JPH0492309A - Flat wire harness and manufacture thereof - Google Patents

Abstract

PURPOSE:To make connection of wires more rapidly and securely by classifying junction bars, which comprise junction circuit boards, into a signal line wire distributing part and a power line wire distributing part, and by forming pressure contact connections between each wire distributing and each pressure contact-style terminal part respectively. CONSTITUTION:At the signal line wire distributing part 24A of a junction bar 24 in each of junction circuit boards 22, 22' etc., on a jig board A, narrower coated wires 26 for signal wire are distributed between desired junction circuit boards so as to produce a partially fabricated item W' of a flat wire harness. When this partially fabricated item W' is passed between heating rolls C, C', insulating films 21 and a protective sheet B equipped with wires are pressurized and heated so that each of hot melt adhesives 21a, 27a is melt to cover a plurality of wires 26 from the above and the bottom, and to be filled between wires and eventually a group of wires 26 are stuck and fixed in a sandwich fashion between the upper and lower protective sheets B and a film 21. At the same time, wires 26' of the protective sheets B equipped with wires are pressed in a pressure-joining dent part 29 so as to be brought in pressure contact with a slot 24c' in a pressure contact-style terminal part 24'.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a flat-seven wire harness used for electrical wiring of a vehicle.

[Conventional technology]

Current wire harnesses have a configuration in which multiple branch wires are provided in a branched manner to a main wire section in which a large number of electric wires are bundled together by wrapping tape, etc., and the shape is complex, making it difficult to automate manufacturing. Due to the increase in the number of in-vehicle electrical components, they have become bulky and bulky, and it takes a great deal of labor and time to assemble them into the vehicle, which is one of the factors that hinders improvements in automobile productivity.

Therefore, the applicant has developed a wire harness as shown in FIGS. 6 to 8 in order to make it thinner and lighter, to facilitate automation of manufacturing, and to improve assembly into a vehicle, in place of the conventional wire harness type. proposed a flat wire harness (Japanese Patent Application No. 115827/1999).

In these figures, 1 indicates a long rigid insulating board, on which a plurality of relay circuit boards 2.2', 2 are placed at predetermined intervals.
″... is fixed in the − column.

The relay circuit board is formed by press-fitting and fixing junction bars 4 into a plurality of slits 3a arranged in parallel on a circuit board 3, as represented by the reference numeral 2 in FIG. The junction bar 4 has a tab 4a serving as a connector terminal at one end or both ends, and a pressure contact terminal portion 4b having a slot 7) 4C protrudes from one side edge in the elongated direction.

5.5' indicates a connector attached to the tab 4a;
It is constructed by inserting a female relay terminal 6 into a terminal accommodating chamber 5b within a housing 5a. In the figure, 5c and 3d indicate locking means for connecting the connector 5 and the circuit board 3, and 50' and 30' indicate insertion means.

Electrical connections between each relay circuit board are made as follows.

After one end of the covering type g1 is pressed into contact with the insulation displacement terminal section indicated by the reference numeral 4b+ of the relay circuit board 2' using an automatic wiring machine IO having a known structure, the wiring is routed toward the adjacent circuit Fi, 2'/. Then, it is press-fitted into the press-contact terminal portion 4bz and cut there, or it is routed toward the adjacent relay circuit board 2'' without being cut.

Thereafter, by repeating this wiring sequentially, the connector 5 is brought into pressure contact with the junction bar of the desired relay circuit board.
．． A circuit electrically connected to (tab 4a of) 5' is formed.

Reference numeral 8 denotes an adhesive protective sheet, which is placed over the insulating plate 1 and each relay circuit board 2, 2', . . . using a heating roller 11.
The wired covered wires 7 are fixed and protected, and a protective cover 9 is attached if necessary.

[Problem to be solved by the invention]

In the manufacturing process of the flat wire harness shown in FIG. 6, when wiring the covered electric wire 7, the automatic wiring machine 10
The wiring speed is very slow, and there is a risk that the electric wire once connected may come off from the pressure contact terminal portion 4b during wiring.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a flat wire harness having a structure that allows wires to be quickly and reliably wired between relay circuit boards, and a method for manufacturing the same. do.

[Means to solve the problem]

In order to achieve the above object, the wire harness of the present invention has a plurality of junction bars arranged in parallel to the circuit board, and a connector at one or both ends of the bars. A plurality of relay circuit boards provided with relay circuit boards, an insulating film or insulating sheet that holds these relay circuit boards at predetermined intervals, and a plurality of relay circuit boards that connect the relay circuit boards to form a desired circuit. A flat wire harness including an electric wire, the electric wire being press-connected to a slot of a press-contact terminal protruding from one side edge of a junction bar to form a circuit electrically connected to the connector, and each of the relay circuit boards Each of the plurality of junction bars is divided into a signal line wiring part on one side and a power line wiring part on the other side, and a protective sheet with electric wire is attached to the insulation displacement terminal part on the power line wiring part side of the junction bar. It is characterized in that the installed power lines are pressure-welded.

As described in claim 3, this flat wire harness manufacturing method includes laying a long insulating film on a plate-shaped jig stand provided with a plurality of circuit board mounting grooves at predetermined intervals, and The process of inserting the relay circuit board into the circuit board mounting groove of A step of manufacturing a semi-finished product of a wire harness, a step of supplying an insulating sheet with electric wires on which electric wires for a power line are arranged on the semi-finished product, and a step of supplying the electric wire for the power line with a pair of rolls to the power line wiring section of the junction bar. The present invention is characterized in that it includes a step of press-contacting the insulation film and the protective sheet with electric wires by heating and bonding the protective sheet with electric wires to the insulation film and the protective sheet with electric wires.

Further, as the sheet with electric wires, as described in claim A, a sheet having electric wires for power lines and signal lines arranged in advance can be used.

[For production]

In the present invention, the junction bar constituting the relay circuit board is divided into a signal line wiring part and a power line wiring part, and the electric wire for the signal line, which is a so-called silk electric wire, is installed by an automatic wiring machine.
In addition, electric wires for power lines of large electric wires are wired and press-connected to the press-contact terminals by heating and pressurizing the protective sheet with electric wires on which the wires are placed in advance, so that the electric wires can be connected faster and faster. It can be done reliably.

Hereinafter, the above configuration and operation will be specifically explained with reference to drawings showing examples.

〔Example〕

1 to 4, W indicates a flat wire harness according to the present invention, A indicates a jig stand for manufacturing the harness, B indicates a protective sheet with electric wires, and c and c' indicate a pair of heating rolls.

The jig stand A is a metal plate-like body, and a plurality of circuit board mounting grooves 20 are formed at predetermined intervals.

On this jig stand A, lay a long insulating film 21 with the true melt adhesive 21a attached with the adhesive side facing up, and place the relay circuit +f22 on top of it, facing the circuit board mounting groove 20.
．． 22'... is set.

As shown in FIG. 2, the relay circuit board 22 has a structure in which a plurality of slits 23a are arranged in parallel on the upper surface of a circuit board 23, and a junction bar 24 is fixed in the correct size. this is,
Although similar to FIG. 7 showing the conventional example, in the present invention, the junction bar 24 is divided into a signal line wiring section 24A and a power line wiring section 24B, and the circuit board 23
A cover 25 with holes 25a and 25a' for press-fitting the electric wires is placed on the cover 25.

Signal line wiring section 2 on one side of the junction bar 24
4A, a pressure contact terminal portion 24b with an intermediate slot 24c is provided protrudingly in the same way as in FIG. ′ is formed by curving into a bow. Note that forming tabs 24a, 24a' as connector terminals at one or both ends of the bar 24 and attaching the connector 5 or 5' is the same as in the case of FIG.

The cover 25 has holes 25a and 25a' for the pressure contact terminal parts 24c and 24c' of each junction bar 24, and the pressure contact terminal part 24b' in the power line wiring part 24B is formed to protrude from the hole 25a'. .

As shown in FIGS. 1 and 2, in the signal line wiring portion 24A of the junction bar 24 on each relay circuit board 22, 22'... on the jig stand A, a thin The covered electric wire 26 is routed between desired relay circuit boards by an automatic wiring machine 10 shown in FIG. 6, which is a conventional example, to produce a semi-finished product W' of a flat wire harness.

In the protective sheet with electric wires) B, a hot/melt adhesive 27a is pasted on the lower surface of the strip-shaped insulating film 27, and a large electric wire 26' for the power line is preliminarily attached to the power line wiring section 24B. A plurality of wires are wired in parallel and wound around a supply roll 28.

In addition, one heating roll C is electrically heated, as shown enlarged in FIG. A press-contact recess 29 that also serves as a press-contact relief groove is provided around the press-contact terminal portion 26' and the press-contact terminal portion 24C'.

In this way, the insulating film 21 is placed on the jig stand A as described above.
and a plurality of relay circuit boards 22, 22', etc., and then route the electric wire 26 for the signal line to the signal line wiring portion 24A of the junction bar 24 on each relay circuit board. Product W' is obtained.

This semi-finished product W' is placed on heating rolls c, c'
When the insulation film 21 and the wire-attached protective sheet B are heated under pressure, the true-melt adhesives 21a and 27a are melted to form a plurality of wires 2.
6 is covered from above and below and filled between the lines,
The group of electric wires 26 is adhesively fixed between the upper and lower protective sheets B and the insulating film 21 in a sandwich-like manner.

At the same time, the electric wire 26' of the protective sheet 1-B with electric wire is pressed by the press-contact recess 29 of the heating roll C, and is pressed into the slot 24C' of the press-contact terminal portion 24b', as shown in FIG.

Thus, the protection of the wires 26 and the power wires 26'
Routing and connecting the group and protecting it are done simultaneously.

FIG. 5 shows another embodiment of the protective sheet with electric wires.

This protective sheet B' is used for arranging the electric wire 26' for the power line as well as for arranging the thin electric wire VA26 for the signal line in the automatic wiring machine.
0, the wires were laid in advance on the true melt adhesive 27a, and only the ends 26a and bent portions 26b of the wire 26 group to be press-contacted to the press-contact terminal portion 24b were locally welded using a heating jig (not shown). It is something.

In this case, the electric wires 2 for power lines are connected to each relay circuit board 22, 22', etc. by heating rolls c and c' shown in FIG.
6' in the pressure welding recess 29, press it from above the protective sheet B' using a pressure welding jig (not shown), and press it against the pressure contact terminal portion 24b of a predetermined junction bar 24 on each relay circuit board. .

〔Effect of the invention〕

As explained above, according to the present invention, it is possible to simultaneously perform the wiring of electric wires between relay circuit boards and the process of covering with an insulating film or a protective sheet.

The above process can be performed more reliably by dividing the junction bar that makes up the relay circuit board into a signal line routing section and a power line routing section, and using a protective sheet with wires, especially in the power line routing section. .

Furthermore, since the wires are fixed with an adhesive such as the protective sheet at the same time as they are connected to the pressure contact terminal portion of the junction bar, there is no fear that the wires will come off, and the reliability of the connection is improved.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of the main parts showing the flat wire harness and the manufacturing method thereof according to the present invention, FIG. 2 is an exploded perspective view of the same relay circuit board, and FIG. 3 is the main part of the insulating sheet B shown in FIG. 1. 4 is a cross-sectional view of a main part showing the connection structure between the electric wire for the power line and the pressure contact terminal in FIG. 1, FIG. 5 is a perspective view showing another embodiment of the insulating sheet, and FIG. 6 is the conventional one. FIG. 7 is an exploded perspective view of the relay circuit board of FIG. 6, and FIG. 8 is an explanatory diagram of a method of covering the flat wire harness of FIG. 6 with a protective sheet. 5.5'...Connector, 20...Circuit board mounting groove, 2
DESCRIPTION OF SYMBOLS 1... Insulating film, 22.22'... Relay circuit board, 23... Circuit board, 24... Junction bar 24A... Signal line wiring part, 24B... Power line wiring part, 24b, 24b'--press contact terminal section, 24c, 24
c'...Slot, 25...Cover 26...Electric wire for signal line, 26'...Electric wire for power line, 28...
・Supply roll, 29... recess, A... jig stand, B.
...protective sheet with electric wire, c, c'...heating roll,
W...Flat wire harness, W'...Flat wire harness semi-finished product. ＼7a

Claims (4)

[Claims] (1) A plurality of relay circuit boards in which a plurality of junction bars are arranged in parallel to a circuit board and a connector is provided at one end or both ends of the bars, and an insulating film that holds these relay circuit boards at predetermined intervals. or an insulating sheet,
A plurality of electric wires connect the relay circuit boards to form a desired circuit, and the electric wires are press-connected to the slots of the press-contact terminals protruding from one side edge of the junction bar to be electrically connected to the connector. A flat wire harness formed by forming a circuit, wherein the plurality of junction bars on each of the relay circuit boards are formed so as to be divided into one side as a signal line wiring part and the other side as a power line wiring part, A flat wire harness characterized in that a power line arranged on a protective sheet with electric wires is pressure-welded to a pressure-welding terminal part on the power line wiring part side. (2) An insulating film or insulating sheet that holds multiple relay circuit boards at predetermined intervals and a protective sheet with electric wires are pasted together, and the signal and power wires that connect the relay circuit boards are coated and fixed. The flat wire harness according to claim 1. (3) A method for manufacturing a flat wire harness according to claim 1, comprising: laying a long insulating film on a plate-shaped jig stand provided with a plurality of circuit board mounting grooves at predetermined intervals; The step of setting the relay circuit boards in each of the plurality of circuit board mounting grooves, routing the signal wire on the signal line wiring part side of the junction bar between each relay circuit board, and press-fitting it to the pressure contact terminal part. A process of manufacturing a semi-finished product of a flat wire harness, a process of supplying an insulating sheet with electric wires on which electric wires for power lines are arranged on the semi-finished product, and a process of supplying the electric wires for the power lines to the power line wiring of the junction bar using a pair of rolls. A method for manufacturing a flat wire harness, comprising the step of press-contacting the insulation film and a protective sheet with electric wires to a pressure-contact terminal portion on the cable portion side and thermally bonding the insulation film and a protective sheet with electric wires. (4) A method for manufacturing a flat wire harness according to claim 1, comprising: laying a long insulating film on a plate-shaped jig stand provided with a plurality of circuit board mounting grooves at predetermined intervals; The step of setting relay circuit boards in the plurality of circuit board mounting grooves, respectively placing the signal lines and power lines corresponding to the signal line wiring part and the power line wiring part of the junction bar on the insulating sheet in the position of the relay circuit board. A step of supplying this insulating sheet with electric wires to the insulating film on the jig table and the relay circuit board, A step of connecting the electric wires for the power line with a pair of rolls to the pressure welding terminal on the power line wiring part side of the junction bar. and heat-bonding the insulating film and the protective sheet with electric wires, and press-contacting the electric wire for the signal line to a press-contact terminal portion on the signal line wiring portion side of the junction bar. A method for manufacturing a flat wire harness.