JPH07156725A - Wire harness for door and its manufacture - Google Patents

Abstract

PURPOSE:To improve the workability by eliminating the assembly of parts through a working hole, the positioning of a connector, the inserting work of a water-proof grommet, and the attaching work of a water-proof sheet. CONSTITUTION:A printing circuit body 45 is constituted by printing the circuit pattern 49 on a base resin plate. The printing circuit body 45 is adhered to an inner panel 35 which is formed separately from a door frame body 31 to realize the integration. A wire harness 79 for a door which is assembled by mounting the electric equipment 71 on the printing circuit body 45 is mounted on the door frame body 31.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wire harness for an automobile door and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in an automobile wiring system, a plurality of branch lines are led out from a main line portion in which a large number of electric wires are bundled to form a wire harness, and the wire harness is routed in a vehicle body space, It was connected to various electrical components via a connector provided in the section. However, in such an electric wire focusing type wire harness, there has been a problem that the diameter of the main line portion increases as the number of electrical components increases, and wiring becomes difficult.

Then, as a solution to this problem,
A wire harness provided in a flat shape on a resin plate integrated with a vehicle frame, for example, as described in JP-A-63-46945 will be described with reference to FIGS. 15 and 16. Figure 1
5 is a perspective view of a conventional wire harness for a door, and FIG. 16 is an explanatory diagram when a waterproof sheet is attached. Working holes 7 are formed in the resin plate 3 that can be integrally attached to the inner surface of the door frame body 1, and the working holes 7 are aligned with the working holes 9 of the door frame body 1. . The conductors of the wire harness 11 are arranged in parallel and are arranged in a flat shape on the vehicle-inside surface of the resin plate 3, and the wire harness 11 has a connecting plate portion 13 at the edge of the working hole 7 whose end portion is a projecting piece. Has become.

On the other hand, inside the door frame body 1, a main harness 15 for the door from the vehicle body is provided with a waterproof grommet 17.
An electric component 19 such as a power window motor and a solenoid for an automatic door lock is fixed through the work hole 9 while being inserted therethrough. A connector 21 connected to the end of the door main harness 15 and a connector connected to the electrical component 19 are fixed to the edge of the work hole 9 of the door frame body 1 by screwing or the like. Therefore, when the connection plate portion 13 of the wire harness 11 is connected to the corresponding connector 21 and the like and the resin plate 3 is fixed to the door frame body 1, the assembly of the door wire harness is completed. A waterproof sheet 23 (see FIG. 16) is stretched on the surface of the door frame body 1 on the inside of the vehicle to prevent water from entering the inside of the vehicle. According to the above-mentioned door wire harness, the manufacturing can be easily automated, and the wiring work of the wire harness in the vehicle assembly line can be omitted, so that the workability can be significantly improved.

[0005]

However, in the conventional wire harness for doors in which the circuit is provided on the resin plate,
Although the wiring work of the wire harness in the vehicle assembly line can be omitted, the assembly of the electrical component 19 such as the power window motor has to be performed on the back side of the door panel through the working holes 7 and 9 as in the conventional case, and the workability is improved. It was bad. Further, in order to fix the resin plate 3 to the door frame body 1, the connection plate portion 13 has to be connected to the corresponding connector 21 or the like, and the alignment at this time is often difficult. Furthermore, the main harness for doors 15
Must still be inserted through the waterproof grommet 17, resulting in a reduction in workability. Also, as a work separate from the assembly of the wire harness,
It also had to be accompanied by a troublesome work of attaching a waterproof sheet 23 for preventing water intrusion. The present invention has been made in view of the above situation, and there is no need to assemble electrical components through the working holes, and connector alignment is not necessary, and there is also no work to insert a waterproof grommet, and moreover, a waterproof sheet. (EN) Provided is a door wire harness that can eliminate the need for pasting work and a method for manufacturing the same, and an object thereof is to improve the workability of assembling.

[0006]

To achieve the above object, a door wire harness according to the present invention has a structure in which a printed circuit body is formed by printing a circuit pattern on a base resin plate and separated from a door frame body. This printed circuit body is adhered to and integrated with the inner panel thus formed, and the electrical component is mounted on this printed circuit body. In this wire harness for doors, the printed circuit body is placed on the inner panel set in the vacuum forming mold, and after heating and softening the printed circuit body, the air between the printed circuit body and the inner panel is sucked. It can be manufactured by vacuum forming the printed circuit body into the same three-dimensional shape as the surface of the inner panel, and by adhering and integrally forming the printed circuit body and the inner panel. Then, the automobile door is assembled by fixing the door wire harness to the door frame body and simultaneously attaching the electric components and the sub wire harness to the door. Further, the waterproof structure of a vehicle door is to seal an inner panel between the vehicle exterior side and the vehicle interior side by attaching an inner panel to which a printed circuit body is adhered to a door frame body. Further, in the method for manufacturing a wire harness for a door, a hole for inserting a connector pin to be connected to a circuit pattern is formed on a circuit pattern of a printed circuit body, the connector is fixed to the printed circuit body, and the pin is inserted into this hole. Alternatively, the printed circuit body may be dipped in an electroless plating bath to deposit copper on the circuit pattern to connect the circuit pattern and the connector pin. In addition, the connection structure of the wire harness for the door is formed by forming a notch in which the housing of the connector is accommodated on the side end surface on the hinge side of the door frame body, and mounting the connector on a printed circuit body integrally molded with the inner panel. The inner panel is fixed to the door frame body at the same time when the connector is arranged in the notch, and the door main harness from the vehicle body side is connected to the printed circuit body via this connector.

[0007]

[Function] A printed circuit body is integrally molded on the inner panel,
Furthermore, by mounting the electrical components, the inner panel, the wire harness, and the electrical components become one single member. By heating and softening, the printed circuit body is vacuum formed in the same manner as the inner panel surface, so that the wire harness can be easily and precisely attached to the complicated inner panel surface. The wire harness for the door is fixed to the door frame body, and the electrical components and the wire harness are attached at once by only attaching the single member. There is no work. When the inner panel to which the printed circuit body is adhered is attached to the door frame body, the base resin plate of the printed circuit body acts as a waterproof sheet, and the outer side and the inner side of the inner panel are sealed. Further, the circuit pattern and the connector pin are connected by electroless plating, so that a large number of small connection parts can be surely and simultaneously connected.
Further, the connector mounted on the printed circuit body is arranged in the notch of the door frame body and can be directly connected to the door main harness, so that it is not necessary to connect the door main harness through the door frame body.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment of a door wire harness and a method for manufacturing the same according to the present invention will be described below in detail with reference to the drawings. FIG. 1 is an explanatory view when assembling a door wire harness of the present invention, FIG. 2 is a perspective view of an inner panel, and FIG. 3 is a perspective view of a printed circuit body. As shown in FIG. 1, an inner panel 35 is sandwiched between the door frame body 31 and a door trim 33 which is an interior member. As shown in FIG. 2, the door frame body 31 and the inner panel 35 are configured separately, and the inner panel 35 is made of the same material as the door frame body 31. A door lock portion 37 is provided on the inner panel 35, a door lock recess 39 corresponding thereto is formed on the door frame body 31 side, and a notch 41 for arranging a connector is formed. Further, the inner panel 35 is formed with a plurality of holes 43 corresponding to the irregularities required for mounting and assembling electrical components.

A printed circuit body 45 shown in FIG. 3 is processed into a three-dimensional shape on the inner surface of the inner panel 35.
And it is attached by integral molding. The printed circuit body 45 is A
A circuit pattern 49 is formed on a thermoplastic resin plate (base resin plate) 47 such as BS using a conductive resin such as low temperature drying type Ag paste. A hot melt adhesive is applied to the back surface of the base resin plate 47 so as to correspond to the contact surface with the inner panel 35.

Here, the manufacture of the inner panel 35 and the printed circuit body 45 will be described. FIG. 4 is a schematic view of a vacuum forming machine. A vacuum forming die 53 is provided on the base 51a of the vacuum forming machine 51, and the inner panel 35 is set on the upper surface of the vacuum forming die 53. On the upper surface of the vacuum forming die 53, an uneven surface that matches the inner panel 35 is formed. An intake pipe 55 is opened on the upper surface of the vacuum forming die 53 corresponding to the holes 43 of the inner panel 35, and the intake pipe 55 is connected to a vacuum pump (not shown). An infrared heater 57 is provided above the vacuum forming die 53, and the infrared heater 57 heats the printed circuit body 45 mounted on the inner panel 35 on the vacuum forming die 53.

Next, a procedure for manufacturing a door wire harness using the above vacuum forming machine 51 will be described. 5 is an explanatory diagram when the inner panel is set, FIG. 6 is an explanatory diagram when the printed circuit body is heated and softened, and FIG. 7 is an explanatory diagram when a vacuum drawing operation is performed.
FIG. 9 is an explanatory diagram when the mold is released, FIG. 9 is an explanatory diagram when the circuit body is trimmed, and FIG. First, the inner panel 35 is set on the vacuum molding die 53 (see FIG. 5), the printed circuit body 45 is placed thereon, and the printed circuit body 45 is heated and softened by the infrared heater 57 (see FIG. 6). The printed circuit body 45 is in a softened state.
Air between the inner panel 35 and the inner panel 35 is sucked from the suction pipe 55, and the printed circuit body 45 is vacuum-formed into a three-dimensional shape (see FIG. 7). At this time, the printed circuit body 45 is bonded to the inner panel 35 with a hot melt adhesive to be integrally molded.

After the inner panel 35 integrally formed with the printed circuit body 45 is removed from the vacuum forming die 53 (see FIG. 8), trimming is performed into a predetermined shape (see FIG. 9). The thus-formed molded product is subjected to drilling, a connector 59 (see FIG. 10) is attached, and electroless plating is performed.
Here, a method of connecting the connector 59 by electroless plating will be described. FIG. 11 is a sectional view of the connector connection structure. A connector 59 is attached to a multi-pole portion (for example, a main connector or a S / W connector) that connects the wire harness and the electric component, and the housing 5 of the connector 59 is attached.
From 9a, a round pin 61 bent perpendicularly to the connecting surface is provided. The connector 59 inserts the round pin 61 into the hole 63 on the circuit pattern 49, and at the same time, inserts the inner panel 3
It is fixed to the printed circuit body 45 integrally formed with the printed circuit board 5. By immersing in this state in a copper electroless plating bath, copper is deposited on the circuit pattern 49, and the circuit pattern 49 and the round pin 61 are connected by the electroless plating layer. By dipping and energizing this electroless plating layer in an electrolytic plating bath, a thick electrolytic plating layer can be deposited on the electroless plating layer, which forms a circuit pattern with a large current capacity. be able to.

FIG. 12 is a perspective view of another connector connection structure. The connection between the wire harness and the electrical components can be made by another connection structure. For example, it is conceivable that a rectangular column-shaped projection 63 is provided on the printed circuit body 45, the circuit pattern 49 itself is formed on the surface of the projection 63, and a card edge type surface contact 65 is connected thereto. Such a connection structure is used for a connector having a relatively small pole, for example, P / W.
It is suitable for use in motors, speakers, etc. By connecting the connector 59 and the like to the printed circuit body 45 as described above, the wire harness board 67 (see FIG. 10) is completed. As described above, the wire harness substrate 67 configured in this manner is in a state in which the entire surface of the inner panel 35 is closely covered with the base resin plate 47, and the base resin plate 47 functions like a waterproof sheet. It will also play a role.

FIG. 13 is a perspective view before the door wire harness is attached, and FIG. 14 is a perspective view of the door frame body to which the door wire harness is attached. On the wire harness board 67 manufactured as described above, P /
W motor 69 (see FIG. 1), D / L motor, speaker 7
The electrical components such as 1 and the sub wire harness are simultaneously attached, and components such as the window glass 73, the door inner handle, and the connector protection plate 75 are mounted. More specifically, the electrical components other than the door mirror 77 are directly connected to the wire harness board 67 without the sub wire harness. On the wire harness board 67, the P / W motor 69,
A door wire harness 7 in which electrical components such as a speaker 71 and components such as a windshield 73 are mounted and modularized.
9 are configured.

The wire harness 79 for a door having such a structure is provided with a packing material such as butyl rubber on the back edge of the inner panel 35 and the back of the connector protection plate 75, and is assembled to the door frame body 31 (see FIG. 14). ). After the door wire harness 79 is assembled, the door mirror connector 81 is connected, the door S / W 83 (see FIG. 1) is connected to the connector, and at the same time, the door trim 33 (see FIG. 1) is assembled to complete the door assembly. . Then, the connector 5 of the door wire harness 79
By connecting the main harness 15 for door (see FIG. 15) to 9, the wiring connection with the vehicle body side is completed.

The door wire harness 79 described above is
Originally, the improvement of the assembling property which is the object of the present invention, since it is possible to manufacture with an inexpensive mold, the design can be easily changed,
Moreover, by changing the circuit pattern, it is possible to easily deal with the grade. Also, because the circuit has a three-dimensional shape,
It also has the advantage that the degree of freedom of the installation space is extremely high.

[0017]

As described in detail above, according to the present invention, the inner panel, the wire harness, and the electrical components can be made into one single member. Further, since the printed circuit body and the inner panel are integrated by vacuum forming, it is possible to attach the wire harness to the complicated inner panel surface easily and precisely, and it is possible to enhance the productivity of the door wire harness. And, in such an assembling method for fixing the wire harness for the door to the door frame main body, it is possible to install the electrical components and the wire harness at one time, the distributed work is eliminated, and the door assembling workability in the mass production line is significantly improved. You can
Further, since the inner panel to which the printed circuit body is adhered is attached to the door frame body, the base resin plate of the printed circuit body serves as a waterproof sheet, and the inner panel can be waterproof-sealed without any separate member or operation. . Furthermore, since the circuit pattern and the connector pin are connected by electroless plating, a large number of small connection portions can be connected reliably and simultaneously, and the workability of mounting the connector can be improved. Further, since the connector is mounted on the printed circuit body and is arranged in the notch of the door frame body, it can be directly connected to the main harness for the door, the conventional work of penetrating the grommet is eliminated, and the workability can be remarkably improved.

[Brief description of drawings]

FIG. 1 is an explanatory view of when assembling a door wire harness of the present invention.

FIG. 2 is a perspective view of an inner panel of the door wire harness shown in FIG.

FIG. 3 is a perspective view of a printed circuit body integrated with the inner panel of FIG.

FIG. 4 is a schematic view of a vacuum forming machine applied to the manufacturing method of the present invention.

FIG. 5 is an explanatory diagram when an inner panel is set.

FIG. 6 is an explanatory diagram when the printed circuit body is heated and softened.

FIG. 7 is an explanatory diagram during vacuuming work.

FIG. 8 is an explanatory diagram when the mold is released.

FIG. 9 is an explanatory diagram when trimming a circuit body.

FIG. 10 is an explanatory diagram when a connector is set.

FIG. 11 is a cross-sectional view of a connector connection structure.

FIG. 12 is a perspective view of another connector connection structure.

FIG. 13 is a perspective view before attaching the door wire harness.

FIG. 14 is a perspective view of a door frame body in which a wire harness is assembled.

FIG. 15 is a perspective view of a conventional door wire harness.

FIG. 16 is an explanatory diagram when a conventional waterproof sheet is attached.

[Explanation of symbols]

 31 Door Frame Main Body 35 Inner Panel 41 Notch 45 Printed Circuit Board 47 Base Resin Plate 49 Circuit Pattern 53 Vacuum Forming Mold 57 Infrared Heater 59 Connector 59a Housing 61 Connector Pin 63 Hole 67 Wire Harness Board 71 Speaker (Electrical Equipment) 79 Door Wire Harness

Claims (6)

[Claims] 1. A printed circuit body is formed by printing a circuit pattern on a base resin plate, and the printed circuit body is adhered to and integrated with an inner panel formed separately from a door frame body, and an electrical component is printed by the printed circuit board. A wire harness for doors that is mounted on a circuit body. 2. A printed circuit body is placed on an inner panel set in a vacuum forming die, the printed circuit body is heated and softened, and then air between the printed circuit body and the inner panel is sucked. A method of manufacturing a wire harness for a door, characterized in that the printed circuit body is vacuum-formed into the same three-dimensional shape as the inner panel surface, and the printed circuit body and the inner panel are bonded and integrally formed. 3. A method for assembling an automobile door, comprising fixing the door wire harness according to claim 1 to a door frame main body, and simultaneously attaching electric components and a sub wire harness to the door. 4. A waterproof structure for an automobile door, characterized in that an inner panel to which a printed circuit body is adhered is attached to a door frame main body to seal between the outer side and the inner side of the inner panel. 5. An insertion hole for a connector pin connected to the circuit pattern is formed on the circuit pattern of the printed circuit body,
By fixing the connector to the printed circuit body and inserting the pin into the hole, and immersing the printed circuit body in an electroless plating bath, copper is deposited on the circuit pattern to form the circuit pattern and the connector pin. A method for manufacturing a wire harness for a door, characterized in that: 6. A notch for accommodating a housing of a connector is formed on a side end surface of a door frame main body on a hinge side, the connector is mounted on a printed circuit body integrally molded with an inner panel, and the connector is formed in the notch. A connection structure for a wire harness for a door, characterized in that the inner panel is fixed to the door frame body at the same time as the arrangement, and a door main harness from the vehicle body side is connected to the printed circuit body via the connector.