JPH11273459A - Wire harness and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wire harness using a multiple and parallel cable consisting of a number of electric wires and offer a manufacturing method for such wire harnesses, which ensures a good yield, can be embodied at a low cost, excels in versatility without increasing the cost. SOLUTION: A number of electric wires 13 formed by covering a conductive core 11 with an insulating material 12 are parallel joined together to form a multiple and parallel cable 10, which is connected with a base board 20 on which a number of parallel patterns 21 are formed. At the end part of each electric wire 13, the insulation 12 on the side where the core 11 joins with the patterns 21 is exfoliated, and the core 11 is exposed in a flat form. The patterns 21 are formed at a pitch whereby the cores 11 are connected by solder 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wire harness using multiple parallel wires and a method of manufacturing the same, and more particularly, to a wire harness using multiple parallel wires having improved connection with a connecting member and a method of manufacturing the same. .

[0002]

2. Description of the Related Art In recent years, in automobiles and the like, automatic electronic control has been advanced, and wire harnesses have been used for wiring a large number of electric wires to doors, instrument panels, and the like. As a wire harness, a flat wire harness using a punched conductor formed by punching a copper plate in accordance with a circuit configuration in order to increase space efficiency and greatly reduce the number of management steps is known. As shown in FIG. 6, for example, a flat wire harness is a flat wiring body manufactured by laminating a wiring pattern and one insulating layer on which an adhesive layer is formed with rollers interposed therebetween to be laminated. A connector 61 is provided at 60 terminals. A method of manufacturing a flat wiring body is disclosed in, for example, Japanese Patent Application Laid-Open No. Hei 6-76661.

As another flat wire harness, there has been proposed a wire harness using a multi-parallel wire in which enamel wires of the same size are insulated from each other and are closely bonded in one plane.

On the other hand, in order to meet diversifying user needs, grade configurations of automobiles have become very complicated, and wiring harnesses mounted on vehicles have the same configuration so as to be able to accommodate complex grades. Even if applied to the same part of a vehicle type, it has a plurality of product numbers and is selectively used depending on the grade of the vehicle, optional equipment, and the like. For example, as shown in FIG. 7A, the wire harness 30 used for the highest grade vehicle model uses all the connectors 31, 32, 33, 34, and 35, and the wire harness 36 used for the lower grade vehicle model.
Are used only for the connectors 31, 32, and 34, and only the connectors 31, 32, and 35 are used for the wire harness 37 used for the intermediate grade vehicle model.

As described above, if the number of wire harnesses increases, the management of the wire harness becomes troublesome.
In order to prevent an increase in management costs due to an increase in the number of parts, a drop-off circuit is incorporated in the wire harness, and one wire harness is used to handle a plurality of parts. However, for example, as shown in FIG. 8A, the connector 40 is connected to the terminal 36 of the electric wire 13 to manufacture one circuit, and as shown in FIG. , The unit price per circuit increases, and the cost increases as the number of discarded circuits increases.

Therefore, in order to secure a layout space and improve assemblability, a molded harness in which a wire harness is embedded in a resin molded product constituting a vehicle, such as an instrument panel or a door trim, is disclosed in, for example, Japanese Patent Application Laid-Open No. HEI 9-64139. 9
No. 23540.

[0007]

According to the conventional flat harness using a stamped conductor, the yield is poor because the conductor is too thin to transfer onto a laminated film. In addition, it is necessary to cover both surfaces of the punched conductor with an insulating laminate, which leads to an increase in cost. Furthermore, since the configuration of the conductor needs to be changed for each vehicle type and each product type, versatility is reduced.

Further, according to the conventional wire harness using multiple parallel wires, for example, when an individually configured conductor is applied as one circuit, a connector portion is formed on an exposed conductor terminal. However, since there was no effective technology regarding the terminal processing technology for inserting and connecting to the housing, it was not applied as a wire harness for automobiles.

Further, according to the conventional molding harness, when the terminal structure is the same as the conventional one, whether the same part number as the wire harness is provided on the buried member side,
It is necessary to provide a large amount of discard circuits on the wire harness side, which also leads to an increase in cost.

The present invention has been made in order to solve the above-mentioned problems, and has a good yield, is inexpensive, has excellent versatility, and uses a multi-parallel wire harness which does not increase the cost. It is intended to provide a manufacturing method.

[0011]

A wire harness according to the present invention connects a large number of electric wires, each having a conductive core covered with an insulator, joined in parallel, and an end of the core of the electric wire. A connection member having a large number of parallel patterns formed thereon, and each end of the electric wire is separated from the insulator on the side where the core wire is joined to the pattern of the connection member, and the longitudinal section of the insulator is substantially C
The core wire at the portion where the insulator has been peeled off is exposed in a flat shape, and the pattern of the connection member has a pitch at which each end of the exposed flat core wire can be electrically connected. Characterized by the following.

According to the present invention, the longitudinal section of the insulator is substantially C-shaped, so that the insulating property between the adjacent core wires is ensured, and the flat surface of the core wire is formed by solder or the like. Joined to.

[0013] The multiple parallel lines may be embedded in a vehicle interior material such as an instrument panel or a door trim.

[0014] In the connection member, it is preferable that a connection portion for connecting to a connector is formed at the other end of the pattern for connecting the core of the electric wire.

The method for manufacturing a wire harness according to the present invention comprises:
Many electric wires with conductive core covered with insulator,
A method for manufacturing a wire harness having multiple parallel wires joined in parallel and a connecting member formed with a number of parallel patterns for connecting the ends of the core wires of the electric wires, comprising: Cutting a portion, making the vertical cross-sectional shape of the end of each insulator substantially C-shaped, and exposing a flat surface to the core wire;
(2) electrically connecting the flat surface of each core wire to the pattern of the connection member, and performing the steps in the order of (1) to (2).

According to the present invention, since the core wire exposed on the flat surface is connected to the connection base member pattern by soldering or the like, the work of connecting the multi-parallel wires to the connection member is improved.

[0017]

FIG. 1 is a block diagram showing an embodiment of the present invention.
This will be described with reference to FIG. However, the same parts as those in the related art are denoted by the same reference numerals, and description thereof is omitted.

In the wire harness according to the present invention, the multiple parallel wires 10 and the connection board 20 are connected. As shown in FIG. 1 (b), the multi-parallel wires 10 are formed by coating a conductive core wire 11 made of copper or the like with an insulator 12 made of polyurethane or the like to form an electric wire 13 made of a solution-soluble polyamide. Are joined in parallel by a fusing agent having the same. As the electric wire 13, for example, an electric wire obtained by insulatingly coating an enameled wire or a single wire is used.

As shown in FIG. 2, the connection board 20 is formed with a large number of parallel patterns 21 for connecting the ends of the electric wires 13 of the multiple parallel wires 10. Has a connecting portion 22 for connecting to the connector 30.

The wire harness according to the present invention has a core wire 1
1 has a substantially C-shaped cross-sectional shape at each end of the insulator 12 so that each end of the core wire 11 is bonded to the pattern 21 of the connection substrate 20.
Is characterized in that a flat joint portion 11a is provided in the longitudinal direction. On the other hand, the patterns 21 of the connection substrate 20 are formed at a pitch that can connect each end of the exposed core wire 11. As shown in FIG. 1C, the solder 1 is applied on the pattern 21 with a width d smaller than the width D of the joint portion 11a of the exposed core wire 11. When the connector 30 is connected to the connection portion 22 formed at the other end of the pattern 21, a circuit is formed by the electric wires 13 whose core wires 11 are insulated by the insulator 12 and one pattern 21. Be composed.

Here, a method for manufacturing a wire harness according to the present invention will be described with reference to FIG. Multiple parallel lines 1
In the case of No. 0, as shown in FIG. 1A, a large number of electric wires 13 are joined in parallel by a fusing agent.

Next, as shown in FIG.
3 is cut off at the side face connected to the connection pattern 21, the longitudinal section of each end of the insulator 12 is peeled into a substantially C-shape, and the core wire 11 is formed with a flat joint portion 11a in the length direction. You.

Next, as shown in FIGS. 1C and 2, each joint portion 11 a of the exposed core wire 11 faces the pattern 21 of the connection board 20, and the core wire 11 and the pattern 21 are joined by the solder 1. You.

As shown in FIG. 1 (c), the solder 1 has the same pitch as the electric wire 13 and the joint 1 of the exposed core wire 11 by a narrow pitch solder mounting technique such as super solder.
It is applied with a width d smaller than the width D of 1a. Therefore,
The core wire 11 is connected to the pattern 21 of the connection board 20 without short-circuiting between the patterns 21 due to the solder 1 and short-circuiting between the electric wires 13. As a result, the electric wires 13 of the multiple parallel wires 10 and the connection substrate 2
As shown in FIG. 2, an existing connector 30 for connecting the connection board 20 is connected to the connection portion 22 formed at the other end of the pattern 21 in which a circuit whose reliability is secured by the pattern 0 is connected. Is done. Thus, the connection board 2
The wires 13 of the multi-parallel wires 10 are connected to one end of the multi-parallel wires 10 as one circuit of a wire harness by connecting the multi-parallel wires 10 to one end of the multi-parallel wires 10 by the solder 1 and connecting the connector 30 to the connection portion 22 of the connection board 20. It can be applied.

The pattern 21 formed on the connection substrate 20 is not limited to the shape shown in FIG. 2, but may be various shapes as shown in FIGS. FIGS. 2 and 3 show the case where the connection portions 22 are formed for each of the patterns 21.

In the pattern 21 shown in FIG. 4, a joint 21a is provided on the connecting portion 22 side of the two patterns 21 and the joint 21a and one connecting portion 22 are connected to each other. The electric wire 13 can be applied as one circuit of a wire harness. Therefore, even if the current capacity of one wire 13 is insufficient, the two wires 13
With the circuit, the current capacity can be increased. By providing the joint portion 21a for connecting the two or more patterns 21 connecting the electric wires 13 in this manner, without changing the diameter of the core wire 11 of the electric wire 13,
It can support circuits of all current capacities.

Here, a case where the wire harness according to the present invention is applied to an instrument panel 50 as an interior material of an automobile will be described with reference to FIG. The terminal processing of the multiple parallel lines 10 is performed by the instrument panel 5.
The multi-parallel wire 10 having a circuit configuration that can be applied to all grades of equipment is molded at the time of molding 0. In order to connect the electric wires 13, only the circuits necessary for the applicable grade are selected from the connectors 30 and used to construct a circuit configuration corresponding to each grade. A predetermined opening portion of the instrument panel 50 is covered with an insulating cover 51.

The present invention is not limited to the above embodiment, and various changes can be made within the technical scope described in the claims. For example, the wire harness according to the present invention may be applied to an interior material of another automobile such as a door trim, or may be applied to a member other than an automobile.

The electrical connection between the flat surface of the core wire and the connecting member is not limited to soldering, and may be performed by, for example, ultrasonic welding or spot welding.

[0030]

According to the present invention, at the end of the multi-parallel wire, the longitudinal section of the insulator is substantially C-shaped, and the flat exposed core is connected to the pattern of the connection board by soldering or the like. Therefore, multiple parallel wires can be applied to a wire harness for an automobile. Therefore, even in a vehicle in which electronic automatic control has advanced to a high degree, wiring can be easily assembled and productivity can be improved, so that the cost of the vehicle can be reduced.

Further, since multiple parallel wires are used, the yield can be improved and the cost can be reduced as compared with a flat harness using a punched conductor.

Further, in the multi-parallel wire of the wire harness according to the present invention, the unit cost per circuit is not much different from the material cost of the multi-parallel wire, and the cost increase with the increase in the number of circuits is very small. Therefore, the cost increase due to having a large number of throw-away circuits can be sufficiently covered by the reduction of the management cost accompanying the reduction of the number of parts. As a result, a highly versatile wire harness can be provided at low cost.

[Brief description of the drawings]

FIG. 1 shows a method for manufacturing a wire harness according to the present invention, wherein (a) is a perspective view showing a multi-parallel line before processing,
(B) is a perspective view showing a multi-parallel line after processing, and (c) is a front view showing a state before connecting the multi-parallel line to a wiring board.

FIG. 2 is a perspective view showing a state before connecting multiple parallel wires according to the present invention to a connection board and a connector.

FIG. 3 is a plan view showing a modification of the connection board.

FIG. 4 is a plan view showing another modified example of the connection board different from FIG. 3;

FIG. 5 is a perspective view showing a state where the wire harness according to the present invention is incorporated in an instrument panel.

FIG. 6 is a perspective view showing a conventional flat wire harness.

FIG. 7 is a perspective view of a wire harness different from that of FIG. 6, (a) being applied to a high-grade vehicle model;
(B) applies to lower grade vehicles,
(C) is a perspective view showing what is applied to an intermediate grade vehicle model.

8 is a perspective view showing a wire harness and a connector different from those in FIGS. 6 and 7, wherein FIG. 8A is a perspective view before connection and FIG. 8B is a perspective view after connection.

[Explanation of symbols]

 1: solder 10: multiple parallel wires 11: core wire 12: insulator 13: electric wire 20: connection board (connection member) 21: pattern 22: connection section 30: connector 50: interior material (instrument panel)

Claims (4)

[Claims] 1. A connecting member formed with a multiplicity of parallel electric wires each having a conductive core covered with an insulator, joined in parallel, and a multiplicity of parallel patterns for connecting the ends of the cores of the electric wires. Each end of the electric wire has a portion where the insulator on the side where the core wire is joined to the pattern of the connecting member is peeled off, and the insulator has a substantially C-shaped longitudinal section, and the insulator is peeled off. Are exposed in a flat shape, and the pattern of the connection member is formed at a pitch capable of electrically connecting each end of the exposed flat core wire. A wire harness characterized by the following. 2. The wire harness according to claim 1, wherein the multiple parallel wires are embedded in a vehicle interior material such as an instrument panel or a door trim. 3. The wire harness according to claim 1, wherein the connection member has a connection portion for connecting to a connector at the other end of the pattern for connecting the core wire of the electric wire. . 4. A connecting member formed with a multiplicity of parallel electric wires each having a conductive core covered with an insulator, joined in parallel, and a multiplicity of parallel patterns connecting end portions of the cores of the electric wires. And (1) cutting a part of the end of the electric wire, making the longitudinal section of the end of each insulator substantially C-shaped, and exposing a flat surface on the core wire. And (2) a step of electrically connecting the flat surface of each core wire to the pattern of the connection member, wherein the steps are performed in the order of (1) to (2). Production method.