JPH07222323A - Splicing for wire harness - Google Patents

Abstract

PURPOSE:To facilitate waterproofing at the spliced parts between the cores of wires and between the core of a wire and an earth terminal. CONSTITUTION:Insulation coatings 11b-13b of wires 11-13 are stripped to expose the cores 11a-13a thereof and then a wire 12, requiring waterproofing, is applied with a waterproof coating 15 over the core and the insulation coating thereof. Cores of respective wires are then brought into contact through a coating layer 15a and the contact part A is irradiated with ultrasonic wave thus removing the coating layer and jointing the cores by welding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for splicing a wire harness, and more particularly, a method for splicing a wire harness in which splice points between core wires of an electric wire or splice points between a core wire of an electric wire and a ground terminal can be easily waterproofed. It is about.

[0002]

2. Description of the Related Art In an automobile wire harness W / H, as shown in FIG. 7, the insulation coatings of the wires 1 to 4 connected to each other are peeled off to expose the core wires 1a to 4a, and the exposed core wires 1a to 1a. There is a case where the splice terminals 5 and 5 are pressure-bonded to each other and joined together. The splices (joints) S1,
S2 must be molded with a synthetic resin for insulation and waterproofing.

For this reason, as shown in FIG. 8, the splice S1 or S2 of the wire harness W / H is set in the mold 6, and the thermoplastic synthetic resin 8 is injected from the injection nozzle 7 into the mold 6. After being cooled and solidified, it is taken out from the mold 6 as shown in FIG.
(See JP-A-64-63073)

[0004]

However, in the above-described molding method, a dedicated mold 6 is required for each size and branch shape of the electric wires 1 to 4 of the wire harness W / H, and the equipment cost is high. The work efficiency of the mold is also poor. In the butyl pad method in which the splices S1 and S2 are wound with a rubber material, the splices S1 and S2 are enlarged and the weight is increased. (See Japanese Patent Publication No. 59-35510) Furthermore, the tube method of contracting a heat-shrinkable tube at the splice point is not practical because the operation of passing the tube through the electric wire 1 is difficult.

Each of the above methods is common in that the entire splice portion is covered with an insulating / waterproof material. However, when the wire harness W / H is actually assembled in an automobile, even the complete waterproofing treatment as described above is required. However, since there are many splice points that can be practically used even with simple waterproofing, the waterproofing is excessive. For example, as shown in FIG. 10, even if only the electric wire 2 requires waterproofing, only the electric wire 2 cannot be waterproofed, and the splice S1
The whole will be molded with synthetic resin 8 and waterproofed.

On the other hand, as shown in FIG. 11, in the ground terminal 9 of the wire harness W / H, the core wire 10a exposed by peeling off the insulating coating of the electric wire 10 is caulked by the crimping portion 9a and crimped. The ground terminal 9 is fixed to the body of the automobile with a bolt.

However, in the above crimping method, since the core wire 10a at one end of the electric wire 10 is exposed, when the other end of the electric wire 10 is connected to the waterproof connector in the engine room, the engine is not operated in the engine room. The temperature rises during the operation of, and the temperature falls when the engine room is stopped. The air in the waterproof connector expands when the temperature rises, passes through the gap between the insulating coating of the electric wire 10 and each core wire, and the gap between the core wires from the other end in the connector, and from the core wire 10a at one end to the outside. Is discharged to the
Negative pressure is generated in the connector, and rainwater, etc., from one end
Water may be absorbed into the connector from the other end through the gap between the insulation coating of 0 and each core wire and the gap between the core wires. Due to this water absorption, the connection part inside the connector leaks, causing malfunction and corrosion due to water.

Therefore, the core wire 10a of the electric wire 10 may be soldered (dub solder), but it is necessary to immerse the core wire 10a together with the ground terminal 9 in a solder bath at about 270 ° C. There is a problem that the coating melts. In addition, conductive paint, conductive rubber,
Crimping portion 9 of ground terminal 9 made of conductive hot melt or the like
There is also a method of waterproofing a, but in this method, there is a risk that a conductive material adheres to the grounding terminal 9 and the resistance of the contact portion with the body or the like increases to generate heat.

The present invention has been made to solve the above problems, and provides a wire harness splicing method capable of easily waterproofing a splice portion between core wires of an electric wire or a splice portion between an electric wire core wire and an earth terminal. The purpose is to do.

[0010]

In order to achieve the above object, the first aspect of the present invention provides an electric wire which requires waterproofing after the insulation coating of the electric wires to be connected to each other is peeled off to expose the core wire. Coating the waterproof coating liquid material across the core wire and the insulation coating, contacting the core wires of each electric wire through the coating layer and applying ultrasonic waves, and removing the coating layer at the contact portion to separate the core wires from each other. The present invention provides a method for splicing a wire harness, which is characterized by welding and joining.

According to a second aspect of the present invention, the insulation coating of the electric wire connected to the ground terminal is peeled off to expose the core wire, and then the waterproof coating liquid material is coated over the core wire and the insulation coating of the electric wire. A method of splicing a wire harness, wherein the core wire of the electric wire is brought into contact with a ground terminal through a coating layer, ultrasonic waves are applied, the coating layer at the contact portion is removed, and the core wire is welded to the ground terminal. Is provided.

[0012]

According to claim 1 of the present invention, among the electric wires in which the insulation coating is stripped to expose the core wires, the wires are waterproof by dipping or the like across the core wires and the insulation coating of the wires that require waterproofing. Coat the dressing. Then, ultrasonic waves are applied in a state where the core wires of the respective electric wires are in contact with each other via the coating layer, and the coating layer at the contact portion is burned and destroyed, so that the core wires are welded and joined. At this time, the coating layer between the root of the core of the electric wire and the insulating coating remains without being destroyed by combustion, so that only this portion is waterproofed by the coating layer.

As a result, only the electric wires which require waterproofing can be easily waterproofed. In addition, the conventional mold type is not required, so the equipment cost is low and
The workability of waterproofing is also improved. Further, since the coating layer is a thin film, the splice portion does not become large and the weight hardly increases.

According to the second aspect of the present invention, the waterproof coating material is coated by dipping or the like across the core wire and the insulating coating that are exposed by peeling the insulating coating of the electric wire. Thereafter, when ultrasonic waves are applied in a state where the core wire of the electric wire is in contact with the ground terminal via the coating layer, the coating layer at the contact portion is burned and destroyed, and the core wire is welded to the ground terminal. At this time, the coating layer between the root of the core of the electric wire and the insulating coating remains without being destroyed by combustion, so that only this portion is waterproofed by the coating layer.

As a result, only the electric wires which require waterproofing can be easily waterproofed. In addition, since there is no need for high temperature soldering as in the prior art, there is no problem that the insulating coating of the electric wire is melted. Furthermore, the conductive material does not adhere to the ground terminal, and the risk of heat generation is eliminated.

[0016]

The present invention will be described in detail below with reference to the embodiments shown in the drawings. The first embodiment of the present invention shown in FIGS. 1 and 2 is an embodiment of a method for simply waterproofing the splice points S between the core wires 11a to 13a of the electric wires 11 to 13.

As shown in FIG. 1 (A), the insulation coating 11 at the end of each of the three electric wires 11 to 13 of the wire harness W / H.
Skins b to 13b are made to expose the core wires 11a to 13a, respectively. After that, an electric wire requiring waterproofing is permeated into the waterproof coating material 15 in the tank 14. In this example, the core wires 11a to 13a of all the electric wires 11 to 13 and the insulating coating 11b to
13b and is immersed in the waterproof coating liquid material 15 in the tank 14. Further, it is pulled out from the tank 14 and naturally dried or heated and dried. Thereby, as shown in FIG. 1 (B), the waterproof coating liquid material 1 is spread over the core wires 11a to 13a and the insulating coatings 11b to 13b of the electric wires 11 to 13.
5 coating layer 15a.

As the waterproof coating liquid material 15, for example, a solution in which butyl rubber is dissolved in toluene is suitable. As a commercially available product, there is ELEPCOAT (trade name) manufactured by Nitto Denko Corporation. In addition, Nanocryl (trade name) manufactured by Toyo Ink Manufacturing Co., Ltd., Cemedine 240 (trade name) manufactured by Cemedine Co., Ltd., and HU manufactured by Asahi Denka Kogyo Co., Ltd.
X-240 (trade name) can be used.

Then, as shown in FIG. 1C, the core wires 11a to 13a of the electric wires 11 to 13 are brought into contact with each other through the coating layers 15a, ..., 15a. In this contact state, as shown in FIG. 1 (D), when ultrasonic waves are applied to the contact portion A, the coating layers 15a, ..., 15a are rubbed against each other by vibration at the contact portion A in the ultrasonic vibration range. At the same time, the coating layers 15a, ...
The exposed core wires 11a to 13a are joined by welding by removing a.

At this time, the core wire 11a of each of the electric wires 11 to 13
.., 15a between the root portions of .about.13a and the insulating coatings 11b.about.13b remain without being deleted, so that only this portion of the coating layers 15a ,.
It will be waterproofed by 5a. In addition, each electric wire 1
1 to 13 core wires 11a to 13a and insulating coatings 11b to 13
When it is dipped in the waterproof coating liquid material 15 across b, the gap between the insulating coatings 11b to 13b of the electric wires 11 to 13 and the core wires 11a to 13a, and the core wires 11a to 1a.
Since the waterproof coating liquid material 15 naturally penetrates into the gaps 3a, these gaps are also waterproofed.

Thereafter, as shown in FIG. 2, the insulating tape 16 is wound around the splice point S for insulation.

As a result of measuring the waterproof performance of the splice portion S which has been subjected to the simple waterproof treatment as described above, the result is 0.5 Kgf.
The waterproof performance of / cm2 was confirmed. It was also confirmed that the low-current voltage resistance indicating the electrical connection resistance at the splice point S was also 3 mΩ or less.

As described above, in this embodiment, the step of setting the splice point S in the mold, injecting the thermoplastic synthetic resin from the injection nozzle into the mold, cooling and solidifying, and then removing from the mold is not necessary. Therefore, the workability of waterproofing is improved. Furthermore, the coating layer 15
Since a is a thin film, the splice point S is not enlarged and the weight is not increased.

FIG. 3 shows a modification of the first embodiment.
In FIGS. 1 and 2, the core wire 1 of all the electric wires 11 to 13 is used.
The coating layers 15a, ..., 1 of the waterproof coating liquid material 15 straddle the layers 1a to 13a and the insulating coatings 11b to 13b.
Although coated with 5a, in FIG. 3, only one electric wire 12 that requires waterproofing is coated with the coating layer 15a, and wires 11 and 13 that do not require waterproofing are not coated with the coating layer 15a. As described above, in this embodiment, since only the electric wires 11 to 13 which require waterproofing of the splice point S of the wire harness W / H can be simply waterproofed, a mold type as in the conventional case is not required, and the equipment cost is reduced. Will be cheaper.

FIG. 4 shows another modification of the first embodiment. In FIG. 4, the insulation coating 17b in the middle portion of the electric wire 17 is peeled off to expose the core wire 17a, and the insulation coating 18b at the end of the electric wire 18 is peeled off to expose the core wire 18a. Then, the core wire 18a of the electric wire 18 that requires waterproofing is coated with the coating layer 15a, and the core wires 17a and 18a are welded to each other in the same manner as described above.

The second embodiment of the present invention shown in FIG.
It is an embodiment of a method of simply waterproofing the splice location S between the core wire 19a of 9 and the ground terminal 20. As shown in the figure, the insulation coating 19b of the end of the electric wire 19 connected to the ground terminal 20 is peeled off to expose it, and then the core wire 19a and the insulation coating 19b of the electric wire 19 which requires waterproofing are spread over the drawing. 1 (A), the waterproof coating liquid material 1
5 coat layer 15a.

Then, the core wire 19a of the electric wire 19 is brought into contact with the ground terminal 20 through the coating layer 15a, and in this contact state, when ultrasonic waves are applied to the contact portion A, the contact portion A within the ultrasonic vibration range is exposed. At the same time that the coating layer 15a is removed, the exposed core wire 19a is welded to the ground terminal 20 by removing the coating layer 15a.

At this time, the coating layer 15a between the root portion of the core wire 19a of the electric wire 19 and the insulating coating 19b remains without being removed, so that only this portion is coated.
It will be waterproofed by a. The insulation coating 19 of the electric wire 19 is immersed in the waterproof coating liquid material 15 while straddling the core wire 19a and the insulation coating 19b of the electric wire 19.
Since the waterproof coating liquid material 15 naturally permeates into the gap between the core wire 19a and the gap b, and the gap between the core wires 19a, these gaps are also waterproofed.

As a result of measuring the waterproof performance of the splice portion S subjected to the simple waterproof treatment as described above, it is 0.5 Kgf.
The waterproof performance of / cm2 was confirmed. It was also confirmed that the low-current voltage resistance indicating the electrical connection resistance at the splice point S was also 3 mΩ or less.

In FIG. 5 described above, the electric wire 19 requiring waterproofing is used.
Only the core wire 19a of No. 1 was welded to the ground terminal 20,
As shown in FIG. 6, two electric wires 2 that do not require waterproofing
The core wires 21a and 22a of 1 and 22 can also be weld-joined at the same time. In the embodiment of FIG. 6, the three electric wires 1
Of the 9, 21, 22 only one electric wire 19 was coated with the coating layer 15a. However, when two or more electric wires are welded to the ground terminal 20, an arbitrary number of electric wires are coated. It goes without saying that it may be coated with the layer 15a.

As described above, in the second embodiment, the electric wire 1 which requires waterproofing at the splice point S of the wire harness W / H.
Since only 9 can be easily waterproofed, there is no need for high temperature soldering as in the conventional case.
There is no problem that 9b melts. In addition, the conductive material does not adhere to the ground terminal 20, and there is no danger of heat generation.

[0032]

As is apparent from the above description, according to the splicing method of the first aspect of the present invention, the core wire of an electric wire which requires waterproofing in each electric wire in which the insulation coating is stripped to expose the core wire. Coating the waterproof coating by dipping etc. across the insulation coating, and then contacting the core wires of each electric wire through the coating layer and applying ultrasonic waves, deleting the coating layer and welding the core wires together Since the coating layer between the root portion of the core wire of the electric wire and the insulating coating remains without being removed, only this portion is waterproofed by the coating layer.

Therefore, only the wires requiring waterproofing can be easily waterproofed, and the conventional mold is not required. Therefore, the equipment cost is low and the workability of waterproofing is improved. Further, since the coating layer is a thin film, the splice portion does not become large and the weight hardly increases.

On the other hand, in the splicing method according to the second aspect of the present invention, the waterproof coating material is coated by dipping or the like over the exposed core wire and insulation coating by peeling the insulation coating of the electric wire, and then the electric wire. The core wire of the wire is in contact with the ground terminal via the coating layer, ultrasonic waves are applied, the coating layer is removed, and the core wire is welded to the ground terminal. Since the coating layer between and remains without being deleted, only this portion is waterproofed by the coating layer.

Therefore, it becomes possible to easily carry out waterproofing treatment only for electric wires which require waterproofing, and there is no need for high temperature soldering as in the conventional case, so that there is no problem that the insulating coating of the electric wires is melted. Furthermore, the conductive material does not adhere to the ground terminal, and the risk of heat generation is eliminated.

[Brief description of drawings]

FIG. 1 shows a sequence of a method for splicing electric wires with each other according to the present invention, where (A) is a side view when an electric wire is immersed in a waterproof coating liquid material, (B) is a side view of an electric wire having a coating layer, (C). ) Is a side view of an electric wire in which core wires are in contact with each other,
(D) is a side view of an electric wire in which core wires are joined by welding.

FIG. 2 is a perspective view of a wire harness in which splice points are tape-wound.

FIG. 3 is a modification of FIG. 1, (A) is a side view of an electric wire in which core wires are in contact with each other, and (B) is a side view of an electric wire in which core wires are welded to each other.

FIG. 4 is a modification of FIG. 1, (A) is a side view of the electric wire before the core wires are brought into contact with each other, and (B) is a side view of the electric wire in which the core wires are welded and joined.

FIG. 5 is a method of splicing an earth terminal and an electric wire according to the present invention, (A) is a perspective view of the electric wire and the earth terminal before the core wire is brought into contact with the earth terminal, and (B) is an electric wire welded to the earth terminal. It is a perspective view.

FIG. 6 is a modification of FIG. 5, (A) is a perspective view of an electric wire and a grounding terminal before the core wire is brought into contact with the grounding terminal,
(B) is a perspective view in which an electric wire is welded to a ground terminal.

FIG. 7 is a side view of a conventional wire harness.

FIG. 8 is a perspective view of a mold die.

FIG. 9 is a perspective view of a wire harness in which a splice is molded with synthetic resin.

10 is a side view of the splice point of FIG. 9. FIG.

FIG. 11 is a perspective view in which an electric wire is connected to a conventional ground terminal.

[Explanation of symbols]

W / H wire harness A connection part S splice point 11-13, 17, 18, 19, 21, 22 electric wire 11a-13a, 17a, 18a, 19a, 21a, 2
2a Core wire 11b-13b, 17b, 18b, 19b Insulation coating 15 Waterproof coating liquid material 15a Coating layer

Claims (2)

[Claims] 1. After stripping the insulation coating of the electric wires to be connected to each other to expose the core wire, a waterproof coating liquid material is coated over the core wire and the insulation coating of the electric wire requiring waterproofing, A splicing method for a wire harness, characterized in that the core wires are brought into contact with each other via a coating layer, ultrasonic waves are applied, the coating layer at the contact portion is deleted, and the core wires are welded and joined. 2. A wire for connecting a grounding terminal is peeled off to expose the core wire, and then a waterproof coating liquid material is coated over the core wire and the insulation coating of the wire to fix the core wire of the wire. A splicing method for a wire harness, which comprises contacting a grounding terminal through a coating layer, applying ultrasonic waves, deleting the coating layer at the contacting portion, and welding and joining the core wire to the grounding terminal.