JPH0754649B2 - Flat wire harness and manufacturing method thereof - Google Patents

Description

TECHNICAL FIELD The present invention relates to a flat wire harness used for electric wiring of a vehicle and a method for manufacturing the flat wire harness.

[Conventional technology]

The current wire harness has a very complicated shape as shown in FIG. This is a structure in which a large number of covered electric wires a are bundled and tape-wrapped b is applied, and the branch line c is branched, so that the weight is likely to be large and heavy, automatic production by a machine is difficult, and manual production is difficult. There are many places to rely on. In the figure, d is a connector and e is a terminal.

Therefore, the applicant has proposed a flat wire harness as shown in FIG. 16 in order to facilitate the automatic production as well as the weighing and simplification of the shape of the wire harness (JP-A-61-2717).
No. 07).

In the figure, f indicates a harness plate and g indicates an electronic circuit pattern portion. The harness plate f is formed by arranging flat conductive paths i such as strips on a strip-shaped insulating substrate h. Further, the electronic circuit pattern portion g has the same configuration as the printed circuit board,
A desired circuit pattern j is arranged side by side on an insulating substrate h ', and necessary electric components or electronic components k are mounted. The connection between the electronic circuit pattern portion g and the harness plate f is performed by inserting the female terminal m and the male terminal l, which are connected to the respective ends of the conduction path i and the circuit pattern j, as shown in FIG. .

[Problems to be Solved by the Invention]

In the flat wire harness shown in FIGS. 16 and 17, since the strip material pattern (i) is used for the circuit of the harness board f, the degree of freedom in wiring is low and it is difficult to cope with the specification change depending on the vehicle type and grade. Further, since the strip material pattern (i) has a constant thickness, it is wide for large currents, but even for small currents, there is a limit to the narrowness in terms of strength and manufacturing technology, and the current flowing is limited. It is difficult to form a circuit suitable for.

The present invention has been made in view of the above-mentioned problems, and has a high degree of freedom in wiring, is easy to change specifications, is suitable for forming a circuit suitable for a current, and is a flat wire that can be easily produced by automation. An object is to provide a harness and a manufacturing method thereof.

[Means for Solving the Problems]

In order to achieve the above-mentioned object, the flat wire harness of the present invention, as set forth in claim 1, is provided with a long insulating plate to which an adhesive is applied, and the flat insulating wire is installed on the insulating plate at a desired interval and bonded. A plurality of sub-circuit bodies fixed by an agent and a plurality of electric wires arranged so that at least a part of the sub-circuit body is embedded in the space on the insulating plate, and the pattern circuit of each sub-circuit body is formed by the electric wires. We adopted a configuration that is electrically connected.

This flat wire harness is manufactured by applying an adhesive to a long insulating plate, arranging a desired pattern circuit on the insulating substrate, and forming necessary electric parts on the insulating plate as described in claim 2. A plurality of sub-circuit bodies formed by incorporating are installed at desired intervals, fixed by the adhesive, and then arranged so that at least some of the plurality of electric wires are embedded in the intervals on the insulating plate. This is accomplished by welding the electric wires to the pattern circuits of the adjacent sub-circuit bodies which sandwich the space portion and are fixed by the adhesive and conductively connected.

[Action]

In the flat wire harness of the present invention, the plurality of sub-circuit bodies are connected to each other or between the sub-circuit bodies and the terminal plate by connecting wires and welding them.

The wiring of the electric wire can be automatically performed by an automatic wiring machine having a known structure, and the welding of the electric wire and the pattern circuit is also easy to automate.

Therefore, it is possible to freely select the standard (wire diameter) that matches the current flowing through the circuit without being restricted by the conventional strip pattern for wiring the wires. Unless it leaks, it is also possible to cross and route by any route. The decision to select the electric wire and its wiring route is
It may be programmed and stored in advance in the controller of the automatic wiring machine.

As a result, it is possible to obtain a flat wire harness that has a high degree of freedom in wiring for connecting the sub-circuit bodies, can easily change the specifications depending on the vehicle type and grade, and has a circuit suitable for the applied current.

Moreover, since the pattern circuits can be connected between the sub-circuit bodies by automatic welding of electric wires,
The female and male terminals m and l as shown in the figure are not necessary, and therefore, there is no step of inserting and connecting the terminals, and automation can facilitate production.

Hereinafter, the present invention will be specifically described with reference to the drawings illustrating embodiments.

〔Example〕

FIG. 1 shows a flat wire harness according to the present invention.

1 is a long insulating plate made of paper, phenol resin, glass, epoxy resin, etc.
An adhesive 2 of hot melt type or the like is applied.

On the insulating plate 1 coated with the adhesive 2, the sub-circuit bodies 3, 3 ', 3 "are fixed at appropriate intervals in the middle part, and the terminal terminal plates 4, 4'are fixed at both ends.

Connection between the sub-circuit bodies 3, 3 ', 3 "and between the terminal terminal boards 4, 4'and the sub-circuit bodies 3, 3" is made by enamel wire laid so as to be embedded in the adhesive 2. It is performed by 5 groups of covered electric wires.

Each sub-circuit unit 3, 3 ′, 3 ″ is formed by forming a desired pattern circuit 7 on an insulating substrate 6 in the same manner as an ordinary printed wiring board, and the circuit 7 includes necessary electric components 8 and connectors 9. In addition, conductive paths 7a for connecting to the covered electric wires 5 are provided in parallel at both ends of the insulating substrate 6 at the end of each circuit 7. The circuit 7 is indicated by a symbol J. By branching into two or more parts, a part or all of each sub-circuit body 3, 3 ', 3 "can also be configured as a branch connecting plate.

As the electric component 8, in addition to chip components such as resistors, capacitors, transistors, and diodes, a part or all of auxiliary machinery such as a CPU including a relay, a control unit, a sensor, and an LSI can be incorporated. The connector 9 is
It is for fitting and connecting a terminal connector of an external wire harness or an electric device (for example, an electric connection box) which is not shown, and accommodates a group of terminals 9b connected to the circuit 7 in a housing 9a.

Similarly to the sub-circuit bodies 3 to 3 ", the terminal terminal boards 4 and 4'are also provided with conductive paths 7a 'as connection terminals arranged on the insulating substrate 6'in the same manner as the printed wiring board.

Covered wire 5 and each sub-circuit 3,3 ', 3 "or terminal board
The connection with 4, 4'is made by using known means such as soldering, ultrasonic welding, resistance welding, laser welding and the like.

2 to 10 show a manufacturing process of the flat wire harness W of FIG. Further, FIGS. 11 to 14 are enlarged explanatory views of main parts.

First, as shown in FIGS. 2 and 3, the adhesive 2 (2A, 2B) is applied to the long insulating plate 1.

FIG. 2 shows an example in which the roll-shaped adhesive sheet 2A is attached while being heated by the heating lamp 10 or a warm air dryer (not shown). Further, FIG. 3 shows an example in which the liquid hot melt adhesive 2B is applied by the dispenser 11.

Thus, as shown in FIG. 4, the adhesive 2 is applied to the entire surface of the insulating plate 1.
Prepare the one coated with.

On the other hand, as shown in FIGS. 5 and 6, the chip component 8a necessary for the pattern circuit 7 of the sub-circuit body 3 (3 ', 3 ") is mounted, and the reinforcing plate 12 is attached to the back surface.

The reinforcing plate 12 reinforces the mounting portion of the connector 9 described above.

Then, as shown in FIGS. 7 and 8, a plurality of sub-circuit bodies 3, 3 ′, 3 ″ are placed on the insulating plate 1 at desired intervals and fixed with an adhesive 2, and both ends of the insulating plate 1 are fixed. Terminal terminal plates 4 and 4'are similarly adhesively fixed to the parts.

The intervals between the sub-circuit bodies 3, 3 ', 3 "are determined according to the arrangement of electrical components inside the vehicle.

Next, as shown in FIG. 9, the covered electric wire 5 is arranged in the terminal terminal board 4, the sub-circuit body 3, and the gap between the sub-circuit bodies.

The wiring of the covered electric wire 5 can be automatically performed by using the automatic wiring machine as described above.

When arranging the coated electric wire 5, as shown in FIG. 11, a welding machine 13 including a coating removal electrode 13a and welding electrodes 13b and 13c is used.

First, the enamel coating is removed by the electrodes 13a, 13c at the one end 5a of the coated electric wire 5, and then the enamel coating is welded and fixed to the conductive path 7a of the circuit 7 by the electrodes 13b, 13c. Then, as shown in FIG. 12, the covered electric wire 5 is applied by the wiring nozzle 15 of the automatic wiring machine.
While being routed, it is pressed by the hot roller 14 to fix the electric wire so that it is embedded in the adhesive 2. Finally, the other end of the covered electric wire 5 is welded and fixed to the conductive path 7a 'of the adjacent terminal terminal plate 4', as described above.

The covered electric wire 5 can take an arbitrary wiring route in accordance with the promming stored in advance in the automatic wiring machine, and is arranged so as to intersect with other electric wires as indicated by reference numeral 5 ', for example. Further, the covered electric wire 5 can be selected according to each circuit with a wire diameter corresponding to the energized current.

Finally, as shown in FIG. 10, the assembly of the flat wire harness W is completed by incorporating the necessary electric components 8 and connectors 9 into the sub-circuit bodies 3, 3 ', 3 ".

That is, as shown in FIGS. 13 and 14, the sub-circuit body 3 ',
The through hole 7b provided in the circuit 7 of the 3 ", insert the pin 8b ₁ of the terminal 9b and electrical components for example relays 8b of the connector 9 may be soldered by automatic solder.

Although the example in which the pattern circuit 7 of each sub-circuit body is connected by using the covered electric wire 5 has been described above, a bare electric wire may be used as long as it can be insulated and held from each other.

〔The invention's effect〕

Since the present invention has been described above, the following effects can be obtained as compared with the conventional wire harness (Japanese Patent Laid-Open No. 61-271707).

(1) Although the wiring of the strip material pattern is limited to a linear pattern, since an electric wire is used in the present invention, there is a high degree of freedom in wiring and high density wiring is possible.

(2) Since the wires are wired one by one, it has high followability to design changes, and wiring design by an electronic computer is easy (CAD / CAM conversion).

(3) By using CAD / CAM and the automatic wiring machine, the wire harness can be fully automatically produced.

(4) By simply changing the wire diameter, it is possible to form circuits suitable for the energizing current, from minute currents of 1 A or less to large current circuits of 10 A or more.

(5) As described above, by changing the sub-circuit body or the pattern circuit thereof, it is possible to easily and swiftly respond to the vehicle type and grade.

[Brief description of drawings]

FIG. 1 is a perspective view of a flat wire harness according to the present invention, FIGS. 2 to 10 are perspective views showing a manufacturing process of the same wire harness, and FIGS. 11 to 14 are enlarged views of main parts of the same. FIGS. 11 and 12 are enlarged perspective views of the wiring process of the electric wire and the welding process to the pattern circuit, and FIGS. 13 and 14 are the assembling process of the connector and the electric component to the sub-circuit body. FIG. 15 is a perspective view showing a conventional electric wire focusing type wire harness, FIG. 16 is a perspective view showing the same conventional flat wire harness, and FIG. 17 is an enlarged disassembly of the main part of FIG. It is a perspective view. W: Flat wire harness, 1 ... Insulation plate, 2,2
A, 2B ... Adhesive, 3,3 ', 3' ... Sub-circuit body, 4,4 '...
Terminal terminal board, 5 ... Coated wire, 6 ... Insulation board, 7 ...
Pattern circuit, 8,8a, 8b ... Electrical parts, 9 ... Connector.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP 61-88475 (JP, A) JP 61-239508 (JP, A) JP 61-271707 (JP, A) JP 62- 105308 (JP, A) JP-A-1-307111 (JP, A) Actual opening Sho 53-96674 (JP, U) Actual opening Sho 53-133181 (JP, U) Actual opening Sho 54-176877 (JP, U) Actually open Sho 56-162873 (JP, U) Japanese Patent Sho 48-33831 (JP, B1)

Claims (2)

[Claims] 1. A long insulating plate coated with an adhesive, a plurality of sub-circuit bodies installed at desired intervals on the insulating plate and fixed with an adhesive, and a pre-spacing portion on the insulating plate. A flat wire harness comprising a plurality of electric wires arranged so that at least a part thereof is embedded, and a pattern circuit of each sub-circuit body is electrically connected by the electric wires. 2. A plurality of sub-circuit bodies formed by applying an adhesive to a long insulating plate, disposing a desired pattern circuit on the insulating substrate, and incorporating necessary electric parts. After being installed with an interval of, and fixed by the adhesive, a plurality of electric wires are routed so that at least a part of them is embedded in the interval on the insulating plate, and the adhesive is fixed together with the interval. A method for manufacturing a flat wire harness, characterized in that an electric wire is welded to the pattern circuits of adjacent sub-circuit bodies sandwiching the wire to establish a conductive connection.