JPH05114310A - Flat wire harness and its manufacture - Google Patents
Flat wire harness and its manufactureInfo
- Publication number
- JPH05114310A JPH05114310A JP3277839A JP27783991A JPH05114310A JP H05114310 A JPH05114310 A JP H05114310A JP 3277839 A JP3277839 A JP 3277839A JP 27783991 A JP27783991 A JP 27783991A JP H05114310 A JPH05114310 A JP H05114310A
- Authority
- JP
- Japan
- Prior art keywords
- relay circuit
- wire harness
- circuit board
- flat wire
- connector
- 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.)
- Withdrawn
Links
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、車両の電気配線に用い
られるフラットワイヤハーネスおよびその製造方法に関
する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flat wire harness used for electric wiring of vehicles and a method for manufacturing the flat wire harness.
【０００２】[0002]
【従来技術】出願人は、従来の電線収束形状のワイヤハ
ーネスに代えて、その薄型軽量化と車体への組付性向上
および生産の自動化を図るため、図１２ないし図１４に
示すようなフラットワイヤハーネス（特願平２−１１５
８２７号）を提案した。 これらの図において、１はホ
ットメルト系接着剤を塗布したシートを示し、その上に
所定間隔で複数の中継回路板２、２1 、２2 、…が固定
されている。各中継回路板は、図１３において符号２で
代表して示すように、回路基板３上に並設した複数のス
リット３ａに内部回路導体としてジャンクションバー４
を圧入固定して成るものである。ジャンクションバー４
の両端または片端には、タブ４ａが形成され、一側縁に
スロット４ｃをもつ圧接端子部４ｂが突設されている。
５、５′は、タブ４ａに装着されるコネクタを示し、コ
ネクタハウジング５ａ内の端子収容室５ｂに雌−雌中継
端子６を挿着して構成されている。2. Description of the Related Art In order to reduce the thickness and weight of a conventional wire harness having a wire-converging shape, to improve the assemblability to a vehicle body, and to automate the production, the applicant has adopted a flat wire harness as shown in FIGS. Wire harness (Japanese Patent Application No. 2-115)
No. 827) was proposed. In these figures, 1 indicates a sheet coated with a hot melt adhesive, on which a plurality of relay circuit boards 2, 2 1 , 2 2 , ... Are fixed. Each relay circuit board is, as represented by reference numeral 2 in FIG.
It is configured by press-fitting and fixing. Junction bar 4
A tab 4a is formed at both ends or one end of the above, and a pressure contact terminal portion 4b having a slot 4c at one side edge is provided in a protruding manner.
Reference numerals 5 and 5'indicate connectors to be attached to the tab 4a, which are formed by inserting the female-female relay terminals 6 into the terminal accommodating chambers 5b in the connector housing 5a.
【０００３】各中継回路板間の電気的接続は、図１２に
示すように既知の構造の自動布線機１０により、被覆電
線７の一端をたとえば中継回路板２1 に固定したジャン
クションバーの圧接端子部４ｂ1 に圧接した後、隣接す
る中継回路板２2 に向けて配索し、中継回路板２2 上の
圧接端子部４ｂ2 に圧入し、ここで切断するか、或いは
切断せずに隣の中継回路板２3 に向けて配索する。以
下、順次この配索を繰り返すことにより、所望の中継回
路板のジャンクションバーと圧接し、前記コネクタ５、
５′と導通する回路が形成される。The electrical connection between the relay circuit boards is carried out by an automatic wiring machine 10 having a known structure, as shown in FIG. 12, by press-fitting a junction bar in which one end of the covered electric wire 7 is fixed to the relay circuit board 2 1 , for example. after pressing the terminal portion 4b 1, and routed toward the relay circuit board 2 2 adjacent, press-fitted into the press-connecting terminal portion 4b 2 on the relay circuit board 2 2, where either cut or without cutting Route it to the adjacent relay circuit board 2 3 . Thereafter, by repeating this wiring in sequence, the junction bar of the desired relay circuit board is pressure-contacted, and the connector 5,
A circuit is formed which is electrically connected to 5 '.
【０００４】配索を終了した後、図１４に示すように、
保護シート８を加熱ローラＲを用いて各中継回路板２、
２1 、２2 、…およびホットメルト系接着剤を塗布した
シート１の上に保護シート８を被せ、加熱ローラＲを用
いて配索された被覆電線７群の固定および保護を行うこ
とによりフラットワイヤハーネスを形成している。な
お、必要に応じて更に保護カバー９を取り付けることも
ある。After the wiring is completed, as shown in FIG.
The protective sheet 8 is attached to each relay circuit board 2 by using the heating roller R,
2 1 , 2 2 , ... And a sheet 1 coated with a hot-melt adhesive is covered with a protective sheet 8 and a heating roller R is used to fix and protect a group of covered electric wires 7 to be flat. Forming a wire harness. A protective cover 9 may be further attached if necessary.
【０００５】[0005]
【発明が解決しようとする課題】上述のようなフラット
ワイヤハーネスの製造方法においては、各中継回路板の
下面に配置するホットメルト系接着剤を塗布したシート
を配索治具の上に的確に配置する作業が煩雑であると共
に、得られるフラットワイヤハーネスは、各中継回路板
を保護シートとホットメルト系接着剤を塗布したシート
すなはち２枚のシートの接着で保持する構造のため、機
械的強度が不十分となる場合があり、また、自動製造工
程への適応が困難であるなどの問題点を有していた。In the method of manufacturing a flat wire harness as described above, the sheet coated with the hot melt adhesive to be placed on the lower surface of each relay circuit board is accurately placed on the routing jig. The arrangement work is complicated, and the resulting flat wire harness has a structure in which each relay circuit board is held by a protective sheet and a sheet coated with a hot-melt adhesive, that is, by holding two sheets together. There is a problem in that the mechanical strength may be insufficient and it is difficult to adapt to an automatic manufacturing process.
【０００６】本発明は、上記問題点に着目し、軽量化と
共に機械的強度が優れ、自動製造性の向上したフラット
ワイヤハーネスおよびその製造方法を提供することを課
題とする。In view of the above problems, it is an object of the present invention to provide a flat wire harness which is lightweight, has excellent mechanical strength, and has improved automatic manufacturability, and a manufacturing method thereof.
【０００７】[0007]
【課題を解決するための手段】前記の課題を達成するた
め、本発明は、内部に複数の回路導体を備えかつ少なく
とも一端に該回路導体と導通するコネクタを具備してな
る複数の中継回路板を所定の間隔で設け、該中継回路板
相互間に電線を配索して所望の回路導体に接続すること
により該コネクタと導通する回路を形成してなるフラッ
トワイヤハーネスにおいて、配索した電線相互間および
前記中継回路板の周囲に、発泡合成樹脂層を形成してな
ることを特徴とする。In order to achieve the above object, the present invention provides a plurality of relay circuit boards each having a plurality of circuit conductors therein and at least one end thereof having a connector electrically connected to the circuit conductors. In a flat wire harness in which electric wires are arranged between the relay circuit boards and connected to desired circuit conductors to form a circuit that is electrically connected to the connector, A foamed synthetic resin layer is formed between and around the relay circuit board.
【０００８】また、内部に複数の回路導体を備えかつ少
なくとも一端に該回路導体と導通するコネクタを具備し
てなる複数の中継回路板を下型の上に所定の間隔で配置
し、該中継回路板相互間に電線を配索して所望の回路導
体に接続してから該中継回路板を覆う上型を該下型に結
合した後、該下型または上型に設けた注入口から発泡材
を注入して配索した電線相互間および該中継回路板の周
囲に発泡材を充填すると共に発泡硬化させることによ
り、配索した電線相互間および前記中継回路板の周囲に
発泡合成樹脂層を形成することを特徴とする（請求項
２）。Further, a plurality of relay circuit boards each having a plurality of circuit conductors therein and at least one end of which is provided with a connector electrically connected to the circuit conductors are arranged on the lower die at predetermined intervals, and the relay circuit is provided. After connecting an electric wire between the plates and connecting it to a desired circuit conductor, an upper die for covering the relay circuit board is joined to the lower die, and then a foam material is injected from an injection port provided in the lower die or the upper die. A foamed synthetic resin layer is formed between the arranged electric wires and around the relay circuit board by filling a foam material between the electric wires injected and routed and around the relay circuit board and by foam-curing. It is characterized by (claim 2).
【０００９】[0009]
【作用】本発明によれば、配索した電線相互間および前
記中継回路板の周囲に発泡合成樹脂を充填して一体成形
することによりフラットワイヤハーネスを形成している
ので、自動製造工程に好適で、軽量化に加え機械的強度
が優れ、発泡合成樹脂の緩衝作用により配索した電線を
安定かつ確実に保持することができる。さらに、発泡合
成樹脂材の組成を選択することにより、フラットワイヤ
ハーネスの剛性あるいは柔軟性を自由に変更することが
可能となる。According to the present invention, since the flat wire harness is formed by filling the foamed synthetic resin between the arranged electric wires and around the relay circuit board and integrally molding them, it is suitable for the automatic manufacturing process. Thus, in addition to being lightweight, the mechanical strength is excellent, and the electric wires routed can be stably and reliably held by the cushioning action of the foamed synthetic resin. Furthermore, the rigidity or flexibility of the flat wire harness can be freely changed by selecting the composition of the foamed synthetic resin material.
【００１０】[0010]
【実施例】図１ないし図４は、本発明の実施例を示すフ
ラットワイヤハーネスの製造工程の説明図である。図１
において、１１と１２は一体成形用金型を構成する下型
と上型であって、この下型１１に所定の間隔で設けた中
継回路板固定用凹部１１ａの上に中継回路板Ａ1 ，
Ａ2 ，Ａ3 ，Ａ4 （以下代表して示す場合は、Ａで表
す）を配置する。そして、下型１１の中継回路板固定用
凹部１１ａの四隅に形成した係合溝部１１ｂに、中継回
路板Ａの四隅に設けた係合突起１３ｂを係合させて下型
１１に中継回路板Ａを固定する。1 to 4 are explanatory views of a manufacturing process of a flat wire harness showing an embodiment of the present invention. Figure 1
11 and 12 are a lower die and an upper die which form a die for integral molding, and a relay circuit board A 1 , a relay circuit board fixing recess 11a provided in the lower die 11 at a predetermined interval.
A 2 , A 3 , and A 4 (in the following representative case, represented by A) are arranged. Then, the engaging projections 13b provided at the four corners of the relay circuit board A are engaged with the engaging groove portions 11b formed at the four corners of the relay circuit board fixing recessed portion 11a of the lower mold 11, and the lower die 11 is connected to the relay circuit board A. To fix.
【００１１】次に、図２に示すように、中継回路板Ａ相
互間に被覆電線７の配索を行うが、そのまえに、中継回
路板Ａの構造について説明する。中継回路板Ａは、図５
の一部切欠斜視図に示すように、合成樹脂材を成形した
箱型の下部ケース１３ａと圧接用孔１３ｃを形成した板
状の上部ケース１３ｂからなるケース１３内に複数の圧
接端子１４を配設し、少なくとも一端にコネクタ１５を
備えている。そして、下部ケース１３ａの両端部には、
下型１１に固定するための係合突起１３ｄを有する発泡
材流出防止用の外壁１３ｅを設けている。Next, as shown in FIG. 2, the covered electric wires 7 are arranged between the relay circuit boards A. Before that, the structure of the relay circuit board A will be described. The relay circuit board A is shown in FIG.
As shown in the partially cutaway perspective view of FIG. 1, a plurality of pressure contact terminals 14 are arranged in a case 13 composed of a box-shaped lower case 13a molded of a synthetic resin material and a plate-shaped upper case 13b having pressure contact holes 13c. The connector 15 is provided at least at one end. Then, at both ends of the lower case 13a,
An outer wall 13e for preventing the foam material from flowing out is provided, which has an engaging projection 13d for fixing to the lower mold 11.
【００１２】中継回路板Ａの内部には、図６に示すよう
に、圧接端子１４とコネクタ１５を導通させるため、コ
ネクタ１５に収容するコネクタ端子１６と圧接端子１４
との間に電線７を接続している。圧接端子１４は、一枚
の導電性金属板をプレスまたは折曲加工により形成され
ており、基板部部１４ａ、その両端に起立連成した一対
のメイン電線圧接部１４ｂ、その一側に起立連成したサ
ブ電線圧接部１４ｃおよび他側に下向きに連成したクリ
ップ状の係止爪１４ｄとから成り、下部ケース１３の底
壁１３ｆの係止孔１３ｇに係止爪１４ｄを係合すること
により固定される。メイン電線圧接部１４ｂおよびサブ
電線圧接部１４ｃには、それぞれ電線圧入用のスロット
１４ｅ、１４ｆを形成すると共に、メイン電線圧接部１
４ｂとサブ電線圧接部１４ｃとの間に高低差を設けて、
被覆電線７を上下に交差して接続できるようにしてお
り、スロット１４ｆの底はスロット１４ｅの底よりも一
段（電線外径より大）低く形成している。Inside the relay circuit board A, as shown in FIG. 6, in order to electrically connect the pressure contact terminal 14 and the connector 15, the connector terminal 16 and the pressure contact terminal 14 accommodated in the connector 15 are accommodated.
The electric wire 7 is connected between and. The pressure contact terminal 14 is formed by pressing or bending a single conductive metal plate, and includes a board portion 14a, a pair of main wire pressure contact portions 14b standing up and down at both ends of the board portion 14a, and a standing upright one side thereof. The sub electric wire pressure contact portion 14c is formed, and the clip-shaped locking claw 14d is formed downwardly on the other side, and the locking claw 14d is engaged with the locking hole 13g of the bottom wall 13f of the lower case 13. Fixed. The main wire press contact portion 14b and the sub wire press contact portion 14c are provided with wire press fitting slots 14e and 14f, respectively, and the main wire press contact portion 1 is formed.
By providing a height difference between the 4b and the sub wire pressure contact portion 14c,
The covered electric wires 7 can be connected so as to cross each other vertically, and the bottom of the slot 14f is formed one step (larger than the outer diameter of the electric wire) lower than the bottom of the slot 14e.
【００１３】一方、コネクタ端子１６の構造は、基板部
１６ａの一端に相手端子に対する電気接触部１６ｂを設
け、他端にスロット１６ｄを有する電線圧接部１６ｃを
設けており、スロット１６ｄに被覆電線７の一端を圧入
し、被覆電線７の他端を圧接端子１４のスロット１４ｆ
に圧入することにより、圧接端子１４とコネクタ端子１
６とを電気的に接続する。なお、コネクタ端子１６の電
気接触部１６ｂをコネクタハウジング１５ａに形成した
端子収容室１５ｂに既知の手段により収容係止すること
により、圧接端子１４とコネクタ１５との電気的接続を
行っている。On the other hand, in the structure of the connector terminal 16, an electric contact portion 16b for the mating terminal is provided at one end of the substrate portion 16a, and an electric wire pressure contact portion 16c having a slot 16d is provided at the other end, and the covered electric wire 7 is provided in the slot 16d. Of the insulation wire 7 is press-fitted into the slot 14f
By press fitting into the press contact terminal 14 and the connector terminal 1
6 and 6 are electrically connected. The pressure contact terminal 14 and the connector 15 are electrically connected by accommodating and locking the electrical contact portion 16b of the connector terminal 16 in the terminal accommodating chamber 15b formed in the connector housing 15a by a known means.
【００１４】中継回路板Ａは、上述の構成を採用してい
るため、ケース内の無駄な回路導体を省略することが可
能となり、中継回路板の重量を著しく軽減できる。な
お、本発明においては、上述の構成の中継回路板Ａに限
らず、図１０に示すような、回路導体として圧接端子部
４ｂを設けたジャンクションバー４を収容した中継回路
板２を用いることもできる。Since the relay circuit board A adopts the above-mentioned structure, it is possible to omit a wasteful circuit conductor in the case, and the weight of the relay circuit board can be remarkably reduced. In addition, in the present invention, not only the relay circuit board A having the above-described configuration, but also a relay circuit board 2 containing the junction bar 4 provided with the pressure contact terminal portion 4b as the circuit conductor as shown in FIG. 10 may be used. it can.
【００１５】次に、図２に示すように、下型１１に配置
した各中継回路板Ａの前記圧接端子１４に対し、被覆電
線７を既知の自動布線機により配索して接続する（図１
２参照）。配索を行った後、図３に示すように、下型１
１の上に、上型１２を被せてネジ止め等により結合して
密封し、下型１１の一端に設けた注入口１１ｃから、ポ
リオールとイソシアネートからなる２液反応タイプのウ
レタン発泡材を注入し、配索した被覆電線７相互間およ
び各中継回路板Ａの周囲に充填し、下型１１と上型１２
の中で発泡硬化させることにより一体成形を行う。Next, as shown in FIG. 2, the covered electric wire 7 is routed and connected to the pressure contact terminal 14 of each relay circuit board A arranged in the lower die 11 by a known automatic wiring machine ( Figure 1
2). After installation, as shown in Fig. 3, lower mold 1
1 is covered with an upper mold 12 and is joined by screwing or the like to be hermetically sealed, and a two-liquid reaction type urethane foam material composed of polyol and isocyanate is injected from an injection port 11c provided at one end of the lower mold 11. , Between the arranged covered electric wires 7 and around each relay circuit board A, the lower mold 11 and the upper mold 12 are filled.
Integral molding is performed by foaming and curing in
【００１６】発泡材の発泡硬化が終了した後、上型１２
を下型１１から分離して、図４に示すような、フラット
ワイヤハーネス１７を取り出す。図７は、図４に示すフ
ラットワイヤハーネス１７のＸ−Ｘ線断面図であり、発
泡材の発泡硬化により形成した発泡合成樹脂層１８が、
配索した被覆電線７相互間および中継回路板Ａの周囲に
形成されている状態を示している。After the foaming and curing of the foam material is completed, the upper mold 12
Is separated from the lower mold 11, and the flat wire harness 17 as shown in FIG. 4 is taken out. FIG. 7 is a cross-sectional view taken along line XX of the flat wire harness 17 shown in FIG. 4, in which the foam synthetic resin layer 18 formed by foam hardening of the foam material is
It shows a state in which they are formed between the covered electric wires 7 arranged and around the relay circuit board A.
【００１７】フラットワイヤハーネス１７の各中継回路
板Ａ相互間は、発泡合成樹脂層１８と配索した被覆電線
７で形成されているため、フラットワイヤハーネス１７
の機械的性能は、発泡合成樹脂層１８の特性により大き
く影響を受ける。従って、フラットワイヤハーネス１７
に剛性を持たせたい場合は、硬質系の発泡材を用い、柔
軟性を持たせたい場合は、半硬質系の発泡材を使用する
ことが好ましい。Since the relay circuit boards A of the flat wire harness 17 are formed by the foamed synthetic resin layer 18 and the covered electric wire 7 routed, the flat wire harness 17 is formed.
The mechanical performance of is greatly affected by the characteristics of the foamed synthetic resin layer 18. Therefore, the flat wire harness 17
When it is desired to have rigidity, a hard foam material is preferably used, and when it is desired to have flexibility, a semi-rigid foam material is preferably used.
【００１８】図８は、本発明の他の実施例を示す説明図
であり、一体成形用の下型１９の中継回路板固定用凹部
１９ａに外装部品装着用の凹陥部１９ｃを設けている。
この凹陥部１９ｃに、外装部品として図９に示す斜視図
のようなクランプ２０を配置し、その上に中継回路板Ａ
を載せ、下型の係合溝部１９ｂに中継回路板Ａの係合突
起１３ｂを係合させて下型１９に中継回路板Ａを固定す
る。なお、クランプ２０は、フラットワイヤハーネスを
外部構造体に係合するための外装部品であり、基板部２
０ａと外板部２０ｂを隔離して間隙部２０ｃを設けると
共に、基板部２０ａの略中央から外板部２０ｂを貫通し
て外板部２０ｂに略並行する方向に屈曲した係止突起２
０ｄを備えており、基板部２０ａを中継回路板Ａに当接
させ、基板部２０ａと外板部２０ｂの周囲および間隙部
２０ｃに、発泡材を充填して発泡硬化させ、中継回路板
Ａに固着するようにしている。FIG. 8 is an explanatory view showing another embodiment of the present invention, in which a concave portion 19c for mounting an exterior component is provided in a concave portion 19a for fixing a relay circuit board of a lower mold 19 for integral molding.
A clamp 20 as shown in the perspective view of FIG. 9 is arranged as an exterior component in the recess 19c, and the relay circuit board A is placed on the clamp 20.
Then, the engaging projection 13b of the relay circuit board A is engaged with the engaging groove portion 19b of the lower die to fix the relay circuit board A to the lower die 19. The clamp 20 is an exterior component for engaging the flat wire harness with an external structure, and includes the board portion 2
0a and the outer plate portion 20b are separated from each other to provide a gap portion 20c, and the locking protrusion 2 is bent in a direction substantially parallel to the outer plate portion 20b through the outer plate portion 20b from substantially the center of the substrate portion 20a.
0d, the board portion 20a is brought into contact with the relay circuit board A, and the periphery of the board portion 20a and the outer plate portion 20b and the gap portion 20c are filled with a foam material to foam and harden the relay circuit board A. I'm trying to stick.
【００１９】下型１９に中継回路板Ａを固定した後、前
記図２ないし図４に示す工程と同様に、被覆電線の配
索、上型の結合、発泡材の注入、発泡硬化の工程を経
て、図１０に示すようなフラットワイヤハーネス２１を
形成する。図１１は、図１０のＹ−Ｙ線断面図であり、
配索した被覆電線７相互間に発泡合成樹脂層１８が形成
され、中継回路板Ａの外底部１３ｇに当接したクランプ
の基板部２０ａと外板部２０ｂの周囲および間隙部２０
ｃにも発泡合成樹脂層１８が形成されて、クランプ２０
がフラットワイヤハーネス２１に固着された状態を示し
ている。After fixing the relay circuit board A to the lower die 19, the steps of arranging the covered electric wire, joining the upper die, injecting the foam material, and foaming and curing are carried out in the same manner as the steps shown in FIGS. 2 to 4. Then, the flat wire harness 21 as shown in FIG. 10 is formed. 11 is a sectional view taken along line YY of FIG.
A foamed synthetic resin layer 18 is formed between the arranged covered electric wires 7 and surrounds the gap between the base plate portion 20a and the outer plate portion 20b of the clamp, which is in contact with the outer bottom portion 13g of the relay circuit board A, and the gap portion 20.
The foam synthetic resin layer 18 is also formed on the c, and the clamp 20
Shows the state of being fixed to the flat wire harness 21.
【００２０】上述のように、外部構造体に取り付けるた
めのクランプ２０のような外装部品を、フラットワイヤ
ハーネスを形成すると同時に一体成形により装着するこ
とができ、工程の短縮による生産性が著しく向上する。As described above, the exterior parts such as the clamp 20 for attaching to the external structure can be mounted by the integral molding at the same time when the flat wire harness is formed, and the productivity is remarkably improved by shortening the process. ..
【００２１】[0021]
【発明の効果】以上説明したように、本発明によれば、
発泡材を用いて一体成形することによりフラットワイヤ
ハーネスを形成しているため、自動製造工程に容易に適
合し、また、得られるフラットワイヤハーネスは軽量化
に加え機械的強度が優れ、発泡合成樹脂層の緩衝作用に
より配索した電線を安定かつ確実に保持することができ
ると共に、発泡合成樹脂層材の組成を選択することによ
り、フラットワイヤハーネスの剛性あるいは柔軟性を自
由に変更することが可能となるため外部構造体に対する
取り付けが簡単となり、さらに、外装部品を、フラット
ワイヤハーネスを形成すると同時に装着することができ
るので、工程の短縮により生産性が著しく向上するなど
の利点を有する。As described above, according to the present invention,
Since the flat wire harness is formed by integrally molding using a foam material, it can be easily adapted to the automatic manufacturing process, and the resulting flat wire harness has excellent mechanical strength in addition to weight reduction, and is made of foam synthetic resin. It is possible to stably and reliably hold the wired wires due to the buffering effect of the layers, and it is possible to freely change the rigidity or flexibility of the flat wire harness by selecting the composition of the foam synthetic resin layer material. As a result, the attachment to the external structure is simplified, and since the exterior component can be attached at the same time when the flat wire harness is formed, there is an advantage that productivity is significantly improved by shortening the process.
【図面の簡単な説明】[Brief description of drawings]
【図１】本発明の実施例を示すフラットワイヤハーネス
の製造工程の説明図である。FIG. 1 is an explanatory view of a manufacturing process of a flat wire harness showing an embodiment of the present invention.
【図２】図１の次の工程の説明図である。FIG. 2 is an explanatory diagram of a step subsequent to that in FIG.
【図３】図２の次の工程の説明図である。FIG. 3 is an explanatory diagram of the next step of FIG. 2.
【図４】図３の次の工程の説明図である。FIG. 4 is an explanatory diagram of a step subsequent to that of FIG.
【図５】図１の中継回路板の一部切欠斜視図である。5 is a partially cutaway perspective view of the relay circuit board of FIG. 1. FIG.
【図６】図５の内部構造を示す説明図である。6 is an explanatory diagram showing an internal structure of FIG. 5. FIG.
【図７】図４のＸ−Ｘ線断面図である。7 is a cross-sectional view taken along line XX of FIG.
【図８】本発明の他の実施例についてのフラットワイヤ
ハーネスの製造工程の説明図である。FIG. 8 is an explanatory diagram of a manufacturing process of a flat wire harness according to another embodiment of the present invention.
【図９】図８のクランプを示す斜視図である。9 is a perspective view showing the clamp of FIG. 8. FIG.
【図１０】図８の製造工程で得られたフラットワイヤハ
ーネスの斜視図である。10 is a perspective view of the flat wire harness obtained in the manufacturing process of FIG.
【図１１】図１０のＹ−Ｙ線断面図である。11 is a cross-sectional view taken along the line YY of FIG.
【図１２】従来のフラットワイヤハーネスの説明図であ
る。FIG. 12 is an explanatory diagram of a conventional flat wire harness.
【図１３】図１２の中継回路板の分解斜視図である。13 is an exploded perspective view of the relay circuit board of FIG.
【図１４】図１２のフラットワイヤハーネスの保護シー
トの被覆方法の説明図である。FIG. 14 is an explanatory diagram of a method for covering the protective sheet of the flat wire harness of FIG.
Ａ 中継回路板 ２ 中継回路板 ７ 被覆電線 １１ 下型 １１ｃ 注入口 １２ 上型 １５ コネクタ １６ コネクタ端子 １７ フラットワイヤハーネス １８ 発泡合成樹脂層 ２０ クランプ ２１ フラットワイヤハーネス A Relay circuit board 2 Relay circuit board 7 Covered wire 11 Lower mold 11c Injection port 12 Upper mold 15 Connector 16 Connector terminal 17 Flat wire harness 18 Foam synthetic resin layer 20 Clamp 21 Flat wire harness
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.5 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｈ０１Ｒ 9/09 Ｚ 6901−5Ｅ 23/02 Ｂ 6901−5Ｅ ─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. 5 Identification code Office reference number FI technical display location H01R 9/09 Z 6901-5E 23/02 B 6901-5E
Claims (2)
とも一端に該回路導体と導通するコネクタを具備してな
る複数の中継回路板を所定の間隔で設け、該中継回路板
相互間に電線を配索して所望の回路導体に接続すること
により該コネクタと導通する回路を形成してなるフラッ
トワイヤハーネスにおいて、 配索した電線相互間および前記中継回路板の周囲に、発
泡合成樹脂層を形成してなることを特徴とするフラット
ワイヤハーネス。1. A plurality of relay circuit boards each having a plurality of circuit conductors inside and at least one end of which is provided with a connector electrically connected to the circuit conductors are provided at predetermined intervals, and electric wires are provided between the relay circuit boards. In a flat wire harness formed by arranging and connecting to a desired circuit conductor to form a circuit electrically connected to the connector, a foamed synthetic resin layer is formed between the arranged electric wires and around the relay circuit board. A flat wire harness that is characterized by
とも一端に該回路導体と導通するコネクタを具備してな
る複数の中継回路板を下型の上に所定の間隔で配置し、
該中継回路板相互間に電線を配索して所望の回路導体に
接続してから該中継回路板を覆う上型を該下型に結合し
た後、該下型または上型に設けた注入口から発泡材を注
入して配索した電線相互間および該中継回路板の周囲に
発泡材を充填すると共に発泡硬化させることにより、配
索した電線相互間および前記中継回路板の周囲に発泡合
成樹脂層を形成することを特徴とするフラットワイヤハ
ーネスの製造方法。2. A plurality of relay circuit boards, each having a plurality of circuit conductors therein and at least one end of which is provided with a connector electrically connected to the circuit conductors, are arranged at predetermined intervals on a lower die,
An electric wire is routed between the relay circuit boards and connected to a desired circuit conductor, and then an upper die for covering the relay circuit board is joined to the lower die, and then an injection port provided in the lower die or the upper die. The foamed synthetic resin is filled between the wires arranged and the circumference of the relay circuit board by filling the foam material between the wires arranged by injecting the foam material from the wire and around the relay circuit board, and by foaming and hardening the foam material. A method for manufacturing a flat wire harness, which comprises forming a layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3277839A JPH05114310A (en) | 1991-10-24 | 1991-10-24 | Flat wire harness and its manufacture |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3277839A JPH05114310A (en) | 1991-10-24 | 1991-10-24 | Flat wire harness and its manufacture |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH05114310A true JPH05114310A (en) | 1993-05-07 |
Family
ID=17588986
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP3277839A Withdrawn JPH05114310A (en) | 1991-10-24 | 1991-10-24 | Flat wire harness and its manufacture |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH05114310A (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05250921A (en) * | 1992-03-04 | 1993-09-28 | Yazaki Corp | Flat wire harness and its manufacture |
| WO1999005757A1 (en) * | 1997-07-22 | 1999-02-04 | Ut Automotive Dearborn, Inc. | Foamed-in wire harnesses |
| EP1096134A2 (en) * | 1999-10-29 | 2001-05-02 | Siemens Canada Limited | Wiring harness assembly for an intake manifold |
| EP1120562A3 (en) * | 2000-01-28 | 2002-03-27 | Siemens Canada Limited | A foamed over integrated circuit for intake manifold |
| JP2014088165A (en) * | 2012-10-03 | 2014-05-15 | Yazaki Corp | Wire harness assembling structure |
-
1991
- 1991-10-24 JP JP3277839A patent/JPH05114310A/en not_active Withdrawn
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05250921A (en) * | 1992-03-04 | 1993-09-28 | Yazaki Corp | Flat wire harness and its manufacture |
| WO1999005757A1 (en) * | 1997-07-22 | 1999-02-04 | Ut Automotive Dearborn, Inc. | Foamed-in wire harnesses |
| US6069319A (en) * | 1997-07-22 | 2000-05-30 | Lear Automotive Dearborn, Inc. | Foamed-in harnesses |
| EP1096134A2 (en) * | 1999-10-29 | 2001-05-02 | Siemens Canada Limited | Wiring harness assembly for an intake manifold |
| EP1096134A3 (en) * | 1999-10-29 | 2002-04-03 | Siemens Canada Limited | Wiring harness assembly for an intake manifold |
| US6494174B1 (en) | 1999-10-29 | 2002-12-17 | Siemens Vdo Automotive Inc. | Wiring harness assembly for an intake manifold |
| EP1120562A3 (en) * | 2000-01-28 | 2002-03-27 | Siemens Canada Limited | A foamed over integrated circuit for intake manifold |
| US6502547B2 (en) | 2000-01-28 | 2003-01-07 | Siemens Vdo Automotive Inc. | Foamed over integrated circuit for intake manifold |
| JP2014088165A (en) * | 2012-10-03 | 2014-05-15 | Yazaki Corp | Wire harness assembling structure |
| US10023134B2 (en) | 2012-10-03 | 2018-07-17 | Yazaki Corporation | Wiring harness attaching structure |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| A300 | Withdrawal of application because of no request for examination |
Free format text: JAPANESE INTERMEDIATE CODE: A300 Effective date: 19990107 |