JP3144445B2 - Flat wire harness manufacturing method and flat wire harness with fixture - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flat wire harness used for electric wiring of a vehicle, and more particularly to a method of manufacturing a flat wire harness used for a vehicle door and a flat wire harness provided with a waterproof fitting. .

[0002]

2. Description of the Related Art A conventional flat wire harness for a door is, for example, as shown in FIG. 18, in which a main wire portion a in which electric wires are bundled in parallel is intermittently flattened by bonding with a hot melt adhesive or a vinyl chloride paste. Has been proposed (Japanese Utility Model Laid-Open No. 63-111715).

[0003] In order to manufacture the flat wire harness F, it is necessary to heat the adhesive to harden it, and it is inevitable that the wire and the covering material are adversely affected by the heating. The line portion c has problems such as the necessity of winding a tape for focusing and protection.
Furthermore, since the crimping type connector d is mounted on the terminal connector, there is a disadvantage that the workability of the assembling process of the mating electrical component to the connector is poor.

On the other hand, when a flat wire harness is attached to a door of a vehicle, means for using a fixture e as shown in FIG. 19 has been proposed in Japanese Utility Model Laid-Open No. 62-57849. The electric wire W must be bent while being attached to the fixture e, and a waterproof grommet g is attached to the electric wire lead-out surface f of the fixture e to provide waterproofness, and a door mounting surface is provided. It is necessary to attach a waterproof packing, and there is a problem that the work of assembling the door and the flat wire harness is complicated and productivity is low.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and eliminates the adverse effects of heating at the time of manufacturing on electric wires and connector housings constituting a flat wire harness. Provided is a method for manufacturing a highly reliable and flat wire harness which does not require tape winding around a branching portion of a wiring, and a flat wire harness having a waterproof wire harness mounting tool with excellent assembling workability. The task is to

[0006]

In order to achieve the above-mentioned object, according to the present invention, a wiring groove is formed in a lower die constituting a molding die, and a wiring groove is formed at a predetermined position of the wiring groove. After providing a product recess, a connector housing and a wire harness fitting accommodating a plurality of terminals are disposed in the accessory recess, and a plurality of wires are routed between the connector housing and the wire harness fitting. By joining the upper mold to the lower mold and injecting the molding material into the wiring groove, filling the molding material between the arranged electric wires and around the accessories, and curing the same, the length direction of the electric wires is reduced. It is characterized in that the mold coating part is formed intermittently.

Further, as described in claim 2, a plurality of electric wires are bundled in parallel between the connector housing and the wire harness fixture, and the electric wires are intermittently flattened by a synthetic resin layer in the length direction of the electric wires. a flat wire harness formed by forming a mold coating unit, provided side plates both edges of opposing substrate constituting the wiring harness fixture freely raised or lowered, respectively, molding material a focused electrical wire to one of the side plates The other side plate is formed with an electric wire lead-out window, a cover plate is detachably mounted, and a mold material is attached to the entire periphery of the peripheral portion formed by the substrate and the both side plates. And a wire harness fitting for leading out the bundled wires from the wire lead-out window.

[0008]

According to the present invention, since the routing groove is formed in the molding die, the molding die can be used as a routing jig.
Since the branch line portion can be covered with the mold, the tape winding step is not required. In addition, by using a cold-setting synthetic resin as a molding material, cold molding can be performed, so that electric wires and connector housings,
There is no adverse effect of heating on accessories such as the branch housing.

[0009] Further, after the fixture according to claim 2 is arranged in a mold, the cover plate is removed, and the electric wires are routed in a state in which the substrate and the side plate are positioned parallel to the wiring surface, and then combined. By performing molding with a resin material, attaching a lid plate to one side plate and developing it on the same plane as the substrate, and bending the other side plate at a substantially right angle to the substrate, an L-shaped fixture is formed. A mounted flat wire harness can be obtained.

In the flat wire harness according to the second aspect, since the fixture is integrally attached by molding, it is not necessary to attach the electric wire again to the structure on the mating side with the fixture. In addition, since the mold material is annularly attached around the entire periphery of the board and side plate, it is not necessary to attach special waterproof packing, etc., reducing the number of parts and workability in the assembly process. Can be simplified.

[0011]

FIG. 1 is a perspective view of a lower mold 1 constituting a molding die according to an embodiment of the present invention. The lower mold 1 is formed of a rectangular metal, and has a wiring groove 2 formed in the upper surface 1a thereof, and also serves as a wiring jig for an electric wire constituting a flat wire harness.

In the routing groove 2, accessory recesses 3A, 3B, 3C, 3D, 3E, 3F, 3G, 3G for accommodating connector housings, branch housings, and fixtures at predetermined positions.
H, 3I (hereinafter, simply represented by 3) and a mold material blocking recess 4 are engraved.

A connector housing 5 as shown in FIG. 2 is disposed in the accessory recesses 3A, 3G, 3H and 3I provided at the end of the wiring groove 2. A branch housing is provided in the accessory recess 3D. 6 is arranged.

The connector housing 5 contains a plurality of terminal press-connecting terminals 7 having an electric wire holding mechanism inside a case formed of a synthetic resin material. As shown in FIG. 3, the terminal press contact terminal 7 is formed by bending a conductive metal plate to form a wire press-fit portion 6 a,
The terminal is formed with the electric wire holding portion 7b and the fixing portion 7c. The fixing portion 7c is inserted in the terminal accommodating chamber 5a of the connector housing 5 in the direction of the arrow and fixed. Then, after the wire 8 is press-fitted into the wire press-fitting portion 7a, the wire holding portion 7b is bent so as to be wound around the wire 8 as shown in FIG.

The branch housing 6 is, as shown in FIG.
An openable and closable upper case 6b is formed integrally with the lower case 6a. As shown in FIG.
A conductive metal plate is bent to form an electric wire press-fitting portion 9a in two directions.
9a 'and the wire holding portions 9b and 9 respectively.
b 'is provided. Then, as shown in FIG. 7, after press-fitting the wire 7 into the wire press-fitting portions 9a, 9a ', the wire holding portions 9b, 9b' are folded so as to be wound around the wire 8, similarly to the terminal press-connecting terminal 7. The bent and press-fitted electric wire 8 is held.

An attachment clamp 10 is arranged in the accessory recesses 3C, 3E and 3G.

Then, as shown in FIG.
1 and connector housing 5 and branch housing 6
The electric wires 8 are routed between each other, and the electric wires 8 are connected to the terminal press contact terminals 7 and the branch press contact terminals 9. After the wiring of the electric wire 8 is completed, as shown in FIG. 9, the wire harness fixture 12 is disposed in the accessory concave portion 3B from above the electric wire 8, and the mold material blocking concave portion 4 is provided with a butyl adhesive sheet or the like. The mold material outflow prevention material 13 is mounted.

Next, an upper mold (not shown) constituting a molding die is joined onto the lower mold 1 and partitioned by the recess 3 for accessories and the material 13 for preventing the mold material from flowing out of the wiring groove 2. The molding material is injected into the cut portion.

As the molding material, a general synthetic resin material for molding can be used, and particularly, a two-liquid type urethane foam material of isocyanate and polyol is preferable. Since the urethane foam material is foamed and cured at room temperature after being injected into the molding die, after the urethane foam material is cured, the upper mold and the lower mold 1 are separated from each other, as shown in FIG. 6. A flat wire harness A in which a mold material covering portion P is formed around accessories such as the wire harness fitting 12 and a predetermined portion of the electric wire 8 is obtained. In addition, since the said urethane foam material is room temperature curability, a shaping | molding process can be implemented without performing a heat treatment.

In the above embodiment, the mold material blocking recess 4 is formed in the lower mold 1 at a predetermined position in order to keep the mold material to be injected into the wiring groove 2 in a predetermined section. And butyl adhesive sheet etc. to prevent outflow of mold material 1
11, the lower mold 1 was not engraved with the mold material blocking recess 4, but a low-hardness silicone rubber S having an appropriate width was attached to the corresponding position, and the lower mold 1 was attached. The lower mold 1 and the upper mold 1 'are attached to the upper mold 1' by bonding the lower mold 1 to the upper mold 1 '. May be prevented from flowing out. In this case, it is not necessary to attach the mold material outflow prevention material 13 such as a butyl adhesive sheet.

FIG. 12 shows a cross section of the mounting clamp 10 after molding.
A is filled with a molding material 14 around the electric wire 8, and a fixing claw 10b is protruded from the bottom of the clamp body 10a. As shown in FIG. 13, a fixing claw 9b is inserted and fixed into a mounting hole 15a provided in a mating structure (for example, a vehicle door 15) to which the flat wire harness A is mounted.

The clamp body 10a is provided with a buffer hole 10c, and a part of the molding material 14 is discharged from the buffer hole 10c to form a buffer protrusion 14a. And the structure 15 is buffered.

Next, the structure of the wire harness fixture 12 will be described. As shown in FIG. 14, the wire harness mounting fixture 12 includes a substrate 16 formed by molding a synthetic resin material, and opposing edges 16a, 16a of the substrate 16.
It is composed of side plates 17 and 18 provided to be able to be turned upside down and a lid plate 19 mounted on one side plate 17.

The one side plate 17 is integrally connected to one edge 16a of the substrate 16 via a thin flexible hinge 16b, and has an electric wire lead-out window 1 formed by cutting off the peripheral edge at the center.
7a are provided, and locking claws 17b, 17b are protruded from both sides thereof.

The other side plate 18 is integrally connected to the other edge 16a 'of the substrate 16 via a thin flexible hinge 16b', and connects two locking arms 20 corresponding to the locking claws 18b. It is standing.

[0026] The portion connected to the flexible hinge 16b of the substrate 16 to form a step 16c, when to credit the side plate 17 is an integral flat plate and the substrate 16, the thin portion 17c of the one side plate 17 They are matched so that the same surface is maintained. Further, a mounting hole 16d is provided in a peripheral portion of the substrate 16.

The cover plate 19 is provided with guide grooves 19a on both side edges, and is detachably engaged with an insertion projection (not shown) provided on the periphery of the electric wire lead-out window 17a of one side plate 17. I have to. 19b is a mounting hole for mounting to a counterpart structure.

In order to incorporate the wire harness fitting 12 into the wired electric wire 8 and perform molding, the cover plate 19 is not inserted into the electric wire lead-out window 17a of one side plate 17 and the other side plate 18 is locked. With the arm 20 down, as shown in FIG. 9, the board 16 and the other side plate 1
8 is placed on the accessory recess 3 </ b> B of the lower die 1.

FIG. 15 is a perspective view of the wire harness fixture 12 after the molding, and shows a state in which the cover plate 19 is attached and the bundled wires 8 are led out from the wire lead-out window 17a. I have. The arranged electric wires 8 are connected to side plates 18.
The substrate 16
A ridge-shaped molding material 14b is formed in an annular shape over the entire periphery of the peripheral portion formed by the side plates 17 and 18, so as to function as a waterproof packing.

FIG. 16 is a cross-sectional view showing a state in which the flat wire harness A is fixed by mounting the above-mentioned wire harness fitting 12 to a door 15 of a vehicle. In order to attach the wire harness attachment 12 to the door 15 of the vehicle, first, the side plates 17 and 18 after molding are bent in the directions of arrows in FIG. And the tip 2 of the locking arm 20 of the other side plate 18
The L-shaped wire harness fitting 12 is formed by engaging the base plate 16 and the side plate 17 with each other, as shown in FIG.

A mounting hole 16d of the wire harness mounting tool 12 is inserted into a mounting hole provided in the door 15 of the vehicle.
The wire harness fitting 12 is fixed by fitting the fixing bolt 21 with the mounting hole 19 b and fitting the bolt 21 with the nut 22. FIG. 17 shows a state in which the flat wire harness A is attached inside the door 15 of the vehicle.

[0032]

According to the present invention, since the wiring groove is formed in the molding die, the molding die can be used as a wiring jig, so that the branch line portion is covered with the mold. And the tape winding step is omitted, and the productivity is improved. In addition, since cold molding can be performed by using a cold-setting synthetic resin as a molding material, there is no adverse effect of heating on accessories such as electric wires and connector housings and branch housings, and the quality and reliability of the obtained flat wire harness. The properties are significantly improved. Further, a flat wire harness in which a fitting is attached to a predetermined position of the routed electric wire can be obtained by integral molding, so that the manufacturing process is simplified.

In the flat wire harness according to the second aspect, since the fixture is integrally attached by molding, there is no need to re-attach the electric wire to the fixture, and the flat wire harness is formed by the board and the side plate. Since the molding material is attached all around the peripheral part, there is no need to attach special waterproof packing, etc., and the number of parts can be reduced and the workability of the assembly process can be simplified. There is.

[Brief description of the drawings]

FIG. 1 is a perspective view of a lower mold for molding according to an embodiment of the present invention.

FIG. 2 is a perspective view showing a state in which terminal press-contact terminals are arranged in a connector housing arranged in the accessory recess of FIG. 1;

FIG. 3 is a perspective view of the terminal press contact terminal of FIG. 2;

FIG. 4 is an explanatory view showing an electric wire holding mechanism of the terminal shown in FIG. 3;

5 is an exploded perspective view showing the interior of a branch housing arranged in the accessory recess shown in FIG. 1; FIG.

FIG. 6 is a perspective view showing the branch press contact terminal of FIG. 6;

FIG. 7 is an explanatory view showing an electric wire holding mechanism of the branch press contact terminal of FIG. 6;

FIG. 8 is a perspective view showing a state in which electric wires are routed in the lower routing groove of FIG. 1;

FIG. 9 is a perspective view showing a state where a wire harness attachment is arranged on the electric wires routed through the process of FIG. 8;

10 is a perspective view of a flat wire harness formed by joining the upper mold to the lower mold in FIG. 9 and performing molding.

11 is a cross-sectional view of a lower mold and an upper mold when low-hardness silicone rubber is used instead of the mold material outflow prevention material of FIG. 9;

FIG. 12 is a sectional view of a mounting clamp constituting the flat wire harness of FIG. 10;

13 is a cross-sectional view showing a state where the mounting clamp of FIG. 12 is mounted on a mating structure.

FIG. 14 is a perspective view of the wire harness attachment of FIG. 10;

FIG. 15 is a perspective view of the wire harness mounting tool of FIG. 14 after molding.

FIG. 16 is a sectional view showing a state where the wire harness attachment of FIG. 15 is attached to a vehicle door.

FIG. 17 is a perspective view showing a state where the flat wire harness of FIG. 10 is attached to a door of a vehicle.

FIG. 18 is a perspective view showing a conventional flat wire harness for a door.

FIG. 19 is a perspective view showing a conventional fixture for a door wire harness.

[Explanation of symbols]

 Reference Signs List A Flat wire harness P Mold coating part 1 Lower mold 2 Routing groove 3 Accessory concave part 4 Mold material cutoff concave part 5 Connector housing 6 Branch housing 8 Electric wire 12 Wire harness fixture 13 Mold material outflow prevention material 14 Mold material 16 Substrate 17 Side plate 17a Wire lead-out window 18 Side plate 19 Cover plate

Continuation of the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) H01B 13/00 H01B 13/012 H01B 7/00 B60R 16/02

Claims (2)

(57) [Claims] 1. A wiring groove is formed in a lower die constituting a molding die, an accessory recess is provided at a predetermined position of the wiring groove, and a plurality of terminals are provided in the accessory recess. After arranging the accommodated connector housing and the wire harness fitting, arranging a plurality of electric wires between the connector housing and the wire harness fitting, and then joining the upper mold to the lower mold and molding the molded article in the wiring groove. A flat wire characterized by forming a mold coating part intermittently in the length direction of the electric wire by injecting a material, filling a mold material between the arranged electric wires and around the accessories, and curing the molded material. Harness manufacturing method. 2. A flat cable comprising: a plurality of wires bundled in parallel between a connector housing and a wire harness fitting; and a flat mold covering portion formed intermittently by a synthetic resin layer in the length direction of the wires. a wire harness, the substrate constituting the wiring harness fixture opposing both edge portions respectively raised or lowered freely provided the side plates of, and integrally covered with the molding material a focused electric wire on one of the side plates, the other An electric wire lead-out window is formed on the side plate, a cover plate is detachably mounted, a molding material is attached around the entire periphery formed by the substrate and the both side plates, and the electric wires bundled from the electric wire lead-out window. A flat wire harness comprising a wire harness mounting tool for deriving a wire harness.