WO2011135741A1 - コネクタの保護構造およびその製造方法 - Google Patents
コネクタの保護構造およびその製造方法 Download PDFInfo
- Publication number
- WO2011135741A1 WO2011135741A1 PCT/JP2010/068276 JP2010068276W WO2011135741A1 WO 2011135741 A1 WO2011135741 A1 WO 2011135741A1 JP 2010068276 W JP2010068276 W JP 2010068276W WO 2011135741 A1 WO2011135741 A1 WO 2011135741A1
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- WIPO (PCT)
- Prior art keywords
- connector
- protective
- protection
- nonwoven fabric
- temperature
- Prior art date
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/516—Means for holding or embracing insulating body, e.g. casing, hoods
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/502—Bases; Cases composed of different pieces
- H01R13/504—Bases; Cases composed of different pieces different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/533—Bases, cases made for use in extreme conditions, e.g. high temperature, radiation, vibration, corrosive environment, pressure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
- H01R13/639—Additional means for holding or locking coupling parts together, after engagement, e.g. separate keylock, retainer strap
Definitions
- the present invention relates to a protective structure for a connector used in an in-vehicle wire harness, and a manufacturing method thereof.
- an object of the present invention is to provide a connector protection structure that can satisfactorily protect the connector, and a manufacturing method thereof.
- a connector protection structure includes a connector electrically connected to an electric wire, and a protection unit that protects the connector by surrounding the connector,
- the protective part is formed by a protective material having a base material and a binder material having a melting point lower than that of the base material, and the molten binder material is cooled and solidified to be joined at its joint part, and the protective part
- the connector is housed in an inner space formed on the inner surface of the protective member, and the binder material on the inner surface and the outer surface is melted and cooled and solidified so that the inner surface of the protective portion is harder than the outer surface of the protective portion. It is characterized by.
- the protective structure of the connector according to the second aspect is the protective structure according to the first aspect, wherein the protective part has a main body part and an overhang part extending from the main body part along the electric wire. The overhanging portion is fixed to the electric wire.
- the connector protection structure according to a third aspect is the protection structure according to the first or second aspect, wherein the connector is accommodated in the inner space through an opening formed on the electric wire side.
- the connecting surface of the connector is closed by a closing portion.
- a method for manufacturing a connector protection structure includes a connector protection structure having a connector electrically connected to an electric wire, and a protection portion for housing the connector in an inner space formed on an inner surface.
- the protective part is formed of a protective material having a base material having a first melting point and a binder material having a second melting point and a lower melting point than the base material ( a) heating the first surface and the second surface of the protective material; and (b) molding the protective portion so that the first surface is the inner surface and the second surface is the outer surface.
- the manufacturing method of the protective structure of the connector according to the fifth aspect is the manufacturing method according to the fourth aspect, wherein the step (b) includes the protective material in a state where an inner surface forming portion is sandwiched between the protective materials By pressurizing the inner space, the inner space for accommodating the connector is formed on the inner surface side of the protection portion.
- the outer surface of the protection part is shaped to be softer than the inner surface of the protection part.
- the inner space of the protection portion can be formed according to the size of the connector to be mounted.
- a connector can fully be fixed with respect to a protection part only by accommodating a connector in inner space. That is, further work for fixing the protective part to the connector, such as winding work, can be reduced, and the number of work steps required for manufacturing the protective structure can be reduced. Therefore, the manufacturing cost of the connector protective structure can be suppressed.
- the overhanging portion of the protection portion is fixed to the electric wire, and the protection portion is easily fixed to the electric wire. Therefore, it is possible to further prevent the protective portion from falling off the connector.
- connection surface of the connector can be satisfactorily covered by the protection portion. Therefore, it is possible to effectively prevent dust and the like from adhering to the connection surface of the connector.
- the inner space corresponding to the size of the connector can be formed in the protection portion by selecting various inner surface forming portions. Therefore, the protection part corresponding to various connectors can be manufactured, without increasing the manufacturing cost of the whole wire harness.
- FIG. 1 is a plan view showing an example of the configuration of the wire harness in the first to third embodiments of the present invention.
- FIG. 2 is a front perspective view showing an example of the structure of the connector protection structure in the first and third embodiments.
- FIG. 3 is a side view showing an example of the configuration of the connector protection structure according to the first and third embodiments.
- FIG. 4 is a side perspective view showing an example of the configuration of the heating device in the first and second embodiments.
- FIG. 5 is a front perspective view showing an example of a configuration of a mold used for molding the protective part in the first and second embodiments.
- FIG. 6 is a side view showing an example of a method for forming a protective part in the first and second embodiments.
- FIG. 1 is a plan view showing an example of the configuration of the wire harness in the first to third embodiments of the present invention.
- FIG. 2 is a front perspective view showing an example of the structure of the connector protection structure in the first and third embodiments.
- FIG. 3
- FIG. 7 is a rear view showing an example of a method for forming a protective part in the first and second embodiments.
- FIG. 8 is a side cross-sectional view showing an example of a method for forming a protective part in the first to third embodiments.
- FIG. 9 is a front perspective view showing an example of the configuration of the connector protection structure according to the second embodiment.
- FIG. 10 is a side view showing an example of the configuration of the connector protection structure according to the second embodiment.
- FIG. 11 is a side cross-sectional view showing an example of a method for forming a protective part in the second embodiment.
- FIG. 12 is a side cross-sectional view showing an example of the configuration of a mold and an example of a method for forming a protective part in the second embodiment of the present invention.
- FIG. 1 is a plan view showing an example of the configuration of the wire harness 10 in the first to third embodiments of the present invention.
- 2 and 3 are a front perspective view and a side view showing an example of the configuration of the protective structure 33.
- FIG. 1 is a plan view showing an example of the configuration of the wire harness 10 in the first to third embodiments of the present invention.
- 2 and 3 are a front perspective view and a side view showing an example of the configuration of the protective structure 33.
- the wire harness 10 is a bundle of a plurality of electric wires 22 (see FIG. 1) and a plurality of electric wires 32 (FIGS. 2 and 3), and is used for power supply and signal transmission / reception.
- the wire harness 10 mainly includes a main line 20, a branch line 30, and a protective structure 33. 1 and the subsequent drawings have an XYZ orthogonal coordinate system in which the Z-axis direction is a vertical direction and the XY plane is a horizontal plane, as necessary, in order to clarify the directional relationship. .
- the trunk line 20 has a plurality of electric wires 22 and electrically connects connectors 25 (25a, 25b) attached to both ends. And the connector 25 (25a, 25b) of both ends is connected with the connector (illustration omitted) of a corresponding electrical component.
- the branch line 30 has one or a plurality of electric wires 32 branched from the trunk line 20, and as shown in FIGS. 2 and 3, the branch line 30 is inserted into a connector 35 attached to one end 30a. ing.
- the protective structure 33 is a structure for preventing the connector 35 and other elements from interfering with each other. As shown in FIGS. 2 and 3, the protection structure 33 mainly includes a connector 35 and a protection unit 40.
- the connector 35 is electrically connected to a plurality of electric wires 32 included in the branch line 30 as shown in FIGS.
- the connector 35 is used, for example, for connection with an electrical component (not shown) that is optionally provided. Therefore, when this electrical component is not used, the connector 35 is disposed in the vicinity of the main line 20 without being connected to other connectors (not shown).
- the protection unit 40 protects unused connectors 35 that are not connected to electrical components (not shown). Details of the protection unit 40 will be described later.
- the protection unit 40 is an impact absorbing member formed of, for example, a nonwoven fabric 41. As shown in FIG. 2 and FIG. 3, the protection unit 40 protects the unused connector 35 that is not connected to an electrical component (not shown) by surrounding the connector 35. As shown in FIG. 2 and FIG. 3, the protection part 40 mainly has a main body part 40a and an overhang part 40b.
- the nonwoven fabric 41 (protective material) mainly has PET (polyethylene terephthalate: base material) and a binder material formed by copolymerization of PET and PEI (polyethylene isophthalate). More specifically, the nonwoven fabric 41 mainly has basic fibers formed in a linear shape by a base material, and binder fibers in which a sheath-like binder material is arranged around the basic fibers.
- the melting point (second temperature) of the binder material is 110 to 150 ° C., which is set to be lower than the base material (the melting point of PET: about 250 ° C. (first temperature)).
- the main body 40a is a cylindrical body formed by heating and pressurizing the nonwoven fabric 41. As shown in FIGS. 2 and 3, the shape of the main body 40a is a rounded rectangular parallelepiped or a cube.
- an inner space 40c is formed inside the main body 40a.
- the connector 35 is accommodated in the inner space 40c through the opening 40e formed in the electric wire 32 side.
- the connection surface (surface on the opposite side to the surface where the electric wire 32 was connected) 35a (refer FIG. 3) of the connector 35 is closed by the closing part 40f.
- the protection unit 40 can satisfactorily cover the connection surface 35a of the connector 35. Therefore, dust and the like are effectively prevented from adhering to the connection surface 35a of the connector 35.
- the overhanging portion 40b is a fixed piece provided on the main body portion 40a. As shown in FIGS. 2 and 3, the overhanging portion 40 b protrudes from the main body portion 40 a and extends along the plurality of electric wires 32.
- the fixing part 40 d fixes the overhanging part 40 b to the electric wire 32.
- a fixing method by the fixing portion 40d for example, tape winding may be employed.
- the protection part 40 has the overhanging part 40b protruding from the main body part 40a, and the protection part 40 is easily fixed to the plurality of electric wires 32. Therefore, it is possible to effectively prevent the protection unit 40 from falling off the connector 35.
- FIG. 4 is a side perspective view showing an example of the configuration of the heating device 50 used when the protection unit 40 is molded.
- FIG. 5 is a front perspective view showing an example of the configuration of a mold 60 used for molding the protection unit 40.
- 6 to 8 are a side view, a rear view, and a side sectional view showing an example of a method for forming the protection part 40 in the present embodiment, respectively.
- the heating device 50 heats the main surface (first and second surfaces 41a and 41b: see FIG. 6) of the single nonwoven fabric 41 sandwiched. As shown in FIG. 4, the heating device 50 mainly includes an inner surface heating unit 51 and an outer surface heating unit 56.
- the shape of the nonwoven fabric 41 used in the present embodiment is a battledore shape, and mainly includes a base portion 42a and a connecting piece 42b as shown in FIG.
- the base portion 42 a has a substantially rectangular shape (square or rectangular shape) in plan view, and corresponds to the molded main body portion 40 a.
- the connecting piece 42b has a substantially rectangular shape in plan view, and is provided continuously with the base portion 42a.
- the base 42a and the connecting piece 42b are provided side by side so that the center line of the base 42a and the connecting piece 42b in the connecting direction (X-axis direction) is a single straight line.
- a single straight line connecting both center lines is a folding line 44 of the nonwoven fabric 41.
- the first surface 41 a of the base part 42 a of the nonwoven fabric 41 is the inner surface of the protection part 40
- the second surface 41 b of the base part 42 a of the nonwoven fabric 41 is the protection part.
- the outer surface of 40 is formed.
- the inner surface heating unit 51 heats the first surface 41a that becomes the inner surface of the protection unit 40 after molding at a first processing temperature that is equal to or higher than the melting point (second temperature) of the binder material and lower than the melting point (first temperature) of the base material. To do. As shown in FIG. 4, the inner surface heating unit 51 has a heater 53.
- the heater 53 is a heating element embedded in the main body 51a, as shown in FIG. Therefore, when the heater 53 is driven, the temperature of the main body 51a is increased and the first surface 41a of the nonwoven fabric 41 is heated.
- the outer surface heating unit 56 heats the second surface 41b, which becomes the outer surface of the protection unit 40 after molding, at a second processing temperature that is equal to or higher than the melting point of the binder material and lower than the melting point of the base material and lower than the first processing temperature. . As shown in FIG. 4, the outer surface heating unit 56 has a heater 58.
- the heater 58 is a heating element embedded in the main body 56a as shown in FIG. Therefore, when the heater 58 is driven, the temperature of the main body 56a is increased and the second surface 41b of the nonwoven fabric 41 is heated.
- the control unit 90 realizes, for example, heating control by the heaters 53 and 58, data calculation, and the like.
- the control unit 90 mainly includes a ROM 91, a RAM 92, and a CPU 93.
- the control unit 90 is electrically connected to elements (for example, heaters 53 and 58) of the heating device 50 through a signal line 99.
- ROM (Read Only Memory) 91 is a so-called nonvolatile storage unit, and stores, for example, a program 91a.
- a flash memory that is a readable / writable nonvolatile memory may be used.
- a RAM (Random Access Memory) 92 is a volatile storage unit, and stores, for example, data used in the calculation of the CPU 93.
- a CPU (Central Processing Unit) 93 executes control (for example, heating control of the nonwoven fabric 41), data calculation, and the like according to the program 91a of the ROM 91.
- the mold 60 presses the non-woven fabric 41 heated by the heating device 50 to form the non-woven fabric 41 into a protection part 40 having a desired shape.
- the mold 60 mainly has a holding part 61, a support plate 62, a compression part 63, and an inner surface forming part 66.
- the holding portion 61 is a holding element having a substantially U shape when viewed from the front, and holds the support plate 62.
- the holding space 61 a is formed as a space sandwiched between the side walls 61 b of the holding portion 61.
- the support plate 62 is held by the holding portion 61 in a state of being fitted in the holding space 61a.
- a partition plate 62 b that partitions the arrangement space 62 a is provided on the front side (plus X axis side) of the support plate 62.
- the support plate 62 accommodates the nonwoven fabric 41 to be pressurized.
- the nonwoven fabric 41 is accommodated in the support plate 62 by being inserted into the arrangement space 62a after being bent along the folding line 44 (see FIG. 7).
- the compression part 63 is a pressurizing element that applies pressure to the nonwoven fabric 41 inserted into the arrangement space 62a. As shown in FIG. 5, the compression part 63 mainly has the flat part 63a, the insertion part 63b, and the protrusion part 63c.
- Each of the flat part 63a, the insertion part 63b, and the protrusion part 63c is a substantially rectangular parallelepiped block body.
- the protruding portion 63 c is provided in the insertion portion 63 b so that the shape when combined with the insertion portion 63 b is substantially L-shaped in a side view.
- the insertion part 63b is provided in the flat part 63a so that the shape when combined with the flat part 63a is substantially T-shaped when viewed from the front.
- the insertion portion 63 b and the protruding portion 63 c can be inserted into the arrangement space 62 a of the support plate 62. Therefore, the nonwoven fabric 41 held by the support plate 62 is pressurized by inserting the insertion portion 63b and the protruding portion 63c into the arrangement space 62a (see FIG. 8).
- the first surface 41a of the nonwoven fabric 41 is heated at a first processing temperature higher than the heating temperature (second processing temperature) of the second surface 41b of the nonwoven fabric 41. That is, the operations of the heaters 53 and 58 are controlled so that the amount of binder material melted on the first surface 41a is larger than the amount of binder material melted on the second surface 41b. Therefore, the inner surface (corresponding to the first surface 41a) of the protection part 40 molded by the mold 60 is harder than the outer surface (corresponding to the second surface 41b).
- the nonwoven fabric 41 can be inserted into the arrangement space 62a with the partition plate 62b provided on the support plate 62 as a reference plane. Further, the insertion portion 63b can be inserted into the arrangement space 62a while being guided by the partition plate 62b. Therefore, the compression part 63 can be satisfactorily positioned with respect to the nonwoven fabric 41.
- the inner surface forming part 66 is a rod-like body used for forming the inner space 40 c in the protection part 40.
- the inner surface forming portion 66 is sandwiched between the nonwoven fabrics 41 bent by the folding line 44 so as to face the first surface 41 a of the nonwoven fabric 41. Thereby, the space for accommodating the connector 35 in the pressurized protection part 40 can be shape
- the nonwoven fabric 41 is valley-folded at the fold line 44 so that the first surface 41a is on the inner side and the outer surface 41b is on the outer side.
- the first surface 41 a becomes the inner surface of the protection unit 40
- the outer surface 41 b becomes the outer surface of the protection unit 40.
- the folded nonwoven fabric 41 is inserted into the arrangement space 62 a of the support plate 62.
- the inner surface forming portion 66 is sandwiched between the folded nonwoven fabric 41 so as to face the first surface 41a of the nonwoven fabric 41 (see FIG. 7).
- the protection part 40 before pressurization is shape
- the inner surface forming portion 66 is arranged at a desired distance D1 from the partition plate 62b (see FIG. 8).
- the nonwoven fabric 41 is pressed in the direction of the arrow AR1 (compression direction: see FIG. 7) in a state where the rod-shaped inner surface forming portion 66 is sandwiched between the nonwoven fabric 41.
- the base part 42a of the nonwoven fabric 41 is compressed by the insertion part 63b of the compression part 63, and the inner space 40c for accommodating the connector 35 is formed on the first surface 41a (inner surface) side of the protection part 40 (FIG. 8).
- the connecting piece 42b of the nonwoven fabric 41 is compressed by the protruding portion 63c of the compression portion 63, and the overhang portion 40b is formed (see FIG. 8).
- the inner space 40c corresponding to the size of the connector 35 can be formed in the protection part 40 by selecting the inner surface forming part 66 of various sizes (for example, various cross-sectional sizes). Therefore, the protection part 40 corresponding to various connectors can be molded without increasing the manufacturing cost of the protection structure 33 and the wire harness 10.
- the protection part 40 is cooled by air cooling or the like, whereby the formation of the protection part 40 is completed.
- the protection part 40 is joined by its own joint part 49 as the melted binder material is cooled and solidified.
- the first and second surfaces 41a and 41b are cured according to the amount of pressure applied by the compression unit 63 and the amount of melting of the binder material.
- the first surface 41a (inner surface) of the protection unit 40 is protected so as to be harder than the second surface 41b (outer surface) of the protection unit 40.
- the binder material on the first and second surfaces 41a and 41b of the portion 40 is melted and cooled and solidified. That is, the second surface 41 b of the protection part 40 is shaped to be softer than the first surface 41 a of the protection part 40.
- the inner space 40c of the protection part 40 can be molded according to the size of the connector 35 to be mounted.
- the connector 35 can be sufficiently fixed to the protection part 40 only by housing the connector 35 in the inner space 40c. That is, further work for fixing the protection unit 40 to the connector 35 such as winding work can be reduced, and the number of work steps required for manufacturing the protection structure 33 can be reduced. Therefore, the manufacturing cost of the protective structure 33 of the connector 35 can be suppressed.
- the protective part 40 can be formed by an inexpensive nonwoven fabric 41. Therefore, the manufacturing cost of the protective structure 33 of the connector 35 can be suppressed.
- Second Embodiment> Next, a second embodiment of the present invention will be described.
- the second embodiment is the same as the first embodiment, except that the configuration of the protection part and the molding method are different from those of the first embodiment. Therefore, in the following, this difference will be mainly described.
- FIG. 9 and FIG. 10 are a front perspective view and a side view showing an example of the configuration of the protective structure 133.
- the protective structure 133 is a structure for preventing the connector 35 from interfering with other elements, like the protective structure 33 of the first embodiment. As shown in FIGS. 9 and 10, the protective structure 133 mainly includes a connector 35 and a protective part 140.
- the protection unit 140 is an impact absorbing member formed of the nonwoven fabric 41, like the protection unit 40 of the first embodiment. As shown in FIGS. 9 and 10, the protection part 140 mainly has a main body part 140a and an overhang part 40b.
- the main body 140a is a cylinder formed by heating and pressurizing the nonwoven fabric 41. As shown in FIGS. 9 and 10, the shape of the main body 140a is a rounded rectangular parallelepiped or a cube similar to the main body 40a of the first embodiment.
- the inner space 140c is formed as a through-hole penetrating the protection part 140. As shown in FIG. 10, the connector 35 is accommodated in the inner space 140c so that the electric wire 32 side becomes an opening 40e and the connection surface 35a side becomes an opening 140f.
- FIG. 11 is a side cross-sectional view showing an example of a method for forming the protection part 140 in the present embodiment.
- a method of manufacturing the protective structure 133 by the heating device 50 and the mold 60 will be described with reference to FIGS. 6, 7, and 11.
- the heaters 53 and 58 are driven by the control unit 90, whereby the first and second surfaces 41a and 41b of the nonwoven fabric 41 are moved. These are heated at the first and second processing temperatures, respectively (see FIG. 6). Thereby, a part or all of the binder material of the 1st and 2nd surfaces 41a and 41b of the nonwoven fabric 41 fuse
- the nonwoven fabric 41 is valley-folded at the fold line 44 so that the first surface 41a is on the inside and the outer surface 41b is on the outside.
- the first surface 41 a becomes the inner surface of the protection unit 40
- the outer surface 41 b becomes the outer surface of the protection unit 40.
- the folded nonwoven fabric 41 is inserted into the arrangement space 62 a of the support plate 62.
- the inner surface forming portion 66 is sandwiched between the folded nonwoven fabric 41 so as to face the first surface 41a of the nonwoven fabric 41 (see FIG. 7).
- the protection part 40 before pressurization is shape
- the front end of the inner surface forming portion 66 is in contact with the partition plate 62b (see FIG. 11).
- the nonwoven fabric 41 is pressed in the direction of the arrow AR1 (compression direction: see FIG. 7) in a state where the rod-shaped inner surface forming portion 66 is sandwiched between the nonwoven fabric 41.
- the base part 42a of the nonwoven fabric 41 is compressed by the insertion part 63b of the compression part 63, and the inner space 140c for accommodating the connector 35 on the 1st surface 41a (inner surface) side of the protection part 40 is shape
- the connecting piece 42b of the nonwoven fabric 41 is compressed by the protruding portion 63c of the compression portion 63, and the overhang portion 40b is formed (see FIG. 11).
- the inner space 140c corresponding to the size of the connector 35 can be formed in the protection part 140 by selecting the inner surface forming part 66 of various sizes (for example, various cross-sectional sizes). Therefore, the protection part 140 corresponding to various connectors can be molded without increasing the manufacturing cost of the protection structure 133 and the wire harness 10.
- the protection part 140 is cooled by air cooling or the like, whereby the formation of the protection part 140 is completed.
- the second surface 41b of the protection unit 140 is softer than the first surface 41a of the protection unit 140, as in the case of the first embodiment. Can be molded. Thereby, even if the second surface 41 b of the protection unit 140 collides with another element, the impact of the collision is absorbed by the protection unit 140. Therefore, it is possible to prevent the occurrence of abnormal noise due to this collision.
- the inner space 140c of the protection unit 140 can be formed according to the size of the connector 35 to be mounted, as in the case of the first embodiment.
- the connector 35 can be sufficiently fixed to the protection part 40 only by housing the connector 35 in the inner space 140c. Therefore, as in the case of the first embodiment, the manufacturing cost of the protective structure 133 of the connector 35 can be suppressed.
- the protective portion 140 can be formed by an inexpensive non-woven fabric 41 as in the case of the first embodiment. Therefore, the manufacturing cost of the protective structure 133 of the connector 35 can be suppressed.
- 3rd Embodiment is a point which performs the heating and shaping
- FIG. 12 is a side view showing an example of the configuration of the mold 260 and an example of a method for forming the protection part 40 in the present embodiment.
- the mold 260 heats and pressurizes the non-woven fabric 41 to form the non-woven fabric 41 into a protection part 40 having a desired shape.
- the mold 260 mainly has a holding portion 261, a support plate 62, a compression portion 263, and an inner surface forming portion 266.
- the holding unit 261 has the same external shape as the holding unit 61 of the first embodiment, and holds the support plate 62. Moreover, the holding
- the compression part 263 has the same external shape as the compression part 63 of the first embodiment, and applies pressure to the nonwoven fabric 41 inserted into the arrangement space 62a. Moreover, the compression part 263 has the heater 58 which is embed
- the inner surface forming portion 266 has the same outer shape as the inner surface forming portion 66 of the first embodiment, and is used for forming the inner space 40 c in the protection portion 40. Further, as shown in FIG. 12, the inner surface forming portion 266 has a heater 53 embedded therein, and can heat the first surface 41 a of the nonwoven fabric 41.
- the nonwoven fabric 41 is bent around the fold line 44 so that the first surface 41a is on the inner side and the outer surface 41b is on the outer side. Thereby, the first surface 41 a becomes the inner surface of the protection unit 40, and the outer surface 41 b becomes the outer surface of the protection unit 40.
- the folded nonwoven fabric 41 is inserted into the arrangement space 62 a of the support plate 62. Subsequently, the inner surface forming portion 266 is sandwiched between the folded nonwoven fabric 41 so as to face the first surface 41 a of the nonwoven fabric 41. Thereby, the protection part 40 before pressurization is shape
- the heaters 53 and 58 are driven by the controller 90, the first and second surfaces 41a and 41b of the nonwoven fabric 41 are heated at the first and second processing temperatures, respectively. Thereby, a part or all of the binder material of the 1st and 2nd surfaces 41a and 41b of the nonwoven fabric 41 fuse
- the nonwoven fabric 41 is pressed in the direction of the arrow AR1 (see FIG. 12) by the compression unit 263 in addition to the heat treatment.
- the base part 42a of the nonwoven fabric 41 is compressed by the insertion part 63b of the compression part 63, and the inner space 40c for accommodating the connector 35 is formed on the first surface 41a (inner surface) side of the protection part 40 (FIG. 12).
- the connecting piece 42b of the nonwoven fabric 41 is compressed by the protruding portion 63c of the compression portion 63, and the overhang portion 40b is formed (see FIG. 12).
- the protection part 40 is joined at its own joint part 49 as the molten binder material cools and solidifies. Moreover, the 1st and 2nd surface 41a, 41b is hardened
- the protection part 40 can be heated and shape
- the protection unit 40 has been described as being formed by one nonwoven fabric 41, but the method of forming the protection unit 40 is not limited to this.
- the protection part 40 may be shape
- the protection part 40 may be comprised by the 3 or more nonwoven fabric.
Abstract
Description
<1.1.ワイヤーハーネスの構成>
図1は、本発明の第1ないし第3の実施の形態におけるワイヤーハーネス10の構成の一例を示す平面図である。図2および図3は、保護構造33の構成の一例を示す正面斜視図および側面図である。
保護部40は、例えば不織布41により成形された衝撃吸収部材である。図2および図3に示すように、保護部40は、コネクタ35を囲繞することによって、電装品(図示省略)と接続されていない未使用のコネクタ35を保護する。図2および図3に示すように、保護部40は、主として、本体部40aと、張出部40bと、を有している。
図4は、保護部40の成形時に用いられる加熱装置50の構成の一例を示す側面斜視図である。図5は、保護部40の成形に用いられる金型60の構成の一例を示す正面斜視図である。図6から図8は、それぞれ本実施の形態における保護部40の成形方法の一例を示す側面図、背面図、および側断面図である。
ここでは、加熱装置50のハードウェア構成について説明する。加熱装置50は、挟み込まれた1枚の不織布41の主面(第1および第2面41a、41b:図6参照)を加熱する。図4に示すように、加熱装置50は、主として、内面加熱部51と、外面加熱部56と、を有している。
ここでは、金型60のハードウェア構成について説明する。金型60は、加熱装置50により加熱された不織布41を加圧することによって、不織布41を所望の形状の保護部40に成形する。図5に示すように、金型60は、主として、保持部61と、支持プレート62と、圧縮部63と、内面形成部66と、を有している。
ここでは、図6から図8を参照しつつ、保護構造33の製造方法について説明する。保護構造33の製造方法では、まず、制御部90によりヒータ53、58が駆動させられることによって、不織布41の第1および第2面41a、41bが、それぞれ第1および第2処理温度で加熱される(図6参照)。これにより、不織布41の第1および第2面41a、41bのバインダ材の一部または全部は、溶融して基材の間を広がる。
以上のように、本実施の形態の保護構造33において、保護部40の第1面41a(内面)が、保護部40の第2面41b(外面)と比較してより硬くなるように、保護部40の第1および第2面41a、41bにおけるバインダ材が、溶融および冷却凝固されている。すなわち、保護部40の第2面41bは、保護部40の第1面41aより柔らかくなるように成形されている。これにより、保護部40の第2面41bが他の要素と衝突しても、衝突の衝撃は保護部40で吸収される。そのため、この衝突に起因した異音が発生することを未然に防止できる。
次に、本発明の第2の実施の形態について説明する。第2の実施の形態は、第1の実施の形態と比較して、保護部の構成および成形方法が相違する点を除いては、第1の実施の形態と同様である。そこで、以下ではこの相違点を中心に説明する。
図9および図10は、保護構造133の構成の一例を示す正面斜視図および側面図である。保護構造133は、第1の実施の形態の保護構造33と同様に、コネクタ35と他の要素とが干渉することを防止するための構造である。図9および図10に示すように、保護構造133は、主として、コネクタ35と、保護部140と、を有している。
図11は、本実施の形態における保護部140の成形方法の一例を示す側断面図である。ここでは、図6、図7、および図11を参照しつつ、加熱装置50および金型60により保護構造133を製造する方法を説明する。
以上のように、本実施の形態の保護構造133において、保護部140の第2面41bは、第1の実施の形態の場合と同様に、保護部140の第1面41aより柔らかくなるように成形できる。これにより、保護部140の第2面41bが他の要素と衝突しても、衝突の衝撃は保護部140で吸収される。そのため、この衝突に起因した異音が発生することを未然に防止できる。
次に、本発明の第3の実施の形態について説明する。第3の実施の形態は、同一の装置(金型260)で不織布41の加熱および成形を実行する点で、それぞれ別の装置(加熱装置50および金型60)で加熱および成形を実行する第1の実施の形態と相違する。
<3.1.1.金型の構成>
図12は、本実施の形態における金型260の構成の一例、および保護部40の成形方法の一例を示す側面図である。金型260は、不織布41を加熱および加圧することによって、不織布41を所望の形状の保護部40に成形する。図12に示すように、金型260は、主として、保持部261と、支持プレート62と、圧縮部263と、内面形成部266と、を有している。
ここでは、図12を参照しつつ、保護構造33の製造方法について説明する。本実施の形態の製造方法では、まず、第1面41aが内側となり、外面41bが外側となるように、不織布41が折り曲げ線44を中心に折り曲げられる。これにより、第1面41aが保護部40の内面となり、外面41bが保護部40の外面となる。
以上のように、本実施の形態によっても、第1の実施の形態と同様な保護部40を成形することができる。
以上、本発明の実施の形態について説明してきたが、本発明は上記実施の形態に限定されるものではなく様々な変形が可能である。
20 幹線
22、32 電線
25、35 コネクタ
30 分岐線
33 保護構造
35a 接続面
40、140 保護部
40a、140a 本体部
40b 張出部
40c、140c 内側空間
40d 固定部
40e、140f 開口
40f 閉鎖部
41 不織布
41a 第1面(内面)
41b 第2面(外面)
44 折り曲げ線
49 接合部
50 加熱装置
51 内面加熱部
53、58 ヒータ
56 外面加熱部
60、260 金型
61、261 保持部
62 支持プレート
63、263 圧縮部
66、266 内面形成部
90 制御部
Claims (5)
- (a) 電線と電気的に接続されたコネクタと、
(b) 前記コネクタを囲繞することにより前記コネクタを保護する保護部と、
を備え、
前記保護部は、
基材と、前記基材より低融点のバインダ材と、を有する保護材により成形され、
溶融した前記バインダ材が冷却凝固することによって、自身の接合部にて接合され、
前記保護部の内面に成形された内側空間に前記コネクタを収容するとともに、
前記保護部の前記内面が前記保護部の外面より硬くなるように、前記内面および前記外面における前記バインダ材が、溶融および冷却凝固されていることを特徴とするコネクタの保護構造。 - 請求項1に記載の保護構造において、
前記保護部は、
(b-1) 本体部と、
(b-2) 前記本体部から突出し、前記電線に沿って延びる張出部と、
を有し、
前記張出部が前記電線に対して固定されることを特徴とするコネクタの保護構造。 - 請求項1または請求項2に記載の保護構造において、
前記コネクタは、前記電線側に形成された開口を介して前記内側空間に収容されるとともに、
前記コネクタの接続面は、閉鎖部により閉鎖されていることを特徴とするコネクタの保護構造。 - 電線と電気的に接続されたコネクタと、内面に成形された内側空間に前記コネクタを収容する保護部と、を有するコネクタの保護構造の製造方法であって、
前記保護部は、
融点が第1温度の基材と、
融点が第2温度であり、前記基材より低融点のバインダ材と、
を有する保護材により成形されており
(a) 前記保護材の第1面および第2面を加熱する工程と、
(b) 前記第1面が前記内面となり、前記第2面が外面となるように、前記保護部を成形する工程と、
(c) 前記工程(a)により溶融した前記バインダ材を冷却凝固させる工程と、
を備え、
前記工程(a)は、
前記第1面を前記第2温度以上前記第1温度未満となる第1処理温度で、
前記第2面を前記第2温度以上前記第1温度未満となり、前記第1処理温度より低温の第2処理温度で、
それぞれ加熱することを特徴とするコネクタの保護構造の製造方法。 - 請求項4に記載の製造方法において、
前記工程(b)は、前記保護材により内面形成部を挟み込んだ状態で、前記保護材を加圧することによって、前記保護部の前記内面側に前記コネクタを収容する前記内側空間を成形することを特徴とするコネクタの保護構造の製造方法。
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DE112010005535T DE112010005535T5 (de) | 2010-04-30 | 2010-10-18 | Verbinderschutzstruktur und Herstellungsverfahren hierfür |
CN2010800663940A CN102859801A (zh) | 2010-04-30 | 2010-10-18 | 连接器保护结构及其制造方法 |
KR1020127028479A KR101353240B1 (ko) | 2010-04-30 | 2010-10-18 | 커넥터 보호 구조 및 그 제조 방법 |
US13/579,343 US20120309228A1 (en) | 2010-04-30 | 2010-10-18 | Connector protection structure and production method therefor |
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JP2010104899A JP5359984B2 (ja) | 2010-04-30 | 2010-04-30 | コネクタの保護構造およびその製造方法 |
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US (1) | US20120309228A1 (ja) |
JP (1) | JP5359984B2 (ja) |
KR (1) | KR101353240B1 (ja) |
CN (1) | CN102859801A (ja) |
DE (1) | DE112010005535T5 (ja) |
WO (1) | WO2011135741A1 (ja) |
Cited By (1)
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US9306378B2 (en) | 2012-03-15 | 2016-04-05 | Sumitomo Wiring Systems, Ltd. | Method for producing wire harness, and wire harness |
Families Citing this family (6)
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JP5392171B2 (ja) * | 2010-04-09 | 2014-01-22 | 株式会社オートネットワーク技術研究所 | ワイヤーハーネスおよびその製造方法 |
JP5353814B2 (ja) * | 2010-05-19 | 2013-11-27 | 住友電装株式会社 | ワイヤーハーネスの保護構造 |
JP5768634B2 (ja) * | 2011-09-29 | 2015-08-26 | 住友電装株式会社 | ワイヤーハーネスの製造方法及びワイヤーハーネス |
JP2013145708A (ja) * | 2012-01-16 | 2013-07-25 | Sumitomo Wiring Syst Ltd | コネクタカバー、ワイヤーハーネス及びコネクタカバーの製造方法 |
JP5884620B2 (ja) | 2012-04-23 | 2016-03-15 | 住友電装株式会社 | ワイヤーハーネス、ワイヤーハーネスの製造方法及び保護部材 |
JP2014068458A (ja) * | 2012-09-26 | 2014-04-17 | Sumitomo Wiring Syst Ltd | ワイヤーハーネス、ワイヤーハーネスの製造方法及び保護部材 |
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- 2010-10-18 US US13/579,343 patent/US20120309228A1/en not_active Abandoned
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JP2011233453A (ja) | 2011-11-17 |
KR101353240B1 (ko) | 2014-01-17 |
CN102859801A (zh) | 2013-01-02 |
US20120309228A1 (en) | 2012-12-06 |
JP5359984B2 (ja) | 2013-12-04 |
KR20130018825A (ko) | 2013-02-25 |
DE112010005535T5 (de) | 2013-03-14 |
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