02278615A (en) | 1990-11-14 |
Family
ID=14226671
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1098696A Pending JPH02278615A (en) | 1989-04-20 | 1989-04-20 | Manufacture of flat wire harness |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH02278615A (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5750002A (en) * | 1994-10-04 | 1998-05-12 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Method for fabricating piezoelectric polymer acoustic sensors |
| US5888324A (en) * | 1996-05-09 | 1999-03-30 | Sumitomo Wiring Systems, Inc. | Wiring harness a method for producing a wiring harness and a wiring harness producing apparatus |
| US6101695A (en) * | 1996-05-09 | 2000-08-15 | Sumitomo Wiring Systems, Ltd. | Apparatus for producing a wiring harness |
| JP2007149566A (en) * | 2005-11-29 | 2007-06-14 | Furukawa Electric Co Ltd:The | Method for fixing branch of wire harness, film for fixing branch, and structure for fixing branch of wire harness |
| JP2011034716A (en) * | 2009-07-30 | 2011-02-17 | Icom Inc | Flat cable bending device |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS62186418A (en) * | 1986-02-12 | 1987-08-14 | 三菱化成ビニル株式会社 | Manufacture of flat cable |
-
1989
- 1989-04-20 JP JP1098696A patent/JPH02278615A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS62186418A (en) * | 1986-02-12 | 1987-08-14 | 三菱化成ビニル株式会社 | Manufacture of flat cable |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5750002A (en) * | 1994-10-04 | 1998-05-12 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Method for fabricating piezoelectric polymer acoustic sensors |
| US5888324A (en) * | 1996-05-09 | 1999-03-30 | Sumitomo Wiring Systems, Inc. | Wiring harness a method for producing a wiring harness and a wiring harness producing apparatus |
| US6101695A (en) * | 1996-05-09 | 2000-08-15 | Sumitomo Wiring Systems, Ltd. | Apparatus for producing a wiring harness |
| US6230404B1 (en) | 1996-05-09 | 2001-05-15 | Sumitomo Wiring Systems, Ltd. | Method and apparatus for producing a wiring harness |
| JP2007149566A (en) * | 2005-11-29 | 2007-06-14 | Furukawa Electric Co Ltd:The | Method for fixing branch of wire harness, film for fixing branch, and structure for fixing branch of wire harness |
| JP2011034716A (en) * | 2009-07-30 | 2011-02-17 | Icom Inc | Flat cable bending device |
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