WO2012114732A1 - Method for forming short circuit in wire harness - Google Patents

Method for forming short circuit in wire harness Download PDF

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Publication number
WO2012114732A1
WO2012114732A1 PCT/JP2012/001186 JP2012001186W WO2012114732A1 WO 2012114732 A1 WO2012114732 A1 WO 2012114732A1 JP 2012001186 W JP2012001186 W JP 2012001186W WO 2012114732 A1 WO2012114732 A1 WO 2012114732A1
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WO
WIPO (PCT)
Prior art keywords
sheet body
joint connector
electric wire
sheet
short circuit
Prior art date
Application number
PCT/JP2012/001186
Other languages
French (fr)
Japanese (ja)
Inventor
明洋 西尾
平井　宏樹
松本　浩一
洋樹 下田
康雄 大森
雪清 董
Original Assignee
株式会社オートネットワーク技術研究所
住友電装株式会社
住友電気工業株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by 株式会社オートネットワーク技術研究所, 住友電装株式会社, 住友電気工業株式会社 filed Critical 株式会社オートネットワーク技術研究所
Publication of WO2012114732A1 publication Critical patent/WO2012114732A1/en

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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
    • H01R31/00—Coupling parts supported only by co-operation with counterpart
    • H01R31/08—Short-circuiting members for bridging contacts in a counterpart
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/70—Insulation of connections

Definitions

  • the present invention relates to a method for forming a short circuit by connecting specific wires among a plurality of wires included in the wire harness, and a wire harness including the short circuit in a wire harness of an automobile or the like. It relates to a method for manufacturing.
  • the joint connector includes, for example, a plurality of connector terminals that are respectively attached to terminals of specific wires among a plurality of wires bundled together in the wire harness, a connector housing that holds these connector terminals, and the connector housing And a short-circuit conductor that short-circuits the connector terminals by fitting with the connector terminals.
  • Patent Document 1 discloses that the joint connector is inserted into a bag-like connector cover made of an elastic material, and the connector cover is opened. It is described that the side end portion is brought into close contact with each electric wire connected to the joint connector using its elastic restoring force.
  • the opening end of the connector cover is brought into close contact with the electric wire only by its elastic restoring force, the opening end of the connector cover is securely attached to all the plural electric wires.
  • a considerable elastic restoring force is required, and it is not easy to obtain such an elastic restoring force.
  • the natural opening diameter of the connector cover (the diameter when not elastically deformed) must be set to be considerably smaller than the maximum outer diameter of the joint connector. Inserting the joint connector into the cover is very troublesome. That is, the operator must forcibly expand the opening of the connector cover with a very large force using a special jig or the like. Also, automation of such operations is extremely difficult.
  • the method provided by the present invention includes a short-circuiting step of short-circuiting these electric wires by connecting terminals of a plurality of electric wires included in the wire harness to a common joint connector; A waterproof body manufacturing process for forming a waterproof body that seals and waterproofs the joint connector by closely contacting an end portion of an electric wire connected to the joint connector while covering the joint connector in the periphery.
  • the waterproof body manufacturing process includes a first sheet body, an end of each joint connector and each electric wire connected thereto, and a second sheet body around the joint connector and the electric wire.
  • An overlapping process in which both side portions in the width direction of the first sheet body and the peripheral portion of the second sheet body are directly brought into contact with each other, and air from the side of the first sheet body in the overlapping state
  • the joint connector between the two sheet bodies is brought into close contact with the peripheral portion of the second sheet body and the peripheral portion of the first sheet body by sucking Sealing step for sealing.
  • the air suction may be performed from the stage of the superimposing step. That is, the timing at which the air suction is started does not matter before or after completion of the superposition process.
  • FIG. 1 shows a wire harness 100 according to this embodiment and a joint connector JC used to form a short circuit of the wire harness 100.
  • the joint connector JC is waterproofed by being sealed inside a waterproof body 50 including a first sheet body 52A and a second sheet body 52B as shown in FIG.
  • the wire harness 100 according to this embodiment is manufactured by the following process.
  • a plurality of electric wires 10 are bundled to form the main wire 12, and a plurality of the electric wires 10 (four in this embodiment) Is drawn out from the trunk line 12 as the branch wire group 14.
  • the state where the electric wire 10 was bundled is hold
  • Each electric wire 10 is a so-called covered electric wire, and the electric wire 10 has a conductor and an insulating coating that covers the conductor.
  • the electric wire side terminals 20 in order to connect the electric wires 10 included in the branch electric wire group 14 to the common joint connector JC, the electric wire side terminals 20 as shown in FIGS. It is installed.
  • the electric wire side terminal 20 has a female electrical contact portion 22 and an electric wire crimping portion 24 at the front and rear.
  • the electrical contact portion 22 has a hollow rectangular tube-shaped main body and a contact spring piece 26 provided so as to be able to bend in the main body. From the bottom wall of the electrical contact portion 22, a locked piece 28 for locking to the joint connector JC protrudes outward.
  • each electric wire 10 included in the branch electric wire group 14 is previously subjected to a treatment for removing the insulating coating and exposing the conductor, and the electric wire crimping portion 24 is connected to the end of the conductor and the vicinity thereof.
  • the electric wire crimping portion 24 is connected to the end of the conductor and the vicinity thereof.
  • the joint connector JC includes a single short-circuit conductor 30 and an insulating housing 40 for holding the short-circuit conductor 30.
  • the short-circuiting conductor 30 is made of a conductive material, and is short-circuited between the electric wire side terminals 20 by being commonly connected to the electric wire side terminals 20.
  • the insulating housing 40 is integrally formed of an insulating material such as synthetic resin, and can be held in a state in which the shorting conductor 30 is stored, specifically, the thickness direction of the shorting conductor 30. It has a flat shape.
  • the short-circuit conductor 30 is composed of a short-circuit metal plate formed by punching a single metal plate into an appropriate shape, and a plurality of fitting portions 32 and short-circuit portions 34 are integrated.
  • Each fitting portion 32 is a male (tab) fitting portion that can be fitted into the female electrical contact portion 22 of each electric wire side terminal 20, and these fitting portions 32 are parallel to the width direction thereof. It is arranged in the direction, that is, the direction orthogonal to the thickness direction of the metal plate for short circuit.
  • the short-circuit portion 34 extends in the arrangement direction of the fitting portions 32, and the short ends 34 are connected to the base ends of the fitting portions 32.
  • the insulating housing 40 has a pair of side walls that connect the flat top wall 41 and the bottom wall 42 that are parallel to each other, and both ends of the walls 41 and 42 in the width direction (that is, the left end portions and the right end portions). 44 integrally. These walls 41, 42, 44 constitute the outer wall of the insulating housing 40.
  • the rear end portion (right end portion in FIGS. 3 to 6) of the outer wall constitutes a conductor holding portion 43.
  • the short-circuit portion 34 is held by the conductor holding portion 43 by press-fitting the short-circuit portion 34 of the short-circuiting conductor 30 into the conductor holding portion 43 from the opening 43 a.
  • the conductor holding portion 43 has a shape for holding the short-circuit portion 34 of the short-circuit conductor 30. Specifically, it has an outer shape that is slightly larger than the short-circuit portion 34 and extends in the arrangement direction of the fitting portions 32 of the short-circuit conductor 30, and the short-circuit portion 34 is inserted from the rear (left side in FIG. 8). A possible short-circuit metal plate insertion opening 43a is enclosed.
  • the short-circuit portion 34 is press-fitted into the conductor holding portion 43 from the insertion port 43a with the fitting portions 32 facing forward. More specifically, protrusions 34 a as shown in FIG. 6 are formed at both ends in the width direction of the short-circuit part 34, and these conductors 34 a dig into the inner side surface of the conductor holding part 43.
  • the short-circuit part 34 is fixed to.
  • a plurality of (three in the figure) partition walls 45 parallel to the side walls 44 are arranged in the connector width direction at a portion on the front side of the conductor holding portion 43.
  • Each partition wall 45 defines a terminal accommodating chamber 47 between another partition wall 45 or a side wall 44 adjacent thereto.
  • These terminal accommodating chambers 47 are formed corresponding to the respective fitting portions 32 and receive the electric wire side terminals 20 so as to allow the electric wire side terminals 20 to be fitted into the fitting portions 32. It has a shape, specifically a shape that opens forward and allows the wire-side terminal 20 to be inserted through the opening.
  • each fitting portion 32 of the short-circuiting conductor 30 protrudes from the rear, and the electric contact portion 22 of the electric wire side terminal 20 inserted into the terminal accommodating chamber 47 is the fitting portion.
  • the electric wire side terminal 20 and the short-circuiting conductor 30 are electrically connected to each other by being engaged with the terminal 32.
  • the bottom wall 42 is formed with a lance 46 that is a terminal locking portion at a position corresponding to each terminal accommodating chamber 47.
  • each lance 46 has a slit 42a formed in the bottom wall 42, that is, a pair of parallel linear portions extending in the front-rear direction of the connector and the ends of these linear portions are connected to each other in the connector width.
  • a claw-like locking portion 46a is formed at the free end.
  • the engaging portion 46a is flexibly displaced as shown in FIG. 3 by coming into contact with the inserted electric wire side terminal 20, and allows the electric wire side terminal 20 to pass. By returning, the locked piece 28 of the electric wire side terminal 20 is restrained from the rear.
  • the lance 46 has a locking position (position shown in FIG. 4) where the locking portion 46 a locks the electric wire side terminal 20 at a position where the electric wire side terminal 20 is engaged with the fitting portion 32. And a retraction position (position shown in FIG. 3) that retreats to the outside with the elastic deformation of the lance 46 from this locking position, which is the same as the outer surface of the other part of the bottom wall 42 at the locking position. It is located on the surface and protrudes outward from the outer surface of the other part of the bottom wall 42 at the retracted position.
  • the wire-side terminal 20 at the end of the wire 10 included in the branch wire group 14 is inserted into the terminal accommodating chamber 47 and is directly fitted into the fitting portion 32 of the short-circuiting conductor 30.
  • the short circuit between the electric wire side terminals 20 using the shorting conductor 30 as a connection medium is achieved. That is, the short circuit about the some electric wire 10 with which the said electric wire side terminal 20 was each mounted
  • a waterproof body 50 as shown in FIG. 2 is formed around the joint connector JC and an end portion 10a of the electric wire 10 connected thereto (the electric wires 10 included in the branch wire group 14). By sealing the joint connector JC, the short circuit is waterproofed.
  • the waterproof body 50 can be efficiently manufactured by the following process, for example.
  • This process includes the first sheet body 52A having a dimension sufficiently larger than the planar shape of the joint connector JC, the joint connector JC, and the electric wires 10 connected thereto, as shown in FIG.
  • the thickness of the joint connector JC includes the end portion 10a and the second sheet body 52B having a dimension sufficiently larger than the planar shape of the joint connector JC (having a shape larger than the first sheet body 52A in this embodiment).
  • the peripheral portion 52a of the first sheet body 52A and the peripheral portion 52b of the second sheet body 52B can directly contact each other around the joint connector JC and the electric wire 10. It is done to become.
  • a vacuum forming die 60 as shown in FIG. 7 is used for forming the waterproof body 50.
  • the vacuum forming die 60 has a flat upper surface, which forms a forming surface 62.
  • a plurality of suction ports 64 are opened on the molding surface 62, and these suction ports 64 are connected to a vacuum pump (not shown) through an air passage formed in the vacuum molding die 60. Air above the suction port 64 is sucked.
  • the first sheet body 52B is laid on the molding surface 62 of the vacuum forming mold 60.
  • the first sheet body 52A is constituted by a sheet made of, for example, a synthetic resin.
  • a number of ventilation holes are provided in the peripheral portion 52a of the first sheet body 52A (the portion protruding outward from the joint connector JC) in order to promote close contact with the second sheet body 52B by air suction described later. May be.
  • the diameter of the vent hole is preferably about 3 mm, for example.
  • the joint connector JC and the end portion 10a of the electric wire 10 connected to the joint connector JC are placed on the first sheet body 52A in a relative positional relationship such that the first sheet body 52A protrudes outside the joint connector JC.
  • the second sheet body 52B is also composed of a synthetic resin, for example, a sheet made of a synthetic resin made of the same material as the first sheet body 52A. Then, the second sheet body 52B covers the joint connector JC and the electric wire 10 connected thereto so that the peripheral portion 52b of the second sheet body 52B is in direct contact with the peripheral portion 52a of the first sheet body 52A. It is done.
  • the material of the two sheet bodies 52A and 52B is not particularly limited, but at least the second sheet body 52B is more preferably a thermoplastic resin such as polyvinyl chloride, polyethylene, or polyester. Since the second sheet body 52B made of such a thermoplastic resin is softened by being heated, the thickness of the second sheet body 52B is set to be relatively large in order to ensure the strength of the second sheet body 52B. Even if the flexibility of the second sheet body 52B at room temperature is low, the second sheet body 52B is sufficiently softened to the shape of the joint connector JC and the end portion 10a of the electric wire 10 connected thereto due to the softening. The peripheral portion 52a of the body 52A and the surface of the electric wire 10 can be satisfactorily contacted.
  • a thermoplastic resin such as polyvinyl chloride, polyethylene, or polyester. Since the second sheet body 52B made of such a thermoplastic resin is softened by being heated, the thickness of the second sheet body 52B is set to be relatively large in order to ensure the strength of the second sheet
  • a heater 66 as shown in FIG. 7 is disposed above the vacuum forming die 60, and the second sheet body 52B is held by the holding portion 68 on the lower surface of the heater 66 and softened.
  • the second sheet body 52B is preferably cut off from the heater 66 and placed on the joint connector JC and the end portion 10a of the electric wire 10 connected thereto.
  • the suction of air from the suction port 64 may be performed only in the next sealing step, but preferably it is performed from the stage of the superimposing step.
  • the suction of the air in the overlapping step holds the first sheet body 52A on the molding surface 62, and further, the second sheet body 52B on the first sheet body 52A and the joint connector JC. Contributes to attraction.
  • the distance between the electric wires 10 becomes narrower as the distance from the joint connector JC increases.
  • the both sheets can be used regardless of the distance between the electric wires 10.
  • the bodies 52 ⁇ / b> A and 52 ⁇ / b> B can be satisfactorily adhered to the surface of each electric wire 10 by the vacuum forming mold 60.
  • the contact state between the peripheral portions 52a and 52b of the both sheet bodies 52A and 52B is more reliably maintained by bonding the peripheral portions 52a and 52b to each other.
  • the adhesive provided on the sheet body layer for example, the above-described synthetic resin sheet
  • the back surface the surface facing the other sheet body. What has an agent layer should just be prepared.
  • the adhesive layer strengthens the contact state by adhering the peripheral portions 52a and 52b of the two sheet bodies 52A and 52B.
  • a flexible material such as a butyl rubber-based pressure-sensitive adhesive or a thermosetting liquid agent such as an epoxy resin is suitable.
  • both the first sheet body 52A and the second sheet body 52B include an adhesive layer. That is, the first sheet body 52A includes a sheet main body layer 54A and an adhesive layer 56A provided on the back surface thereof, and the second sheet body 52B includes a sheet main body layer 54B and an adhesive layer 56B provided on the back surface thereof. have. According to such a combination of sheet bodies 52A and 52B, not only the peripheral portions 52a and 52b are in close contact with each other, but also the peripheral portions 52a and 52b (on the rear end side) as shown in FIG. The close contact with the surface of the portion 10a is also firmly held by adhesion by the adhesive layers 56A and 56B.
  • the method described above does not require the troublesome work of inserting the joint connector into the waterproof body while forcibly expanding the opening of the bag-shaped waterproof body with a dedicated jig as in the prior art.
  • the operator can surely form the short circuit and waterproof it by a process with very little burden.
  • This method is particularly suitable for the case where at least a part of the electric wire side terminal 20 is composed of different metal materials for the electric wire side terminal 10 and the electric wire to which the electric wire side terminal 10 is attached.
  • the electric wire side terminal 20 is made of an alloy and is made of copper or a copper alloy, a significant advantage is exhibited. That is, the wire-side terminal 20 composed of different metal materials and the conductor to which the wire-side terminal 20 is attached are likely to corrode when moisture enters the joint portion, so that the short circuit including the wire-side terminal 20 is surely provided. Waterproofing greatly contributes to improvement of connection reliability and extension of life.
  • the specific shape and structure of the joint connector used is not particularly limited.
  • the connector terminals may be arranged over a plurality of upper and lower stages, or the electric wire side terminal 20 and the short-circuiting conductor 30 may be held in separate connector housings, and these connector housings may be fitted together. .
  • the joint connector JC as shown in each figure has a flat shape with a small dimension in the thickness direction
  • the joint connector JC and the electric wire 10 connected to the joint connector JC and both sheet bodies 52A and 52B are arranged in the thickness direction.
  • the close contact between the peripheral portions 52a and 52b of both the sheet bodies 52A and 52B and the close contact between the peripheral portions 52a and 52b and the surface of the electric wire 10 are more easily and reliably performed.
  • the lance 46 as the terminal locking portion is formed on the outer wall (the bottom wall 42 in the figure) as described above, the dimension in the thickness direction is further reduced, and the lance 46 is in its retracted position. In this case, the lance 46 is moved outside by the first sheet body 52A or the second sheet body 52B (the first sheet body 52A in FIG. 8) at the locking position.
  • the outer wall (the bottom wall 42 in this embodiment) of the joint connector JC is restrained from the outside by using the first sheet body 52A or the second sheet body 52B that seals the joint connector JC. Therefore, it is possible to prevent the lance 46 from being displaced from the locking position to the retracted position, so that the joint connector JC is not provided with a special structure for double-locking the electric wire side terminal 20, that is, the joint. It is possible to more reliably hold the wire-side terminal 20 by the lance 46 while keeping the shape of the connector JC thin.
  • a method capable of easily forming a waterproof short circuit in a wire harness including a plurality of electric wires bundled together includes a short-circuiting step of short-circuiting these electric wires by connecting ends of a plurality of electric wires included in the wire harness to a common joint connector, and the joint around the joint connector.
  • the waterproof body manufacturing process includes a first sheet body, an end of each joint connector and each electric wire connected thereto, and a second sheet body around the joint connector and the electric wire.
  • the electric wire side terminals are respectively attached to the ends of the specific electric wires
  • the joint connector is made of a single metal plate and has a plurality of fitting portions arranged in a direction perpendicular to the thickness direction. Then, each fitting portion is fitted to each of the electric wire side terminals, and the shorting metal plate for short-circuiting the electric wires in the fitted state, and a flat outer shape in the thickness direction of the shorting metal plate
  • a plurality of terminal accommodating chambers for holding the wire-side terminals so as to hold the short-circuiting metal plate and allow the wire-side terminals to be fitted into the fitting portions of the short-circuiting metal plate. It is preferred to use an insulating housing that surrounds the housing.
  • the joint connector and the end portion of the electric wire connected thereto have a flat shape as a whole (the thickness direction that is perpendicular to the arrangement direction of the electric wires is small), by overlapping both sheet bodies in the thickness direction, It is possible to more reliably and easily join the two sheet bodies.
  • the joint connector has an outer wall facing the terminal accommodating chamber, and a terminal locking portion for locking the electric wire side terminal is formed on the outer wall, and the terminal locking portion locks the electric wire side terminal.
  • the terminal locking portion is elastically displaceable between the locking position and the retracted position retracted outward from the locking position and projecting outward from the outer wall. It is preferable that the peripheral portions of both sheet bodies are joined together so as to be restrained from the outside by the one sheet body or the second sheet body.
  • the terminal engagement portion formed on the outer wall of the joint connector is constrained to the engagement position by using the first sheet body or the second sheet body that is in close contact with the joint connector. It is possible to prevent the stop portion from being displaced from the locking position to the retracted position, and to more reliably hold the state in which the terminal locking portion locks the electric wire side terminal.
  • the method according to the present invention can be performed more efficiently by using a vacuum forming die having a forming surface in which a plurality of suction ports for sucking air are opened.
  • the superimposing step lays the first sheet body on the molding surface, and the peripheral portion of the first sheet body is the joint connector and The joint connector and the end of the electric wire connected to the first connector are placed on the first sheet so as to protrude outside the end of the electric wire connected thereto, and the second sheet is attached to the second sheet.
  • the second sheet body includes a layer made of a thermoplastic resin, and the layer is softened by heating, and the joint connector and the end of the electric wire connected thereto and the first sheet body It is more preferable to cover the peripheral portion of the sheet body.
  • the second sheet body is heated and softened so that the second sheet body is connected to the joint connector and the wires connected thereto. While conforming to the shape of the end, the end of the electric wire and the peripheral portion of the first sheet body can be satisfactorily adhered. Therefore, both the setting of the thickness of the second sheet body for ensuring the strength of the second sheet body and the sealing and waterproofing of the joint connector by the close contact between the first and second sheet bodies can be achieved.
  • a sheet body layer and a back surface of the sheet body layer It is more preferable that what has an adhesive layer provided in is used, and the peripheral parts of both sheet bodies are adhere
  • This method is for at least some of the electric wire side terminals connected to the joint connector, when the electric wire side terminal and the conductor of the electric wire on which the electric wire side terminal is mounted are made of different metal materials, It is particularly effective. If moisture enters the joint portion between the electric wire side terminal composed of different metal materials and the conductor of the electric wire contacting this, there is a risk of accelerating corrosion of the electric wire side terminal or the conductor. It is extremely significant to securely waterproof a short circuit including such a combination of a different metal wire side terminal and a conductor by the method according to the present invention.
  • the present invention also provides a method for efficiently producing a wire harness having a short circuit.
  • the specific electric wires are short-circuited by applying the step of bundling a plurality of electric wires and the method for forming the short circuit for the terminals of the specific electric wires among the electric wires. Forming a short circuit and producing a waterproof body for sealing the short circuit.

Abstract

Provided is method with which it is easy to form a water-proof short circuit in a wire harness containing a plurality of electric cables gathered together in a bundle. This method contains: a step of short-circuiting by connecting the ends of a plurality of specific electric cables (10) with a shared joint connector (JC); and a step of forming a water-proof body (50) and sealing the joint connector (JC) within this water-proof body (50), thereby water-proofing the joint connector (JC). The step of forming a water-proof body (50) comprises: a step of laminating a first sheet body (52A), the joint connector (JC) and the end part (10a) of each electric cable (10) connected thereto, with a second sheet body (52B); and a step in which by sucking air from the first sheet body (52A) side in that laminated state, the peripheral part (52b) of the second sheet body (52B) and the peripheral part (52a) of the first sheet body (52A) are adhered to one another, and the sheet bodies (52A and 52B) are adhered to the surfaces of the end parts (10a) of the electric cables (10).

Description

ワイヤハーネスにおける短絡回路の形成方法Method for forming a short circuit in a wire harness
　本発明は、自動車等のワイヤハーネスにおいて、当該ワイヤハーネスに含まれる複数の電線のうちの特定の電線同士を接続することにより短絡回路を形成するための方法、及び、短絡回路を含むワイヤハーネスを製造するための方法に関する。 The present invention relates to a method for forming a short circuit by connecting specific wires among a plurality of wires included in the wire harness, and a wire harness including the short circuit in a wire harness of an automobile or the like. It relates to a method for manufacturing.
　従来、自動車等のワイヤハーネスにおいて短絡回路を形成する方法として、ジョイントコネクタを用いたものが知られている。このジョイントコネクタは、例えば、前記ワイヤハーネスにおいて互いに束ねられる複数の電線のうちの特定の電線の端末にそれぞれ装着される複数のコネクタ端子と、これらのコネクタ端子を保持するコネクタハウジングと、このコネクタハウジングに保持され、前記各コネクタ端子と嵌合することにより当該コネクタ端子同士を短絡させる短絡用導体とを有する。 Conventionally, as a method of forming a short circuit in a wire harness of an automobile or the like, a method using a joint connector is known. The joint connector includes, for example, a plurality of connector terminals that are respectively attached to terminals of specific wires among a plurality of wires bundled together in the wire harness, a connector housing that holds these connector terminals, and the connector housing And a short-circuit conductor that short-circuits the connector terminals by fitting with the connector terminals.
　さらに、前記ジョイントコネクタを用いて形成された短絡回路部を防水するための方法として、特許文献１には、当該ジョイントコネクタを弾性材料からなる袋状のコネクタカバーに挿入し、当該コネクタカバーの開口側端部をその弾性復帰力を利用して前記ジョイントコネクタにつながる各電線に密着させることが記載されている。 Furthermore, as a method for waterproofing the short circuit portion formed using the joint connector, Patent Document 1 discloses that the joint connector is inserted into a bag-like connector cover made of an elastic material, and the connector cover is opened. It is described that the side end portion is brought into close contact with each electric wire connected to the joint connector using its elastic restoring force.
　しかし、この方法は、コネクタカバーの開口側端部をその弾性復帰力のみによって電線に密着させんとするものであることから、複数本の電線全てに対してコネクタカバーの開口側端部を確実に密着させるには、相当の弾性復帰力が必要であり、このような弾性復帰力を得ることは容易でない。当該弾性復帰力を得るには、コネクタカバーの自然開口径（弾性変形していない状態での径）をジョイントコネクタの最大外径よりもかなり小さく設定しなければならず、このことは、当該コネクタカバー内へのジョイントコネクタの挿入作業を非常に煩わしいものにする。すなわち、作業者は特別な治具等を用いて前記コネクタカバーの開口を非常に大きな力で強制的に拡張させなければならない。また、このような作業の自動化もきわめて困難である。 However, in this method, since the opening end of the connector cover is brought into close contact with the electric wire only by its elastic restoring force, the opening end of the connector cover is securely attached to all the plural electric wires. In order to make it closely contact, a considerable elastic restoring force is required, and it is not easy to obtain such an elastic restoring force. In order to obtain the elastic restoring force, the natural opening diameter of the connector cover (the diameter when not elastically deformed) must be set to be considerably smaller than the maximum outer diameter of the joint connector. Inserting the joint connector into the cover is very troublesome. That is, the operator must forcibly expand the opening of the connector cover with a very large force using a special jig or the like. Also, automation of such operations is extremely difficult.
　前記のような難しい作業を避けながら前記コネクタカバーの電線への密着をより確実にする方法として、前記弾性復帰力だけでなく、例えば粘着テープといった補助的な部材を併用することが考えられるが、このような補助的部材の併用は、著しい工数の増加及び構造の複雑化を招く。 As a method of ensuring the close contact of the connector cover with the electric wire while avoiding the difficult work as described above, it is conceivable to use not only the elastic restoring force but also an auxiliary member such as an adhesive tape, The combined use of such auxiliary members causes a significant increase in man-hours and a complicated structure.
特開平６－１２４７４６号公報JP-A-6-124746
　本発明の目的は、互いに束ねられる複数の電線を含むワイヤハーネスにおいて、防水された短絡回路を容易に形成することが可能な方法、及び、当該短絡回路をもつワイヤハーネスを容易に製造することを可能にする方法の提供にある。本発明が提供する方法は、前記ワイヤハーネスに含まれる電線のうちの特定の複数の電線の端末を共通のジョイントコネクタに接続することによりこれらの電線同士を短絡させる短絡工程と、前記ジョイントコネクタの周囲にこのジョイントコネクタを覆いながらこのジョイントコネクタにつながる電線の端部に密着することにより当該ジョイントコネクタを密封して防水する防水体を形成する防水体製造工程と、を含む。この方法の特徴として、前記防水体製造工程は、第１シート体と、前記ジョイントコネクタ及びこれにつながる各電線の端部と、第２シート体とを、前記ジョイントコネクタ及び前記電線の周囲において前記第１シート体の幅方向の両側部分と前記第２シート体の周縁部分とが直接接触可能となるように重ね合わされる重ね合わせ工程と、その重ね合わせ状態で前記第１シート体の側からエアを吸引することにより前記第２シート体の周縁部分と前記第１シート体の周縁部分とを密着させるとともに両シート体を前記電線の表面に密着させることで両シート体同士の間に前記ジョイントコネクタを密封する密封工程と、を含む。ここで、前記エアの吸引は、前記重ね合わせ工程の段階から行われていてもよい。すなわち、当該エアの吸引を開始するタイミングは、前記重ね合わせ工程の完了の前後を問わない。 It is an object of the present invention to provide a method for easily forming a waterproof short circuit in a wire harness including a plurality of electric wires bundled together, and to easily manufacture a wire harness having the short circuit. It is in providing a method that enables it. The method provided by the present invention includes a short-circuiting step of short-circuiting these electric wires by connecting terminals of a plurality of electric wires included in the wire harness to a common joint connector; A waterproof body manufacturing process for forming a waterproof body that seals and waterproofs the joint connector by closely contacting an end portion of an electric wire connected to the joint connector while covering the joint connector in the periphery. As a feature of this method, the waterproof body manufacturing process includes a first sheet body, an end of each joint connector and each electric wire connected thereto, and a second sheet body around the joint connector and the electric wire. An overlapping process in which both side portions in the width direction of the first sheet body and the peripheral portion of the second sheet body are directly brought into contact with each other, and air from the side of the first sheet body in the overlapping state The joint connector between the two sheet bodies is brought into close contact with the peripheral portion of the second sheet body and the peripheral portion of the first sheet body by sucking Sealing step for sealing. Here, the air suction may be performed from the stage of the superimposing step. That is, the timing at which the air suction is started does not matter before or after completion of the superposition process.
本発明の実施の形態に係るワイヤハーネスの製造過程において複数の電線の端末に共通のジョイントコネクタが接続された状態を示す斜視図である。It is a perspective view which shows the state in which the common joint connector was connected to the terminal of a some electric wire in the manufacture process of the wire harness which concerns on embodiment of this invention. 前記ジョイントコネクタがその防水のための防水体の内部に密封された状態を示す斜視図である。It is a perspective view which shows the state by which the said joint connector was sealed inside the waterproofing body for the waterproofing. 前記電線の端末に装着された電線側端子が前記ジョイントコネクタに挿入される途中の状態を示す断面側面図である。It is a cross-sectional side view which shows the state in the middle of the wire side terminal with which the terminal of the said electric wire was mounted | worn being inserted in the said joint connector. 前記電線の端末に装着された電線側端子が前記ジョイントコネクタに完全に挿入された状態を示す断面側面図である。It is a cross-sectional side view which shows the state by which the electric wire side terminal with which the terminal of the said electric wire was mounted | worn was completely inserted in the said joint connector. 前記ジョイントコネクタの底面図である。It is a bottom view of the joint connector. 前記ジョイントコネクタの断面平面図である。It is a cross-sectional plan view of the joint connector. 前記ジョイントコネクタを密封する防水体を形成するための重ね合わせ工程を示す断面図である。It is sectional drawing which shows the superimposition process for forming the waterproof body which seals the said joint connector. 前記防水体を形成するための密封工程を示す断面図である。It is sectional drawing which shows the sealing process for forming the said waterproof body. （ａ）（ｂ）は前記密封工程における各電線と両シート体との密着状態を示す断面図である。(A) (b) is sectional drawing which shows the contact | adherence state of each electric wire and both sheet bodies in the said sealing process.
　本発明の好ましい実施の形態を、図面を参照しながら説明する。 A preferred embodiment of the present invention will be described with reference to the drawings.
　図１は、この実施形態に係るワイヤハーネス１００と、当該ワイヤハーネス１００の短絡回路を形成するのに用いられるジョイントコネクタＪＣとを示す。このジョイントコネクタＪＣは、図２に示すような第１シート体５２Ａ及び第２シート体５２Ｂからなる防水体５０の内部に密封されることにより防水される。 FIG. 1 shows a wire harness 100 according to this embodiment and a joint connector JC used to form a short circuit of the wire harness 100. The joint connector JC is waterproofed by being sealed inside a waterproof body 50 including a first sheet body 52A and a second sheet body 52B as shown in FIG.
　この実施の形態にかかるワイヤハーネス１００は、次の工程により製造される。 The wire harness 100 according to this embodiment is manufactured by the following process.
　１）幹線１２の形成及び特定の電線１０の引き出し
　複数本の電線１０が束ねられることにより幹線１２が形成されるとともに、その電線１０のうちの複数本（この実施の形態では４本）の電線が分岐電線群１４として前記幹線１２から引き出される。幹線１２については、その周囲に例えばテープが螺旋状に巻き付けられることにより、電線１０が束ねられた状態が保持される。前記各電線１０には、いわゆる被覆電線が用いられ、当該電線１０は導体とこれを被覆する絶縁被覆とをそれぞれ有する。 1) Formation of trunk line 12 and withdrawal of specific electric wire 10 A plurality of electric wires 10 are bundled to form the main wire 12, and a plurality of the electric wires 10 (four in this embodiment) Is drawn out from the trunk line 12 as the branch wire group 14. About the trunk line 12, the state where the electric wire 10 was bundled is hold | maintained, for example by winding a tape helically around the circumference | surroundings. Each electric wire 10 is a so-called covered electric wire, and the electric wire 10 has a conductor and an insulating coating that covers the conductor.
　この実施の形態では、前記分岐電線群１４に含まれる電線１０を共通のジョイントコネクタＪＣに接続するために、予め当該電線１０の端末に図３及び図４に示すような電線側端子２０がそれぞれ装着されている。この電線側端子２０は、雌型の電気接触部２２と電線圧着部２４とを前後に有する。前記電気接触部２２は、中空角筒状の本体と、この本体内で撓み可能に設けられる接触ばね片２６とを有する。この電気接触部２２の底壁からは、前記ジョイントコネクタＪＣに係止されるための被係止片２８が外向きに突出している。前記分岐電線群１４に含まれる各電線１０の端末には、予め、その絶縁被覆を除去して導体を露出させる処理が施されており、前記電線圧着部２４は、前記導体の端末及びその近傍の絶縁被覆をそれぞれ抱き込むように曲げ加工されることにより、前記分岐電線群１４の端末に圧着され、その導体に電気的に接続されている。 In this embodiment, in order to connect the electric wires 10 included in the branch electric wire group 14 to the common joint connector JC, the electric wire side terminals 20 as shown in FIGS. It is installed. The electric wire side terminal 20 has a female electrical contact portion 22 and an electric wire crimping portion 24 at the front and rear. The electrical contact portion 22 has a hollow rectangular tube-shaped main body and a contact spring piece 26 provided so as to be able to bend in the main body. From the bottom wall of the electrical contact portion 22, a locked piece 28 for locking to the joint connector JC protrudes outward. The terminal of each electric wire 10 included in the branch electric wire group 14 is previously subjected to a treatment for removing the insulating coating and exposing the conductor, and the electric wire crimping portion 24 is connected to the end of the conductor and the vicinity thereof. Are bent so as to embrace each of the insulating coatings, so that they are crimped to the ends of the branch wire group 14 and electrically connected to the conductors.
　２）ジョイントコネクタＪＣへの接続（短絡工程）
　前記各電線側端子２０が図３～図６に示されるようなジョイントコネクタＪＣに接続されることにより、当該電線側端子２０がそれぞれ装着される電線１０同士の短絡が行われる。 2) Connection to the joint connector JC (short circuit process)
By connecting each electric wire side terminal 20 to a joint connector JC as shown in FIGS. 3 to 6, the electric wires 10 to which the electric wire side terminals 20 are respectively attached are short-circuited.
　この実施の形態にかかるジョイントコネクタＪＣは、単一の短絡用導体３０と、この短絡用導体３０を保持するための絶縁ハウジング４０とを備える。前記短絡用導体３０は、導電材料からなり、前記各電線側端子２０に共通して接続されることによりこれらの電線側端子２０同士を短絡させる。前記絶縁ハウジング４０は、合成樹脂等の絶縁材料により全体が一体に成型され、前記短絡用導体３０を格納した状態で保持することが可能な形状、具体的には当該短絡用導体３０の厚み方向に偏平な形状を有する。 The joint connector JC according to this embodiment includes a single short-circuit conductor 30 and an insulating housing 40 for holding the short-circuit conductor 30. The short-circuiting conductor 30 is made of a conductive material, and is short-circuited between the electric wire side terminals 20 by being commonly connected to the electric wire side terminals 20. The insulating housing 40 is integrally formed of an insulating material such as synthetic resin, and can be held in a state in which the shorting conductor 30 is stored, specifically, the thickness direction of the shorting conductor 30. It has a flat shape.
　この実施の形態に係る短絡用導体３０は、単一の金属板を適当な形状に打ち抜くことにより形成された短絡用金属板からなり、複数の嵌合部３２と、短絡部３４とを一体に有する。各嵌合部３２は、前記各電線側端子２０の雌型の電気接触部２２に嵌入可能な雄型（タブ）の嵌合部であり、これらの嵌合部３２がその幅方向と平行な方向、すなわち短絡用金属板の厚み方向と直交する方向に配列されている。前記短絡部３４は、前記嵌合部３２の配列方向に延び、この短絡部３４に前記各嵌合部３２の基端がつながっている。 The short-circuit conductor 30 according to this embodiment is composed of a short-circuit metal plate formed by punching a single metal plate into an appropriate shape, and a plurality of fitting portions 32 and short-circuit portions 34 are integrated. Have. Each fitting portion 32 is a male (tab) fitting portion that can be fitted into the female electrical contact portion 22 of each electric wire side terminal 20, and these fitting portions 32 are parallel to the width direction thereof. It is arranged in the direction, that is, the direction orthogonal to the thickness direction of the metal plate for short circuit. The short-circuit portion 34 extends in the arrangement direction of the fitting portions 32, and the short ends 34 are connected to the base ends of the fitting portions 32.
　前記絶縁ハウジング４０は、互いに平行な平板状の天壁４１及び底壁４２と、両壁４１，４２の幅方向両端部同士（すなわち左側端部同士及び右側端部同士）をそれぞれつなぐ一対の側壁４４とを一体に有する。これらの壁４１，４２，４４は絶縁ハウジング４０の外壁を構成する。 The insulating housing 40 has a pair of side walls that connect the flat top wall 41 and the bottom wall 42 that are parallel to each other, and both ends of the walls 41 and 42 in the width direction (that is, the left end portions and the right end portions). 44 integrally. These walls 41, 42, 44 constitute the outer wall of the insulating housing 40.
　前記外壁の後端部（図３～図６では右端部）は、導体保持部４３を構成する。この導体保持部４３内に前記開口部４３ａから前記短絡用導体３０の短絡部３４が圧入されることにより、当該短絡部３４が当該導体保持部４３に保持される。 The rear end portion (right end portion in FIGS. 3 to 6) of the outer wall constitutes a conductor holding portion 43. The short-circuit portion 34 is held by the conductor holding portion 43 by press-fitting the short-circuit portion 34 of the short-circuiting conductor 30 into the conductor holding portion 43 from the opening 43 a.
　前記導体保持部４３は、前記短絡用導体３０の短絡部３４を保持する形状を有する。具体的には、前記短絡部３４よりも一回り大きく、前記短絡用導体３０の嵌合部３２の配列方向に延びる外形を有し、前記短絡部３４が後方（図８では左方）から挿入可能な短絡用金属板挿入口４３ａを囲む。この挿入口４３ａから前記短絡部３４が前記各嵌合部３２を前方に向けた姿勢で導体保持部４３内に圧入される。より詳しくは、当該短絡部３４の幅方向両端部に図６に示すような突起３４ａが形成されており、これらの突起３４ａが前記導体保持部４３の内側面に食い込むことで前記導体保持部４３に前記短絡部３４が固定されている。 The conductor holding portion 43 has a shape for holding the short-circuit portion 34 of the short-circuit conductor 30. Specifically, it has an outer shape that is slightly larger than the short-circuit portion 34 and extends in the arrangement direction of the fitting portions 32 of the short-circuit conductor 30, and the short-circuit portion 34 is inserted from the rear (left side in FIG. 8). A possible short-circuit metal plate insertion opening 43a is enclosed. The short-circuit portion 34 is press-fitted into the conductor holding portion 43 from the insertion port 43a with the fitting portions 32 facing forward. More specifically, protrusions 34 a as shown in FIG. 6 are formed at both ends in the width direction of the short-circuit part 34, and these conductors 34 a dig into the inner side surface of the conductor holding part 43. The short-circuit part 34 is fixed to.
　前記導体保持部４３よりも前側の部分には、両側壁４４と平行な複数（図では３つ）の仕切り壁４５がコネクタ幅方向に配列される。各仕切り壁４５は、これに隣接する他の仕切り壁４５または側壁４４との間にそれぞれ端子収容室４７を画定する。これらの端子収容室４７は、各嵌合部３２に対応して形成され、当該嵌合部３２に前記各電線側端子２０が嵌合されるのを許容するように当該電線側端子２０を受け入れる形状、具体的には前方に開口してその開口から前記電線側端子２０が挿入可能な形状を有する。各端子収容室４７内にはそれぞれ後方から前記短絡用導体３０の各嵌合部３２が突出しており、当該端子収容室４７に挿入された電線側端子２０の電気接触部２２が前記嵌合部３２と嵌合することにより当該電線側端子２０と短絡用導体３０とが電気的に導通する。 A plurality of (three in the figure) partition walls 45 parallel to the side walls 44 are arranged in the connector width direction at a portion on the front side of the conductor holding portion 43. Each partition wall 45 defines a terminal accommodating chamber 47 between another partition wall 45 or a side wall 44 adjacent thereto. These terminal accommodating chambers 47 are formed corresponding to the respective fitting portions 32 and receive the electric wire side terminals 20 so as to allow the electric wire side terminals 20 to be fitted into the fitting portions 32. It has a shape, specifically a shape that opens forward and allows the wire-side terminal 20 to be inserted through the opening. In each terminal accommodating chamber 47, each fitting portion 32 of the short-circuiting conductor 30 protrudes from the rear, and the electric contact portion 22 of the electric wire side terminal 20 inserted into the terminal accommodating chamber 47 is the fitting portion. The electric wire side terminal 20 and the short-circuiting conductor 30 are electrically connected to each other by being engaged with the terminal 32.
　前記底壁４２には、前記各端子収容室４７に対応する位置に、端子係止部であるランス４６が形成されている。各ランス４６は、図５に示すように前記底壁４２に形成されたスリット４２ａ、すなわち、コネクタの前後方向に延びる互いに平行な一対の直線状部分とこれらの直線状部分の端同士をコネクタ幅方向につなぐ部分とを有する形状のスリット４２ａにより囲まれていて、当該底壁４２の本体に対してその厚み方向に撓む（すなわち弾性変位する）することが可能な自由端部を有し、その自由端部に爪状の係止部４６ａが形成されている。この係止部４６ａは、挿入される電線側端子２０と接触することにより図３に示すように撓み変位して当該電線側端子２０の通過を許容し、その通過後に正規の位置に弾性的に復帰することにより前記電線側端子２０の被係止片２８を後方から拘束する。 The bottom wall 42 is formed with a lance 46 that is a terminal locking portion at a position corresponding to each terminal accommodating chamber 47. As shown in FIG. 5, each lance 46 has a slit 42a formed in the bottom wall 42, that is, a pair of parallel linear portions extending in the front-rear direction of the connector and the ends of these linear portions are connected to each other in the connector width. A free end portion that is surrounded by a slit 42a having a shape that connects in a direction and can bend (i.e., elastically displaced) in the thickness direction with respect to the main body of the bottom wall 42; A claw-like locking portion 46a is formed at the free end. As shown in FIG. 3, the engaging portion 46a is flexibly displaced as shown in FIG. 3 by coming into contact with the inserted electric wire side terminal 20, and allows the electric wire side terminal 20 to pass. By returning, the locked piece 28 of the electric wire side terminal 20 is restrained from the rear.
　つまり、当該ランス４６は、前記係止部４６ａが前記電線側端子２０をこの電線側端子２０が前記嵌合部３２と嵌合する位置に係止する係止位置（図４に示す位置）と、この係止位置から当該ランス４６の弾性変形を伴って外側に退避する退避位置（図３に示す位置）とを有し、前記係止位置では前記底壁４２の他の部分の外面と同じ面上に位置し、前記退避位置では当該底壁４２の他の部分の外面から外向きに突出する。 That is, the lance 46 has a locking position (position shown in FIG. 4) where the locking portion 46 a locks the electric wire side terminal 20 at a position where the electric wire side terminal 20 is engaged with the fitting portion 32. And a retraction position (position shown in FIG. 3) that retreats to the outside with the elastic deformation of the lance 46 from this locking position, which is the same as the outer surface of the other part of the bottom wall 42 at the locking position. It is located on the surface and protrudes outward from the outer surface of the other part of the bottom wall 42 at the retracted position.
　従って、このジョイントコネクタＪＣでは、その端子収容室４７内に前記分岐電線群１４に含まれる電線１０の端末の電線側端子２０が挿入されてそのまま短絡用導体３０の嵌合部３２に嵌合されることにより、当該短絡用導体３０を接続媒体とした電線側端子２０同士の短絡が達成される。すなわち、当該電線側端子２０がそれぞれ装着された複数の電線１０についての短絡回路が形成される。 Therefore, in this joint connector JC, the wire-side terminal 20 at the end of the wire 10 included in the branch wire group 14 is inserted into the terminal accommodating chamber 47 and is directly fitted into the fitting portion 32 of the short-circuiting conductor 30. Thereby, the short circuit between the electric wire side terminals 20 using the shorting conductor 30 as a connection medium is achieved. That is, the short circuit about the some electric wire 10 with which the said electric wire side terminal 20 was each mounted | worn is formed.
　３）短絡回路の防水（防水体製造工程）
　前記ジョイントコネクタＪＣ及びこれにつながる電線１０（分岐電線群１４に含まれる電線１０）の端部１０ａの周囲に、図２に示すような防水体５０が形成され、この防水体５０の内部に前記ジョイントコネクタＪＣが密封されることにより、前記短絡回路の防水がなされる。前記防水体５０は、例えば次の工程によって効率よく製造されることが可能である。 3) Waterproofing of short circuit (waterproof body manufacturing process)
A waterproof body 50 as shown in FIG. 2 is formed around the joint connector JC and an end portion 10a of the electric wire 10 connected thereto (the electric wires 10 included in the branch wire group 14). By sealing the joint connector JC, the short circuit is waterproofed. The waterproof body 50 can be efficiently manufactured by the following process, for example.
　３－１）重ね合わせ工程
　この工程は、図７に示すように前記ジョイントコネクタＪＣの平面形状よりも十分大きな寸法を有する第１シート体５２Ａと、前記ジョイントコネクタＪＣ及びこれにつながる各電線１０の端部１０ａと、前記ジョイントコネクタＪＣの平面形状よりも十分大きな寸法を有する（この実施の形態では第１シート体５２Ａよりも大きな形状を有する）第２シート体５２Ｂとを前記ジョイントコネクタＪＣの厚み方向に重ね合わせる工程であり、この重ね合わせは、前記ジョイントコネクタＪＣ及び前記電線１０の周囲において前記第１シート体５２Ａの周縁部分５２ａと前記第２シート体５２Ｂの周縁部分５２ｂとが直接接触可能となるように行われる。 3-1) Overlaying process This process includes the first sheet body 52A having a dimension sufficiently larger than the planar shape of the joint connector JC, the joint connector JC, and the electric wires 10 connected thereto, as shown in FIG. The thickness of the joint connector JC includes the end portion 10a and the second sheet body 52B having a dimension sufficiently larger than the planar shape of the joint connector JC (having a shape larger than the first sheet body 52A in this embodiment). In this process, the peripheral portion 52a of the first sheet body 52A and the peripheral portion 52b of the second sheet body 52B can directly contact each other around the joint connector JC and the electric wire 10. It is done to become.
　この実施の形態では、防水体５０の形成のために図７に示すような真空成形用型６０が用いられる。この真空成形用型６０は、平坦な上面を有し、これが成形面６２を構成する。当該成形面６２では複数の吸引口６４が開口し、これらの吸引口６４は前記真空成形用型６０の内部に形成されたエア通路を介して図略の真空ポンプに接続され、この真空ポンプは前記吸引口６４からその上方のエアを吸引する。 In this embodiment, a vacuum forming die 60 as shown in FIG. 7 is used for forming the waterproof body 50. The vacuum forming die 60 has a flat upper surface, which forms a forming surface 62. A plurality of suction ports 64 are opened on the molding surface 62, and these suction ports 64 are connected to a vacuum pump (not shown) through an air passage formed in the vacuum molding die 60. Air above the suction port 64 is sucked.
　前記第１シート体５２Ｂは、前記真空成形用型６０の成形面６２の上に敷かれる。この第１シート体５２Ａは、例えば合成樹脂からなるシートにより構成される。この第１シート体５２Ａの周縁部分５２ａ（前記ジョイントコネクタＪＣから外側にはみ出した部分）には、後述のエアの吸引による第２シート体５２Ｂとの密着を促進するために多数の通気孔が設けられてもよい。この場合、前記通気孔の孔径は例えば３ｍｍ程度が好適である。 The first sheet body 52B is laid on the molding surface 62 of the vacuum forming mold 60. The first sheet body 52A is constituted by a sheet made of, for example, a synthetic resin. A number of ventilation holes are provided in the peripheral portion 52a of the first sheet body 52A (the portion protruding outward from the joint connector JC) in order to promote close contact with the second sheet body 52B by air suction described later. May be. In this case, the diameter of the vent hole is preferably about 3 mm, for example.
　前記ジョイントコネクタＪＣ及びこれにつながる電線１０の端部１０ａは、その外側に前記第１シート体５２Ａがはみ出すような相対位置関係で当該第１シート体５２Ａ上に載置される。 The joint connector JC and the end portion 10a of the electric wire 10 connected to the joint connector JC are placed on the first sheet body 52A in a relative positional relationship such that the first sheet body 52A protrudes outside the joint connector JC.
　前記第２シート体５２Ｂも、合成樹脂、例えば前記第１シート体５２Ａと同じ材質の合成樹脂からなるシートにより構成される。そして、当該第２シート体５２Ｂの周縁部分５２ｂが前記第１シート体５２Ａの周縁部分５２ａと直接接触するように当該第２シート体５２Ｂが前記ジョイントコネクタＪＣ及びこれにつながる電線１０の上に被せられる。 The second sheet body 52B is also composed of a synthetic resin, for example, a sheet made of a synthetic resin made of the same material as the first sheet body 52A. Then, the second sheet body 52B covers the joint connector JC and the electric wire 10 connected thereto so that the peripheral portion 52b of the second sheet body 52B is in direct contact with the peripheral portion 52a of the first sheet body 52A. It is done.
　前記両シート体５２Ａ，５２Ｂの材質は特に限定されないが、少なくとも第２シート体５２Ｂは例えばポリ塩化ビニル、ポリエチレン、ポリエステルといった熱可塑性樹脂であることがより好ましい。このような熱可塑性樹脂からなる第２シート体５２Ｂは、加熱されることにより軟化するため、当該第２シート体５２Ｂの強度を確保するためにその厚みが比較的大きく設定されていても、すなわち当該第２シート体５２Ｂの常温での柔軟性が低い場合でも、その軟化によって第２シート体５２Ｂは前記ジョイントコネクタＪＣやこれにつながる電線１０の端部１０ａの形状に十分なじみながら前記第１シート体５２Ａの周縁部分５２ａや電線１０の表面と良好に接触することができる。 The material of the two sheet bodies 52A and 52B is not particularly limited, but at least the second sheet body 52B is more preferably a thermoplastic resin such as polyvinyl chloride, polyethylene, or polyester. Since the second sheet body 52B made of such a thermoplastic resin is softened by being heated, the thickness of the second sheet body 52B is set to be relatively large in order to ensure the strength of the second sheet body 52B. Even if the flexibility of the second sheet body 52B at room temperature is low, the second sheet body 52B is sufficiently softened to the shape of the joint connector JC and the end portion 10a of the electric wire 10 connected thereto due to the softening. The peripheral portion 52a of the body 52A and the surface of the electric wire 10 can be satisfactorily contacted.
　具体的には、例えば図７に示すようなヒータ６６が前記真空成形用型６０の上方に配置され、このヒータ６６の下面上に前記第２シート体５２Ｂが保持部６８によって保持されかつ軟化し、その状態で当該ヒータ６６から前記第２シート体５２Ｂが切り離されて前記ジョイントコネクタＪＣおよびこれにつながる電線１０の端部１０ａの上に被せられるのがよい。 Specifically, for example, a heater 66 as shown in FIG. 7 is disposed above the vacuum forming die 60, and the second sheet body 52B is held by the holding portion 68 on the lower surface of the heater 66 and softened. In this state, the second sheet body 52B is preferably cut off from the heater 66 and placed on the joint connector JC and the end portion 10a of the electric wire 10 connected thereto.
　また、前記吸引口６４からのエアの吸引は、次の密封工程でのみ行われてもよいが、好ましくはこの重ね合わせ工程の段階から行われるのがよい。この重ね合わせ工程でのエアの吸引は、前記成形面６２上での第１シート体５２Ａの保持、さらには、当該第１シート体５２Ａ及び前記ジョイントコネクタＪＣ上への前記第２シート体５２Ｂの誘引に寄与する。 Further, the suction of air from the suction port 64 may be performed only in the next sealing step, but preferably it is performed from the stage of the superimposing step. The suction of the air in the overlapping step holds the first sheet body 52A on the molding surface 62, and further, the second sheet body 52B on the first sheet body 52A and the joint connector JC. Contributes to attraction.
　３－２）密封工程
　前記の重ね合わせ状態で前記第１シート体５２Ａの側、より詳しくは前記各吸引口６４側すなわち第２シート体５２Ｂと反対の側から第１シート体５２Ａの上側（すなわち第２シート体５２Ｂ側）のエアが吸引される。これにより、前記第２シート体５２Ｂの周縁部分５２ｂが吸引されて前記第１シート体５２Ａの周縁部分に密着するとともに、両シート体５２Ａ，５２Ｂの（後端側の）周縁部分５２ａ，５２ｂが前記電線１０の端部１０ａに密着し、これにより、前記ジョイントコネクタＪＣを密封する防水体５０が形成される。特に、前記第１シート体５２Ａの周縁部分５２ａに多数の通気孔が設けられている場合には、その通気孔を通じて当該周縁部分５２ａ上のエアが直接的に吸引されるから、当該周縁部分５２ａと第２シート体５２Ｂの周縁部分５２ｂとの密着が促進される。当該通気孔が設けられていない場合は、前記周縁部分５２ａ上のエアが当該周縁部分５２ａの外側に回り込むようにして前記吸引口６４へ吸引される。 3-2) Sealing Step In the superposed state, from the side of the first sheet body 52A, more specifically from the side of each suction port 64, that is, the side opposite to the second sheet body 52B, the upper side of the first sheet body 52A (ie The air on the second sheet body 52B side) is sucked. Thereby, the peripheral portion 52b of the second sheet body 52B is sucked and closely adhered to the peripheral portion of the first sheet body 52A, and the peripheral portions 52a and 52b (on the rear end side) of both the sheet bodies 52A and 52B are A waterproof body 50 is formed which is in close contact with the end portion 10a of the electric wire 10 and seals the joint connector JC. In particular, when a large number of vent holes are provided in the peripheral portion 52a of the first sheet body 52A, air on the peripheral portion 52a is directly sucked through the vent holes. And the peripheral portion 52b of the second sheet body 52B are promoted. When the vent hole is not provided, the air on the peripheral portion 52a is sucked into the suction port 64 so as to go around the outer periphery portion 52a.
　一方、前記電線１０同士の間隔は、ジョイントコネクタＪＣから離れるに従って狭くなっているが、図９（ａ）（ｂ）に示されるように、当該電線１０同士の間隔の大小にかかわらず前記両シート体５２Ａ，５２Ｂは前記真空成形用型６０によって各電線１０の表面に良好に密着することができる。 On the other hand, the distance between the electric wires 10 becomes narrower as the distance from the joint connector JC increases. However, as shown in FIGS. 9 (a) and 9 (b), the both sheets can be used regardless of the distance between the electric wires 10. The bodies 52 </ b> A and 52 </ b> B can be satisfactorily adhered to the surface of each electric wire 10 by the vacuum forming mold 60.
　前記両シート体５２Ａ，５２Ｂの周縁部分５２ａ，５２ｂ同士の密着状態は、当該周縁部分５２ａ，５２ｂ同士が接着されることで、より確実に保持される。具体的には、前記両シート体５２Ａ，５２Ｂのうちの少なくとも一方について、シート本体層（例えば上述した合成樹脂製のシート）とその裏面（相手方のシート体に対向する面）上に設けられる接着剤層とを有するものが、用意されればよい。その接着剤層は両シート体５２Ａ，５２Ｂの周縁部分５２ａ，５２ｂ同士を接着することでその密着状態を強固にする。当該接着剤層には、例えば、ブチルゴム系の粘着剤のような柔軟性に富むものや、エポキシ樹脂等の熱硬化性の液状剤が好適である。 The contact state between the peripheral portions 52a and 52b of the both sheet bodies 52A and 52B is more reliably maintained by bonding the peripheral portions 52a and 52b to each other. Specifically, for at least one of the two sheet bodies 52A and 52B, the adhesive provided on the sheet body layer (for example, the above-described synthetic resin sheet) and the back surface (the surface facing the other sheet body). What has an agent layer should just be prepared. The adhesive layer strengthens the contact state by adhering the peripheral portions 52a and 52b of the two sheet bodies 52A and 52B. For the adhesive layer, for example, a flexible material such as a butyl rubber-based pressure-sensitive adhesive or a thermosetting liquid agent such as an epoxy resin is suitable.
　図７～図９に示す例では、第１シート体５２Ａ及び第２シート体５２Ｂの双方に接着剤層を含むものが用いられている。すなわち、第１シート体５２Ａは、シート本体層５４Ａ及びその裏面上に設けられる接着剤層５６Ａを有し、第２シート体５２Ｂは、シート本体層５４Ｂ及びその裏面上に設けられる接着剤層５６Ｂを有している。このようなシート体５２Ａ，５２Ｂの組み合わせによれば、その周縁部分５２ａ，５２ｂ同士の密着だけでなく、図９に示すような（後端側の）周縁部分５２ａ，５２ｂと各電線１０の端部１０ａの表面との密着も前記接着剤層５６Ａ，５６Ｂによる接着でそれぞれ強固に保持される。 In the example shown in FIGS. 7 to 9, both the first sheet body 52A and the second sheet body 52B include an adhesive layer. That is, the first sheet body 52A includes a sheet main body layer 54A and an adhesive layer 56A provided on the back surface thereof, and the second sheet body 52B includes a sheet main body layer 54B and an adhesive layer 56B provided on the back surface thereof. have. According to such a combination of sheet bodies 52A and 52B, not only the peripheral portions 52a and 52b are in close contact with each other, but also the peripheral portions 52a and 52b (on the rear end side) as shown in FIG. The close contact with the surface of the portion 10a is also firmly held by adhesion by the adhesive layers 56A and 56B.
　以上示した方法は、従来のように袋状の防水体の開口を専用の治具で強制的に拡開しながら当該防水体内にジョイントコネクタを挿入するといった面倒な作業を要しない。作業者はきわめて負担の少ない工程で確実に短絡回路の形成及びその防水を実行できる。 The method described above does not require the troublesome work of inserting the joint connector into the waterproof body while forcibly expanding the opening of the bag-shaped waterproof body with a dedicated jig as in the prior art. The operator can surely form the short circuit and waterproof it by a process with very little burden.
　この方法は、特に、前記電線側端子２０のうちの少なくとも一部について、当該電線側端子１０及びこれが装着される電線の導体が互いに異なる金属材料で構成される場合、例えば当該導体がアルミニウムまたはアルミニウム合金からなって前記電線側端子２０が銅または銅合金からなる場合に、顕著な優位性を発揮する。すなわち、互いに異種の金属材料で構成された電線側端子２０及びこれが装着される導体は、その接合部分に水分が浸入すると腐食が進行し易いから、当該電線側端子２０を含む短絡回路を確実に防水することは、接続信頼性の向上及び寿命の延長に大きく寄与する。 This method is particularly suitable for the case where at least a part of the electric wire side terminal 20 is composed of different metal materials for the electric wire side terminal 10 and the electric wire to which the electric wire side terminal 10 is attached. When the electric wire side terminal 20 is made of an alloy and is made of copper or a copper alloy, a significant advantage is exhibited. That is, the wire-side terminal 20 composed of different metal materials and the conductor to which the wire-side terminal 20 is attached are likely to corrode when moisture enters the joint portion, so that the short circuit including the wire-side terminal 20 is surely provided. Waterproofing greatly contributes to improvement of connection reliability and extension of life.
　本発明において、用いられるジョイントコネクタの具体的な形状及び構造は特に限定されない。例えば、コネクタ端子が上下複数段にわたって配列されたものでもよいし、電線側端子２０及び短絡用導体３０がそれぞれ別のコネクタハウジングに保持されていてこれらのコネクタハウジング同士が嵌合されるものでもよい。 In the present invention, the specific shape and structure of the joint connector used is not particularly limited. For example, the connector terminals may be arranged over a plurality of upper and lower stages, or the electric wire side terminal 20 and the short-circuiting conductor 30 may be held in separate connector housings, and these connector housings may be fitted together. .
　しかし、各図に示すようなジョイントコネクタＪＣは、その厚み方向の寸法が小さい偏平な形状を有するから、その厚み方向に当該ジョイントコネクタＪＣ及びこれにつながる電線１０と両シート体５２Ａ，５２Ｂとが重ね合わされることにより、当該両シート体５２Ａ，５２Ｂの周縁部分５２ａ，５２ｂ同士の密着及び当該周縁部分５２ａ，５２ｂと前記電線１０の表面との密着がより容易にかつ確実に行われる。 However, since the joint connector JC as shown in each figure has a flat shape with a small dimension in the thickness direction, the joint connector JC and the electric wire 10 connected to the joint connector JC and both sheet bodies 52A and 52B are arranged in the thickness direction. By overlapping, the close contact between the peripheral portions 52a and 52b of both the sheet bodies 52A and 52B and the close contact between the peripheral portions 52a and 52b and the surface of the electric wire 10 are more easily and reliably performed.
　特に、前記のように外壁（図では底壁４２）に端子係止部であるランス４６が形成されるものでは、厚み方向の寸法がさらに削減されるのに加え、このランス４６がその退避位置において当該外壁から外向きに突出するものを用いる場合には、このランス４６を前記係止位置で前記第１シート体５２Ａまたは前記第２シート体５２Ｂ（図８では第１シート体５２Ａ）によって外側から拘束するように両シート体の周縁部分５２ａ，５２ｂ同士の接合を行うことにより、簡単な構造でジョイントコネクタＪＣでの接続信頼性を高めることができる。すなわち、この方法では、前記ジョイントコネクタＪＣを密封する第１シート体５２Ａまたは第２シート体５２Ｂを利用して当該ジョイントコネクタＪＣの外壁（この実施の形態では底壁４２）を外側から拘束することにより、ランス４６が前記係止位置から前記退避位置に変位するのを抑止できるから、ジョイントコネクタＪＣに電線側端子２０を二重係止するための特別な構造を付与することなく、すなわち当該ジョイントコネクタＪＣの形状を薄型形状に維持したまま、ランス４６による電線側端子２０の係止をより確実に保持することが可能である。 In particular, in the case where the lance 46 as the terminal locking portion is formed on the outer wall (the bottom wall 42 in the figure) as described above, the dimension in the thickness direction is further reduced, and the lance 46 is in its retracted position. In this case, the lance 46 is moved outside by the first sheet body 52A or the second sheet body 52B (the first sheet body 52A in FIG. 8) at the locking position. By connecting the peripheral edge portions 52a and 52b of the two sheet bodies so as to be restrained from each other, the connection reliability at the joint connector JC can be enhanced with a simple structure. That is, in this method, the outer wall (the bottom wall 42 in this embodiment) of the joint connector JC is restrained from the outside by using the first sheet body 52A or the second sheet body 52B that seals the joint connector JC. Therefore, it is possible to prevent the lance 46 from being displaced from the locking position to the retracted position, so that the joint connector JC is not provided with a special structure for double-locking the electric wire side terminal 20, that is, the joint. It is possible to more reliably hold the wire-side terminal 20 by the lance 46 while keeping the shape of the connector JC thin.
　以上のように、本発明によれば、互いに束ねられる複数の電線を含むワイヤハーネスにおいて、防水された短絡回路を容易に形成することが可能な方法が提供される。この方法は、前記ワイヤハーネスに含まれる電線のうちの特定の複数の電線の端末を共通のジョイントコネクタに接続することによりこれらの電線同士を短絡させる短絡工程と、前記ジョイントコネクタの周囲にこのジョイントコネクタを覆いながらこのジョイントコネクタにつながる電線の端部に密着することにより当該ジョイントコネクタを密封して防水する防水体を形成する防水体製造工程と、を含む。この方法の特徴として、前記防水体製造工程は、第１シート体と、前記ジョイントコネクタ及びこれにつながる各電線の端部と、第２シート体とを、前記ジョイントコネクタ及び前記電線の周囲において前記第１シート体の幅方向の両側部分と前記第２シート体の周縁部分とが直接接触可能となるように重ね合わされる重ね合わせ工程と、その重ね合わせ状態で前記第１シート体の側からエアを吸引することにより前記第２シート体の周縁部分と前記第１シート体の周縁部分とを密着させるとともに両シート体を前記電線の表面に密着させることで両シート体同士の間に前記ジョイントコネクタを密封する密封工程と、を含む。ここで、前記エアの吸引は、前記重ね合わせ工程の段階から行われていてもよい。すなわち、当該エアの吸引を開始するタイミングは、前記重ね合わせ工程の完了の前後を問わない。 As described above, according to the present invention, there is provided a method capable of easily forming a waterproof short circuit in a wire harness including a plurality of electric wires bundled together. This method includes a short-circuiting step of short-circuiting these electric wires by connecting ends of a plurality of electric wires included in the wire harness to a common joint connector, and the joint around the joint connector. A waterproof body manufacturing process for forming a waterproof body that seals and waterproofs the joint connector by closely contacting an end portion of an electric wire connected to the joint connector while covering the connector. As a feature of this method, the waterproof body manufacturing process includes a first sheet body, an end of each joint connector and each electric wire connected thereto, and a second sheet body around the joint connector and the electric wire. An overlapping process in which both side portions in the width direction of the first sheet body and the peripheral portion of the second sheet body are directly brought into contact with each other, and air from the side of the first sheet body in the overlapping state The joint connector between the two sheet bodies is brought into close contact with the peripheral portion of the second sheet body and the peripheral portion of the first sheet body by sucking Sealing step for sealing. Here, the air suction may be performed from the stage of the superimposing step. That is, the timing at which the air suction is started does not matter before or after completion of the superposition process.
　この方法では、複数の電線の端部がジョイントコネクタに接続されることにより短絡回路が形成されるのに加え、第１シート体、前記ジョイントコネクタ及びこれにつながる各電線の端部、及び第２シート体がこの順に重ねられた状態で、第１シート体の側からエアが吸引されることにより、両シート体間に前記ジョイントコネクタが密封された構造の構築、すなわち、防水体の製造が達成される。従って、従来のように袋状の防水体の開口を専用の治具で強制的に拡開しながら当該防水体内にジョイントコネクタを挿入するといった面倒な作業は不要であり、作業者の負担の少ない工程で確実に短絡回路の形成及びその防水が達成される。 In this method, in addition to forming the short circuit by connecting the ends of the plurality of electric wires to the joint connector, the first sheet body, the end of the joint connector and each electric wire connected thereto, and the second Construction of a structure in which the joint connector is sealed between the two sheet bodies is achieved by sucking air from the side of the first sheet body in a state where the sheet bodies are stacked in this order, that is, manufacturing a waterproof body. Is done. Therefore, the troublesome work of inserting the joint connector into the waterproof body while forcibly expanding the opening of the bag-shaped waterproof body with a dedicated jig as in the prior art is unnecessary, and the burden on the operator is small. The formation of a short circuit and its waterproofing are reliably achieved in the process.
　この方法では、前記特定の電線の端末にそれぞれ電線側端子が装着される一方、前記ジョイントコネクタとして、単一の金属板からなり、その厚み方向と直交する方向に並ぶ複数の嵌合部を有して各嵌合部が前記各電線側端子とそれぞれ嵌合され、その嵌合状態で当該電線同士を短絡させる短絡用金属板と、この短絡用金属板の厚み方向に偏平な外形を有し、当該短絡用金属板を保持するとともに、当該短絡用金属板の各嵌合部に前記各電線側端子が嵌合されるのを許容するように当該各電線側端子を受け入れる複数の端子収容室を囲む絶縁ハウジングと、を有するものが用いられるのが、好ましい。このジョイントコネクタ及びこれにつながる電線の端部は全体として偏平な（電線の配列方向と直交する方向である厚み方向が小さい）形状を有するので、その厚み方向に両シート体を重ね合わせることにより、両シート体同士の接合をより確実かつ容易に行うことが可能である。 In this method, the electric wire side terminals are respectively attached to the ends of the specific electric wires, and the joint connector is made of a single metal plate and has a plurality of fitting portions arranged in a direction perpendicular to the thickness direction. Then, each fitting portion is fitted to each of the electric wire side terminals, and the shorting metal plate for short-circuiting the electric wires in the fitted state, and a flat outer shape in the thickness direction of the shorting metal plate A plurality of terminal accommodating chambers for holding the wire-side terminals so as to hold the short-circuiting metal plate and allow the wire-side terminals to be fitted into the fitting portions of the short-circuiting metal plate. It is preferred to use an insulating housing that surrounds the housing. Since the joint connector and the end portion of the electric wire connected thereto have a flat shape as a whole (the thickness direction that is perpendicular to the arrangement direction of the electric wires is small), by overlapping both sheet bodies in the thickness direction, It is possible to more reliably and easily join the two sheet bodies.
　さらに、前記ジョイントコネクタは、前記端子収容室に臨む外壁を有してこの外壁に前記電線側端子を係止する端子係止部が形成され、この端子係止部は前記電線側端子を係止する係止位置とこの係止位置から外側に退避して前記外壁から外向きに突出する退避位置との間で弾性変位可能なものであり、この端子係止部が前記係止位置で前記第１シート体または前記第２シート体によって外側から拘束されるように両シート体の周縁部分同士の接合が行われることが、好ましい。この方法では、前記ジョイントコネクタに密着する第１シート体または第２シート体を利用して当該ジョイントコネクタの外壁に形成された端子係止部を前記係止位置に拘束することにより、当該端子係止部が当該係止位置から前記退避位置に変位するのを抑止して当該端子係止部が電線側端子を係止する状態をより確実に保持することが可能になる。 Further, the joint connector has an outer wall facing the terminal accommodating chamber, and a terminal locking portion for locking the electric wire side terminal is formed on the outer wall, and the terminal locking portion locks the electric wire side terminal. The terminal locking portion is elastically displaceable between the locking position and the retracted position retracted outward from the locking position and projecting outward from the outer wall. It is preferable that the peripheral portions of both sheet bodies are joined together so as to be restrained from the outside by the one sheet body or the second sheet body. In this method, the terminal engagement portion formed on the outer wall of the joint connector is constrained to the engagement position by using the first sheet body or the second sheet body that is in close contact with the joint connector. It is possible to prevent the stop portion from being displaced from the locking position to the retracted position, and to more reliably hold the state in which the terminal locking portion locks the electric wire side terminal.
　本発明に係る方法は、エアを吸引するための複数の吸引口が開口する成形面をもつ真空成形用型を用いることにより、さらに効率よく行われることが可能である。具体的に、この真空成形用型を用いた場合には、前記重ね合わせ工程が、前記成形面上に前記第１シート体を敷くことと、前記第１シート体の周縁部分が前記ジョイントコネクタ及びこれにつながる電線の端部の外側にはみ出すように当該第１シート体の上に当該ジョイントコネクタ及びこれにつながる電線の端部を載せることと、前記第２シート体をこの第２シート体が前記ジョイントコネクタ及びこれにつながる電線の端部の周囲で前記第１シート体の周縁部分に重なるように前記ジョイントコネクタ及びこれにつながる電線の端部の上に被せることと、により行われ、前記密封工程が、前記真空成形用型の吸引口からエアを吸引することにより行われる。 The method according to the present invention can be performed more efficiently by using a vacuum forming die having a forming surface in which a plurality of suction ports for sucking air are opened. Specifically, when this vacuum forming mold is used, the superimposing step lays the first sheet body on the molding surface, and the peripheral portion of the first sheet body is the joint connector and The joint connector and the end of the electric wire connected to the first connector are placed on the first sheet so as to protrude outside the end of the electric wire connected thereto, and the second sheet is attached to the second sheet. Covering the joint connector and the end portion of the electric wire connected to the joint connector so as to overlap the peripheral portion of the first sheet body around the end portion of the joint connector and the electric wire connected thereto, and the sealing step Is performed by sucking air from the suction port of the vacuum forming mold.
　前記第２シート体については、当該第２シート体が熱可塑性樹脂からなる層を含み、この層が加熱されることにより軟化した状態で前記ジョイントコネクタ及びこれにつながる電線の端部と前記第１シート体の周縁部分とに被せられるのが、より好ましい。この方法では、前記第２シート体の厚みが比較的大きくて常温での柔軟性が低い場合でも、これを加熱して軟化させることにより当該第２シート体を前記ジョイントコネクタ及びこれにつながる電線の端部の形状になじませながら当該電線の端部及び前記第１シート体の周縁部分に良好に密着させることができる。従って、第２シート体の強度を確保するための当該第２シート体の厚みの設定と、第１及び第２シート体同士の密着によるジョイントコネクタの密封及び防水とを両立させることができる。 As for the second sheet body, the second sheet body includes a layer made of a thermoplastic resin, and the layer is softened by heating, and the joint connector and the end of the electric wire connected thereto and the first sheet body It is more preferable to cover the peripheral portion of the sheet body. In this method, even when the thickness of the second sheet body is relatively large and the flexibility at normal temperature is low, the second sheet body is heated and softened so that the second sheet body is connected to the joint connector and the wires connected thereto. While conforming to the shape of the end, the end of the electric wire and the peripheral portion of the first sheet body can be satisfactorily adhered. Therefore, both the setting of the thickness of the second sheet body for ensuring the strength of the second sheet body and the sealing and waterproofing of the joint connector by the close contact between the first and second sheet bodies can be achieved.
　前記ジョイントコネクタの密封による短絡回路の防水をより確実に行うには、前記第１シート体及び前記第２シート体のうちの少なくとも一方のシート体として、シート本体層及びこのシート本体層の裏面上に設けられる接着剤層とを有するものが用いられ、当該接着剤層により両シート体の周縁部分同士が接着されることが、より好ましい。さらには、両シート体に前記シート体及び前記接着剤層を有するものが用いられ、それぞれの接着剤層により両シート体が前記ジョイントコネクタにつながる電線の端部の表面にそれぞれ接着されることが、より好ましい。 In order to more reliably perform waterproofing of the short circuit by sealing the joint connector, as at least one of the first sheet body and the second sheet body, a sheet body layer and a back surface of the sheet body layer It is more preferable that what has an adhesive layer provided in is used, and the peripheral parts of both sheet bodies are adhere | attached by the said adhesive layer. Furthermore, what has the said sheet | seat body and the said adhesive bond layer is used for both sheet | seat bodies, and both sheet | seat bodies are each adhere | attached on the surface of the edge part of the electric wire connected to the said joint connector by each adhesive bond layer. Is more preferable.
　この方法は、前記ジョイントコネクタに接続される電線側端子のうちの少なくとも一部の電線側端子について、当該電線側端子及びこれが装着される電線の導体が互いに異なる金属材料で構成される場合に、特に有効である。このように互いに異種の金属材料で構成された電線側端子とこれに接触する電線の導体との接合部分に水分が浸入すると、当該電線側端子や当該導体の腐食を促進するおそれがあるから、このような異種金属の電線側端子と導体との組み合わせを含む短絡回路を本発明に係る方法によって確実に防水することは、極めて意義が高い。 This method is for at least some of the electric wire side terminals connected to the joint connector, when the electric wire side terminal and the conductor of the electric wire on which the electric wire side terminal is mounted are made of different metal materials, It is particularly effective. If moisture enters the joint portion between the electric wire side terminal composed of different metal materials and the conductor of the electric wire contacting this, there is a risk of accelerating corrosion of the electric wire side terminal or the conductor. It is extremely significant to securely waterproof a short circuit including such a combination of a different metal wire side terminal and a conductor by the method according to the present invention.
　また本発明は、短絡回路をもつワイヤハーネスを効率よく製造するための方法を提供する。この製造方法は、複数本の電線を束ねる工程と、その電線のうちの特定の複数の電線の端末について前記の短絡回路を形成するための方法を適用することにより当該特定の電線同士を短絡させる短絡回路を形成し、かつ、これを密封する防水体を製造する工程と、を含む。 The present invention also provides a method for efficiently producing a wire harness having a short circuit. In the manufacturing method, the specific electric wires are short-circuited by applying the step of bundling a plurality of electric wires and the method for forming the short circuit for the terminals of the specific electric wires among the electric wires. Forming a short circuit and producing a waterproof body for sealing the short circuit.

Claims (8)

  1. 　互いに束ねられる複数の電線を含むワイヤハーネスにおいて、防水された短絡回路を形成するための方法であって、
    　前記ワイヤハーネスに含まれる電線のうちの特定の複数の電線の端末を共通のジョイントコネクタに接続することによりこれらの電線同士を短絡させる短絡工程と、
    　前記ジョイントコネクタの周囲にこのジョイントコネクタを覆いながらこのジョイントコネクタにつながる電線の端部に密着することにより当該ジョイントコネクタを密封して防水する防水体を形成する防水体製造工程と、を含み、
    　前記防水体製造工程は、第１シート体と、前記ジョイントコネクタ及びこれにつながる各電線の端部と、第２シート体とを、前記ジョイントコネクタ及びこれにつながる電線の端部の周囲において前記第１シート体の周縁部分と前記第２シート体の周縁部分とが直接接触可能となるように重ね合わされる重ね合わせ工程と、その重ね合わせ状態で前記第１シート体の側からエアを吸引することにより前記第２シート体の周縁部分と前記第１シート体の周縁部分とを密着させるとともに両シート体を前記電線の端部の表面に密着させることで前記両シート体同士の間に前記ジョイントコネクタを密封する密封工程と、を含む、ワイヤハーネスにおける短絡回路の形成方法。     In a wire harness including a plurality of electric wires bundled together, a method for forming a waterproof short circuit,
    A short-circuit step of short-circuiting these wires by connecting the terminals of a plurality of specific wires among the wires included in the wire harness to a common joint connector,
    A waterproof body manufacturing process for forming a waterproof body that seals and waterproofs the joint connector by closely contacting an end portion of an electric wire connected to the joint connector while covering the joint connector around the joint connector, and
    In the waterproof body manufacturing process, the first sheet body, the joint connector and an end portion of each electric wire connected thereto, and the second sheet body are arranged around the joint connector and the end portion of the electric wire connected thereto. A superposition process in which the peripheral portion of the one sheet body and the peripheral portion of the second sheet body are superposed so as to be in direct contact, and air is sucked from the first sheet body side in the superposed state. The joint connector between the two sheet bodies by closely contacting the peripheral edge portion of the second sheet body and the peripheral edge portion of the first sheet body together with the two sheet bodies closely contacting the surface of the end portion of the electric wire. A method for forming a short circuit in a wire harness, comprising: a sealing step for sealing the wire harness.
  2. 　請求項１記載のワイヤハーネスにおける短絡回路の形成方法において、
    　前記特定の電線の端末にそれぞれ電線側端子が装着される一方、前記ジョイントコネクタとして、単一の金属板からなり、その厚み方向と直交する方向に並ぶ複数の嵌合部を有して各嵌合部が前記各電線側端子とそれぞれ嵌合され、その嵌合状態で当該電線同士を短絡させる短絡用金属板と、この短絡用金属板の厚み方向に偏平な外形を有し、当該短絡用金属板を保持するとともに、当該短絡用金属板の各嵌合部に前記各電線側端子が嵌合されるのを許容するように当該各電線側端子を受け入れる複数の端子収容室を囲む絶縁ハウジングと、を有するものが用いられ、その厚み方向に両シート体が重ね合わされる、ワイヤハーネスにおける短絡回路の形成方法。     In the formation method of the short circuit in the wire harness of Claim 1,
    Each of the terminals of the specific wire is attached with a wire-side terminal, and the joint connector is made of a single metal plate and has a plurality of fitting portions arranged in a direction perpendicular to the thickness direction thereof. The joint is fitted to each of the electric wire side terminals, and the shorting metal plate that short-circuits the electric wires in the fitted state, and the outer shape flat in the thickness direction of the shorting metal plate, An insulating housing that holds the metal plate and surrounds a plurality of terminal accommodating chambers that receive the electric wire side terminals so as to allow the electric wire side terminals to be fitted into the fitting portions of the shorting metal plate. And a method of forming a short circuit in a wire harness, in which both sheets are overlapped in the thickness direction.
  3. 　請求項２記載のワイヤハーネスにおける短絡回路の形成方法において、
    　前記ジョイントコネクタは、前記端子収容室に臨む外壁を有してこの外壁に前記電線側端子を係止する端子係止部が形成され、この端子係止部は前記電線側端子を係止する係止位置とこの係止位置から外側に退避して前記外壁から外向きに突出する退避位置との間で弾性変位可能なものであり、この端子係止部をその係止位置で前記第１シート体または前記第２シート体が外側から拘束するように両シート体の周縁部分同士の接合が行われる、ワイヤハーネスにおける短絡回路の形成方法。     In the formation method of the short circuit in the wire harness of Claim 2,
    The joint connector has an outer wall facing the terminal accommodating chamber, and a terminal locking portion for locking the electric wire side terminal is formed on the outer wall, and the terminal locking portion is an engagement for locking the electric wire side terminal. It is elastically displaceable between a stopping position and a retracting position that retracts outward from the locking position and protrudes outward from the outer wall, and the terminal locking portion is moved to the first sheet at the locking position. A method of forming a short circuit in a wire harness, wherein the peripheral portions of both sheet bodies are joined so that the body or the second sheet body is restrained from the outside.
  4. 　請求項１または２記載のワイヤハーネスにおける短絡回路の形成方法において、
    　前記重ね合わせ工程は、エアを吸引するための複数の吸引口が開口する成形面をもつ真空成形用型の当該成形面上に前記第１シート体を敷くことと、前記第１シート体の周縁部分が前記ジョイントコネクタ及びこれにつながる電線の端部の外側にはみ出すように当該第１シート体の上に当該ジョイントコネクタ及びこれにつながる電線の端部を載せることと、前記第２シート体をこの第２シート体が前記ジョイントコネクタ及びこれにつながる電線の端部の周囲で前記第１シート体の周縁部分に重なるように前記ジョイントコネクタ及びこれにつながる電線の端部の上に被せることと、を含み、前記密封工程は、前記真空成形用型の吸引口からエアを吸引することを含む、ワイヤハーネスにおける短絡回路の形成方法。     In the formation method of the short circuit in the wire harness of Claim 1 or 2,
    The overlapping step includes laying the first sheet body on the molding surface of a vacuum forming mold having a molding surface with a plurality of suction ports for sucking air, and a peripheral edge of the first sheet body. Placing the joint connector and the end of the electric wire connected thereto on the first sheet body so that the portion protrudes outside the end of the joint connector and the electric wire connected thereto; Covering the joint connector and the end portion of the electric wire connected thereto so that the second sheet body overlaps the peripheral portion of the first sheet body around the end portion of the joint connector and the electric wire connected thereto. The method for forming a short circuit in a wire harness includes the sealing step including sucking air from a suction port of the vacuum forming die.
  5. 　請求項４記載のワイヤハーネスにおける短絡回路の形成方法において、
    　前記第２シート体が熱可塑性樹脂からなる層を含み、この層が前記重ね合わせ工程において加熱されることにより軟化した状態で当該第２シート体が前記ジョイントコネクタ及びこれにつながる電線の端部と前記第１シート体の周縁部分とに被せられる、ワイヤハーネスにおける短絡回路の形成方法。     In the formation method of the short circuit in the wire harness of Claim 4,
    The second sheet body includes a layer made of a thermoplastic resin, and the second sheet body is softened by being heated in the superimposing step, and the second sheet body includes the joint connector and an end portion of an electric wire connected thereto. The formation method of the short circuit in a wire harness covered on the peripheral part of a said 1st sheet | seat body.
  6. 　請求項１～５のうちのいずれか１項に記載のワイヤハーネスにおける短絡回路の形成方法において、
    　前記第１シート体及び前記第２シート体のうちの少なくとも一方について、シート本体層及びこのシートの裏面上に設けられる接着剤層を有するものが用いられ、当該接着剤層により両シート体の周縁部分同士が接着される、ワイヤハーネスにおける短絡回路の形成方法。     In the method for forming a short circuit in the wire harness according to any one of claims 1 to 5,
    For at least one of the first sheet body and the second sheet body, one having a sheet main body layer and an adhesive layer provided on the back surface of the sheet is used. A method of forming a short circuit in a wire harness, wherein the portions are bonded together.
  7. 　請求項６記載のワイヤハーネスにおける短絡回路の形成方法において、
    　前記第１シート体及び前記第２シート体の双方が前記シート本体層及び前記接着剤層を有し、各接着剤層により両シート体が前記電線の端部の表面にそれぞれ接着される、ワイヤハーネスにおける短絡回路の形成方法。     In the formation method of the short circuit in the wire harness of Claim 6,
    Both the first sheet body and the second sheet body have the sheet main body layer and the adhesive layer, and both sheet bodies are respectively bonded to the surface of the end portion of the electric wire by each adhesive layer. A method of forming a short circuit in a harness.
  8. 　短絡回路をもつワイヤハーネスを製造するための方法であって、
    　複数本の電線を束ねる工程と、
    　その電線のうちの特定の複数の電線の端末について請求項１～７のうちのいずれか１項に記載の方法を適用することにより、当該特定の電線同士を短絡させる短絡回路を形成し、かつ、これを密封する防水体を製造する工程と、を含む、短絡回路をもつワイヤハーネスの製造方法。     A method for manufacturing a wire harness having a short circuit,
    Bundling multiple wires,
    Applying the method according to any one of claims 1 to 7 to terminals of a plurality of specific electric wires among the electric wires, thereby forming a short circuit that short-circuits the specific electric wires; and A method of manufacturing a wire harness having a short circuit, the method including manufacturing a waterproof body for sealing the same.
PCT/JP2012/001186 2011-02-24 2012-02-22 Method for forming short circuit in wire harness WO2012114732A1 (en)

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JP2011-038020 2011-02-24
JP2011038020A JP5732901B2 (en) 2011-02-24 2011-02-24 Method for forming a short circuit in a wire harness

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WO2022209626A1 (en) * 2021-03-29 2022-10-06 住友電装株式会社 Wiring member

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PT106994A (en) 2013-06-09 2014-12-09 Active Space Technologies Actividades Aeroespaciais Lda METHOD AND MONITORING SYSTEM FOR AGING ELECTRIC WIRING
JP2015069748A (en) * 2013-09-27 2015-04-13 住友電装株式会社 Waterproof structure of wire harness with connector

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JPH02212125A (en) * 1988-10-20 1990-08-23 Yazaki Corp Manufacture of conductor joint
JPH09102332A (en) * 1995-07-31 1997-04-15 Yazaki Corp Joint section for flat circuit body and manufacture thereof
JPH11111065A (en) * 1997-09-30 1999-04-23 Yazaki Corp Circuit and manufacture therefor
JP2009207299A (en) * 2008-02-28 2009-09-10 Sumitomo Wiring Syst Ltd Splice housing structure of vehicle wire harness
JP2010177037A (en) * 2009-01-29 2010-08-12 Autonetworks Technologies Ltd Earth connecting wiring material, joint connector used for the same, and wire harness incorporated with the same
JP2011165376A (en) * 2010-02-05 2011-08-25 Autonetworks Technologies Ltd Method of manufacturing short-circuit portion of wire harness, and short-circuit portion of wire harness

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JPS63157163U (en) * 1987-04-01 1988-10-14
JPH02212125A (en) * 1988-10-20 1990-08-23 Yazaki Corp Manufacture of conductor joint
JPH09102332A (en) * 1995-07-31 1997-04-15 Yazaki Corp Joint section for flat circuit body and manufacture thereof
JPH11111065A (en) * 1997-09-30 1999-04-23 Yazaki Corp Circuit and manufacture therefor
JP2009207299A (en) * 2008-02-28 2009-09-10 Sumitomo Wiring Syst Ltd Splice housing structure of vehicle wire harness
JP2010177037A (en) * 2009-01-29 2010-08-12 Autonetworks Technologies Ltd Earth connecting wiring material, joint connector used for the same, and wire harness incorporated with the same
JP2011165376A (en) * 2010-02-05 2011-08-25 Autonetworks Technologies Ltd Method of manufacturing short-circuit portion of wire harness, and short-circuit portion of wire harness

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022209626A1 (en) * 2021-03-29 2022-10-06 住友電装株式会社 Wiring member

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