Wire harness and method for manufacturing wire harness

Abstract

A wire harness (1) is provided with: a U-shaped flat wiring member (100) having a linear first portion (110), a linear second portion (120), and an intermediate portion (130) connecting an end portion of the first portion and an end portion of the second portion; a first housing holding the first portion; the first housing holds the first portion, the second housing holds the second portion, the first housing and the second housing can be engaged with each other by setting the shape of the flat wiring member to a linear shape, the linear-shaped flat wiring member has a first folded-back portion (150) at which the intermediate portion is folded back along a folded-back line (L1), and a second folded-back portion (160) at which the intermediate portion is folded back along an extension direction (X) in which the first portion extends, and the second portion is folded back along an extension direction (X) in which the second portion extends. In the second folded-back portion, the second portion is folded back along a folded-back line (L2) orthogonal to the extending direction so that a part of the second portion overlaps the intermediate portion.

Description

Wire harnesses and their manufacturing methods Technical Field

[0001] This invention relates to wire harnesses and methods for manufacturing wire harnesses. Background Technology

[0002] Conventionally, flat wiring components such as flexible printed circuit boards (PCBs) have been used. Patent Document 1 discloses a flexible printed circuit board capable of easily implementing long wiring. The flexible printed circuit board of Patent Document 1 includes: a first strip member and a second strip member having a conductive portion and an insulating portion covering the conductive portion; and a first connecting member connecting a first end of the first strip member to a first end of the second strip member.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2015-170699 Summary of the Invention

[0006] The technical problem that the invention aims to solve

[0007] The goal is to transform U-shaped flat cabling strips into straight lines. Using U-shaped flat cabling strips would reduce manufacturing and installation costs.

[0008] The purpose of this invention is to provide a wire harness capable of transforming a U-shaped flat wiring component into a straight line, and a method for manufacturing the wire harness.

[0009] Technical solutions for solving technical problems

[0010] The wire harness of the present invention is characterized by comprising: a flat wiring member formed in a U-shape, having a straight first portion, a straight second portion, and an intermediate portion connecting the end of the first portion to the end of the second portion; a first housing holding the first portion; and a second housing holding the second portion. The first housing and the second housing are capable of engaging with each other to form the shape of the flat wiring member in a straight shape. In the straight-shaped flat wiring member, when viewed from above, the second portion extends along an extension line of the first portion. The straight-shaped flat wiring member has a first fold-back portion and a second fold-back portion. In the first fold-back portion, the intermediate portion folds back along a fold-back line along the extension direction of the first portion. In the second fold-back portion, the second portion folds back along a fold-back line orthogonal to the extension direction in such a way that a portion of the second portion overlaps with the intermediate portion.

[0011] The method for manufacturing a wire harness according to the present invention is characterized by comprising the following steps: a step of accommodating a straight first portion of a flat wiring component formed in a U-shape in a first housing; a step of accommodating a straight second portion of the flat wiring component in a second housing; a step of overlapping the first housing and the second housing to form a first fold-back portion in the middle portion of the flat wiring component that connects the first portion and the second portion; a step of rotating the first housing and the second housing relative to each other to form a second fold-back portion in the second portion, wherein in the step of forming the first fold-back portion, the middle portion is folded back along a fold-back line along the extension direction of the first portion; and in the step of forming the second fold-back portion, the second fold-back portion is folded back along a fold-back line orthogonal to the extension direction such that a portion of the second portion overlaps with the middle portion.

[0012] Invention Effects

[0013] The wire harness of the present invention comprises: a flat wiring member formed in a U-shape, having a straight first portion, a straight second portion, and an intermediate portion connecting the ends of the first portion and the second portion; a first housing holding the first portion; and a second housing holding the second portion. The first and second housings are capable of engaging with each other to straighten the shape of the flat wiring member. The wire harness according to the present invention has the effect of transforming a U-shaped flat wiring member into a straight line.

[0014] The method for manufacturing a wire harness according to the present invention includes the following steps: accommodating a straight first portion of a U-shaped flat wiring component in a first housing; accommodating a straight second portion of the flat wiring component in a second housing; overlapping the first housing and the second housing to form a first fold-back portion in the middle section connecting the first and second portions of the flat wiring component; and rotating the first housing and the second housing relative to each other to form a second fold-back portion in the second portion. The method for manufacturing a wire harness according to the present invention enables the flat wiring component, which is formed in a U-shape, to be transformed into a straight shape. Attached Figure Description

[0015] Figure 1 is a perspective view of the wiring harness according to the embodiment.

[0016] Figure 2 is a perspective view of a flat wiring component with a straight line shape according to an embodiment.

[0017] Figure 3 is a top view of the flat wiring component according to the embodiment.

[0018] Figure 4 is a top view of the housing of the embodiment.

[0019] Figure 5 is a perspective view of the housing according to the embodiment.

[0020] Figure 6 is a top view of the wiring harness according to the embodiment.

[0021] Figure 7 is a top view of the wiring harness according to the embodiment.

[0022] Figure 8 is a top view of the wiring harness according to the embodiment.

[0023] Figure 9 is a cross-sectional view of the wiring harness according to the embodiment.

[0024] Figure 10 is a perspective view of a flat wiring component with a first fold-back section.

[0025] Figure 11 is a cross-sectional view of the wiring harness according to the embodiment.

[0026] Figure 12 is a perspective view of the wiring harness according to the embodiment.

[0027] Figure 13 is a cross-sectional view of the wiring harness according to the embodiment.

[0028] Figure 14 is a perspective view of the wiring harness according to the embodiment. Detailed Implementation

[0029] Hereinafter, a wire harness and a method for manufacturing a wire harness according to embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to this embodiment. Furthermore, the constituent elements in the following embodiments include elements readily conceived by those skilled in the art or substantially the same elements.

[0030] [Implementation Method]

[0031] The embodiments will be described with reference to Figures 1 to 14. This embodiment relates to a wire harness and a method for manufacturing a wire harness. Figure 1 is a perspective view of the wire harness of the embodiment; Figure 2 is a perspective view showing a flat wiring member with a straight shape according to the embodiment; Figure 3 is a top view of the flat wiring member of the embodiment; Figure 4 is a top view of the housing of the embodiment; Figure 5 is a perspective view of the housing of the embodiment; Figures 6 to 8 are top views of the wire harness of the embodiment; Figure 9 is a cross-sectional view of the wire harness of the embodiment; and Figure 10 is a perspective view of a flat wiring member having a first folded-back portion.

[0032] Figure 11 is a cross-sectional view of the wiring harness according to the embodiment, Figure 12 is a perspective view of the wiring harness according to the embodiment, Figure 13 is a cross-sectional view of the wiring harness according to the embodiment, and Figure 14 is a perspective view of the wiring harness according to the embodiment. Figures 9 and 11 show section IX-IX of Figure 8. Figure 13 shows section XIII-XIII of Figure 1.

[0033] As shown in Figure 1, the wiring harness 1 of this embodiment includes a flat wiring member 100, a first housing 10, and a second housing 20. As will be explained below, the first housing 10 and the second housing 20 of this embodiment are capable of deforming the U-shaped flat wiring member 100 into a straight shape for retention. The first housing 10 and the second housing 20 are configured to engage with each other while retaining the straight flat wiring member 100. The flat wiring member 100 of Figure 1 is held in a straight shape by the two housings 10 and 20.

[0034] Figure 2 shows the main part of the flat wiring component 100 that remains in a straight line shape as shown in Figure 1. Figure 3 shows the U-shaped flat wiring component 100 before it is deformed into a straight line shape. The flat wiring component 100 is, for example, an FPC (flexible printed circuit board). The flat wiring component 100 of this embodiment is disposed in a battery module to detect the voltage and temperature of the battery cells in the battery module.

[0035] When the flat wiring component 100 is an FPC, it includes a base film, a conductive layer, and a capping layer. The conductive layer is protected by being sandwiched between the base film and the capping layer. The conductive layer is, for example, a conductive metal foil having a circuit pattern containing a plurality of detection lines 140. The flat wiring component 100 is flexible and can be bent and wired.

[0036] The flat wiring component 100 shown in Figure 3 has a generally U-shaped form when viewed from above. The flat wiring component 100 has a first portion 110, a second portion 120, and a middle portion 130. The first portion 110 and the second portion 120 are generally rectangular in shape when viewed from above. The flat wiring component 100 has a slit 100s formed between the first portion 110 and the second portion 120.

[0037] The intermediate portion 130 connects the end of the straight first portion 110 and the end of the straight second portion 120. Viewed from above, the intermediate portion 130 is generally trapezoidal in shape. The intermediate portion 130 has a tapered shape that narrows in width as it extends away from the first portion 110 and the second portion 120 along the extending direction X. The extending direction X is the direction in which the first portion 110 extends, and is the length direction of the first portion 110. In the initial shape of the flat wiring member 100 before deformation, the first portion 110 and the second portion 120 extend in the same extending direction X and are arranged in the width direction Y. The width direction Y is a direction orthogonal to the extending direction X, and is the width direction of the first portion 110 and the second portion 120.

[0038] The flat wiring component 100 of this embodiment is provided with a branch portion 170 that is connected to the busbar 200. The branch portion 170 extends from the first portion 110 and the second portion 120 in the width direction Y. The front end of the branch portion 170 is connected to the busbar 200 by solder or the like.

[0039] Figures 4 and 5 show a first housing 10 and a second housing 20 of this embodiment. The first housing 10 and the second housing 20 are molded, for example, from an insulating synthetic resin. The first housing 10 has a body 11 and a cover 18. The body 11 and the cover 18 are, for example, integrally molded. In the first housing 10 of this embodiment, the body 11 and the cover 18 are connected via a hinge portion 11e. The body 11 has a support wall 11a that supports a first portion 110 of the flat wiring member 100. The support wall 11a is formed as a straight line along the extending direction X. The cover 18 has an opposing wall 18a that covers the support wall 11a. The first portion 110 of the flat wiring member 100 is received and held between the support wall 11a and the opposing wall 18a.

[0040] A first shaft support portion 19A and a second shaft support portion 19B are provided at the end of the main body 11 extending in the X direction. The first shaft support portion 19A supports the first rotation shaft 25A of the second housing 20 so that it can rotate freely. The second shaft support portion 19B supports the second rotation shaft 25B of the second housing 20 so that it can rotate freely.

[0041] The second housing 20 of this embodiment has a main body 21 and a cover 24. The main body 21 and the cover 24 are integrally formed, for example. In the second housing 20 of this embodiment, the main body 21 and the cover 24 are connected via a hinge portion 21e. The main body 21 has a support wall 21a that supports a second portion 120 of the flat wiring member 100. The support wall 21a is formed as a straight line along the extending direction X. The cover 24 has an opposing wall 24a that covers the support wall 21a. The second portion 120 of the flat wiring member 100 is received and held between the support wall 21a and the opposing wall 24a.

[0042] A first rotating shaft 25A is provided at the end of the main body 21 in the extending direction X. A second rotating shaft 25B is provided at the end of the cover 24 in the extending direction X. The first rotating shaft 25A protrudes from the side of the main body 21 toward the width direction Y. The second rotating shaft 25B extends along the width direction Y in a manner that it passes through the end of the cover 24. Both ends of the second rotating shaft 25B are supported by a second shaft support portion 19B.

[0043] In the wiring harness 1 of the embodiment, a rotating structure 60 is formed by two shaft support portions 19A and 19B of the first housing 10 and two rotating shafts 25A and 25B of the second housing 20. The rotating structure 60 is capable of relative rotation of the two housings 10 and 20 as shown in FIG. 12.

[0044] As shown in Figure 5, the first housing 10 has a first engaging portion 12, and the second housing 20 has a second engaging portion 22. The first engaging portion 12 is disposed at the end of the main body 11 in the extending direction X. The second engaging portion 22 is disposed at the end of the main body 21 in the extending direction X. The two engaging portions 12 and 22 engage with each other at the second relative position shown in Figure 1.

[0045] Figure 6 shows a flat wiring component 100 assembled to a first housing 10 and a second housing 20. The first housing 10 and the second housing 20 shown in Figures 4 and 6 are arranged in the width direction Y. In this specification, the relative position of the two housings 10 and 20 in the width direction Y is referred to as the first relative position. As shown in Figure 4, when the two housings 10 and 20 are arranged in the first relative position, the support wall 11a of the first housing 10 and the support wall 21a of the second housing 20 are arranged in the width direction.

[0046] The first portion 110 of the flat wiring component 100 is housed within the main body 11 of the first housing 10 and supported by a support wall 11a. The process of accommodating the first portion 110 within the first housing 10 is performed, for example, by an operator. The second portion 120 of the flat wiring component 100 is housed within the main body 21 of the second housing 20 and supported by a support wall 21a. The process of accommodating the second portion 120 within the second housing 20 is performed, for example, by an operator. Both accommodating processes are performed, for example, while the two housings 10 and 20 are held by a clamping plate.

[0047] When the flat wiring component 100 is housed within the two housings 10 and 20, a closing operation of the covers 18 and 24 is performed. During the closing operation, the cover 18 of the first housing 10 is assembled to the main body 11 while bending the hinge portion 11e. During the closing operation, the cover 24 of the second housing 20 is assembled to the main body 21 while bending the hinge portion 21e. Both closing operations are performed, for example, by an operator. Figure 7 shows the closed state of the covers 18 and 24. The opposing wall 18a of the cover 18 covers the first portion 110 of the flat wiring component 100. The opposing wall 24a of the cover 24 covers the second portion 120 of the flat wiring component 100.

[0048] Starting from the state shown in Figure 7, a first rotation process is performed, causing the second housing 20 to rotate relative to the first housing 10. In this first rotation process, the second housing 20 is rotated relative to the first housing 10 with respect to the rotation axis Cx shown in Figure 7 as the center of rotation. The rotation axis Cx is, for example, a straight line extending in the extension direction X between the two covers 18 and 24. This rotation can also be performed using a clamping plate, for example. In this case, the clamping plate may also have a main body supporting the first housing 10 and a support member supporting the second housing 20. The support member is supported by the main body in a manner that allows it to rotate with respect to the rotation axis Cx as the center of rotation.

[0049] The second housing 20 rotates relative to the first housing 10 about the rotation axis Cx, and the second housing 20 overlaps with the first housing 10. Therefore, the second portion 120 of the flat wiring component 100 overlaps with and is opposite to the first portion 110.

[0050] Figure 8 shows the state where the first rotation process is completed and the second housing 20 overlaps with the first housing 10. In this specification, the relative position where the two housings 10 and 20 overlap in the height direction Z is referred to as the intermediate relative position. At the intermediate relative position, the second portion 120 of the flat wiring component 100 overlaps with and is opposite to the first portion 110. Furthermore, the height direction Z is a direction orthogonal to both the extension direction X and the width direction Y.

[0051] When the two housings 10 and 20 rotate about the rotation axis Cx and are positioned in the middle relative position, the middle portion 130 of the flat wiring member 100 bends along the rotation axis Cx. Figure 9 shows the IX-IX section of Figure 8, and Figure 10 shows the flat wiring member 100 in the state of Figure 8. As shown in Figures 9 and 10, a first fold-back portion 150 is formed in the middle portion 130 of the flat wiring member 100.

[0052] In the first fold-back section 150, the intermediate section 130 folds back along a fold-back line L1 in the extension direction X. The fold-back line L1 is, for example, a straight line extending in the extension direction X between the two covers 18 and 24. The intermediate section 130 has a first region 130a connected to the first section 110 and a second region 130b connected to the second section 120. The intermediate section 130 folds back in such a way that the first region 130a and the second region 130b are opposite each other in the height direction Z.

[0053] As shown in FIG11, the first fold-back portion 150 is formed to hold the cover 18 of the first housing 10 through the intermediate portion 130. That is, the first region 130a and the second region 130b of the intermediate portion 130 are opposite each other in the height direction Z through the opposing wall 18a of the cover 18. The opposing wall 18a has a limiting portion 18b that protects the first fold-back portion 150.

[0054] As shown in Figure 11, the limiting portion 18b is disposed at the end of the opposing wall 18a in the width direction Y. The limiting portion 18b is the portion that increases the thickness of the end of the opposing wall 18a and extends in the extension direction X. The cross-sectional shape of the limiting portion 18b is approximately circular. The limiting portion 18b protrudes in the height direction Z toward the side opposite to the supporting wall 11a. The limiting portion 18b supports the first fold-back portion 150 from the inside in a manner that the curvature R of the first fold-back portion 15 is not too small.

[0055] The opposing wall 18a can simultaneously reduce the height of the first housing 10 and protect the first fold-back portion 150. In the opposing wall 18a, the portion other than the limiting portion 18b is formed as a thin wall. This reduces the distance H1 between the first region 130a and the second region 130b in the height direction Z, thereby reducing the height of the first housing 10. Furthermore, by supporting the intermediate portion 130 during the first rotation process, a suitable bend R can be formed in the first fold-back portion 150. The limiting portion 18b and the first fold-back portion 150 are positioned offset relative to the first portion 110 and the second portion 120 in the width direction Y. Therefore, space can be ensured for forming a suitable bend R in the first fold-back portion 150, and the distance H1 between the two regions 130a and 130b can be reduced.

[0056] As shown in Figures 9 and 11, the first housing 10 has a protective cover 11g that protects the middle portion 130 of the flat wiring component 100. The protective cover 11g is connected to the support wall 11a via a hinge portion 11f. After performing a first rotation operation, the protective cover 11g engages with the support wall 11a. The first housing 10 accommodates the U-shaped folded-back middle portion 130 between the support wall 11a and the protective cover 11g. The opposing wall 18a of the cover 18 is clamped inside the folded-back middle portion 130. The hinge portion 11f covers and protects the first folded-back portion 150.

[0057] As shown in Figure 9, the first rotating shaft 25A of the second housing 20 is supported by the first shaft support portion 19A of the first housing 10 and is rotatable. The first shaft support portion 19A has a plate portion 19c and a locking portion 19d that are erected in the height direction Z. A slit 19e extending in the height direction Z is provided in the plate portion 19c. The end of the first rotating shaft 25A is inserted into the slit 19e and locked by the locking portion 19d.

[0058] The second rotating shaft 25B of the second housing 20 is supported by the second shaft support portion 19B of the first housing 10 and is rotatable. The second shaft support portion 19B has a slit 19f provided on the side wall 11h. The side wall 11h is disposed on both sides of the support wall 11a in the width direction Y. The end of the second rotating shaft 25B is inserted into the slit 19f and supported by the side wall 11h to be rotatable. By inserting the two rotating shafts 25A and 25B into the two shaft support portions 19A and 19B, the first housing 10 and the second housing 20 are rotatably connected. Thus, a busbar module 400 is constituted. The busbar module 400 includes a plurality of busbars 200 and a wiring harness 1 according to the embodiment.

[0059] Figure 12 illustrates the second rotation process. This second rotation process is performed, for example, in a factory where the busbar module 400 is assembled into a vehicle, etc. As shown in Figure 12, in the second rotation process, the second housing 20 rotates relative to the first housing 10 from its intermediate relative position toward a second relative position described later. In the second rotation process, the second housing 20 rotates relative to the first housing 10 about the central axes of the two rotation axes 25A and 25B as its rotation center.

[0060] Figure 1 shows the state after the second rotation process is completed, with the two housings 10 and 20 positioned in a second relative position. In this second relative position, the first housing 10 and the second housing 20 are arranged in a straight line along the extension direction X. In this state, the first portion 110 and the second portion 120 of the flat wiring member 100 are arranged in a straight line. In other words, in top view, the second portion 120 is positioned on the extension line of the first portion 110. In addition, a plurality of busbars 200 are arranged in a straight line along the extension direction X. The cover 18 of the first housing 10 covers and protects the first portion 110 by means of the opposing wall 18a. The cover 24 of the second housing 20 covers and protects the second portion 120 by means of the opposing wall 24a.

[0061] A second fold-back portion 160 is formed in the flat wiring component 100 by performing a second rotation process. As shown in Figures 2 and 13, the second fold-back portion 160 is a portion folded back along a fold-back line L2 orthogonal to the extension direction X. In the second fold-back portion 160, the second portion 120 is folded back along the fold-back line L2 in such a way that a portion of the second portion 120 overlaps with the intermediate portion 130. In this embodiment, the fold-back line L2 is a straight line along the width direction Y. When the second fold-back portion 160 is formed, the second region 130b of the intermediate portion 130 is opposite to the base end portion 120a of the second portion 120. The base end portion 120a is the end portion of the second portion 120 located near the intermediate portion 130.

[0062] As shown in Figure 13, the base end portion 120a and the second region 130b are opposite each other in the height direction Z through the protective cover 11g. In the portion where the protective cover 11g is provided, the first region 130a of the middle portion 130, the second region 130b of the middle portion 130, and the base end portion 120a are arranged in the height direction Z.

[0063] The first portion 110 of the flat wiring member 100 extends from the second fold-back portion 160 to a first side X1 in the extension direction X. The second portion 120 extends from the second fold-back portion 160 to a second side X2 in the extension direction X. Therefore, in the flat wiring member 100 with a straight shape shown in Figures 2 and 13, when viewed from above, the second portion 120 extends along the extension line of the first portion 110.

[0064] As shown in Figure 13, the protective cover 11g has a limiting portion 11j that protects the second fold-back portion 160. The limiting portion 11j is disposed at the end of a first side X1 in the extending direction X of the protective cover 11g. The limiting portion 11j is the portion that increases the thickness of the end of the protective cover 11g and extends in the width direction Y. The cross-sectional shape of the limiting portion 11j is approximately circular. The limiting portion 11j protrudes in the height direction Z toward the side opposite to the support wall 11a. The limiting portion 11j supports the second fold-back portion 160 from the inside in a manner that prevents the curvature R of the second fold-back portion 160 from being too small.

[0065] The protective cover 11g of this embodiment can limit the bending origin during the second rotation process. Without the protective cover 11g, there is a possibility of stress concentration at the corner 180 in FIG. 10 during the second rotation process. The corner 180 is the boundary between the middle portion 130 and the second portion 120, and the edges of the flat wiring member 100 intersect at approximately right angles. The limiting portion 11j of the protective cover 11g can limit the lifting of the second portion 120 when the two housings 10, 20 rotate relative to each other, making it difficult for forces to act on the corner 180.

[0066] Figure 15 shows the flat wiring member 100 during deformation in the second rotation process. The protective cover 11g can suppress the middle portion 130 of the flat wiring member 100 and can suppress the deformation of the middle portion 130. In addition, the limiting portion 11j can suppress the base end portion 120a of the second portion 120 and limit the lifting of the base end portion 120a. As a result, stress concentration towards the corner portion 180 is suppressed, and the corner portion 180 is protected. In addition, the limiting portion 11j supports the base end portion 120a, which allows the second folded-back portion 160 to be formed in the desired position.

[0067] As described above, the wiring harness 1 of this embodiment includes a flat wiring member 100, a first housing 10, and a second housing 20. The flat wiring member 100 has a straight first portion 110, a straight second portion 120, and a middle portion 130. The middle portion 130 is the portion that connects the end of the first portion 110 and the end of the second portion 120. The first housing 10 holds the first portion 110, and the second housing 20 holds the second portion 120.

[0068] The first housing 10 and the second housing 20 are capable of engaging with each other to form a straight shape for the flat wiring member 100. In the flat wiring member 100 with a straight shape, when viewed from above, the second portion 120 extends along the extension line of the first portion 110. The straight-shaped flat wiring member 100 has a first fold-back portion 150 and a second fold-back portion 160. In the first fold-back portion 150, the middle portion 130 is folded back along a fold-back line L1 extending in the extension direction X along the first portion 110. In the second fold-back portion 160, the second portion 120 is folded back along a fold-back line L2 orthogonal to the extension direction X, such that a portion of the second portion 120 overlaps with the middle portion 130.

[0069] In this embodiment, the two housings 10 and 20 can interlock the U-shaped flat wiring member 100 into a straight line. Therefore, the wiring harness 1 in this embodiment can straighten the U-shaped flat wiring member 100 into a straight line.

[0070] The first housing 10 of this embodiment has a protective cover 11g that covers the middle portion 130 on which the first fold-back portion 150 is formed. Therefore, the protective cover 11g can cover and protect the middle portion 130. In addition, the protective cover 11g can suppress the deformation of the middle portion 130 and promote the deformation of the flat wiring member 100 into a straight shape.

[0071] The protective cover 11g of this embodiment has a limiting portion 11j. The limiting portion 11j supports the second portion 120 and limits the position of the second fold-back portion 160. By limiting the position of the second fold-back portion 160, the limiting portion 11j can stabilize the shape of the flat wiring member 100 when it deforms during the second rotation process.

[0072] The manufacturing method of the wire harness 1 in this embodiment includes a first receiving step, a second receiving step, a first forming step, and a second forming step. The first receiving step is the step of receiving the straight first portion 110 of the flat wiring member 100, which is formed in a U-shape, into the first housing 10. The second receiving step is the step of receiving the straight second portion 120 of the flat wiring member 100 into the second housing 20. The first receiving step and the second receiving step can be performed simultaneously, or the receiving step can be performed after the other receiving step.

[0073] The first forming process is the process of forming a first fold-back portion 150 on the flat wiring member 100. In the first forming process, the first housing 10 and the second housing 20 overlap, and the first fold-back portion 150 is formed in the middle portion 130 of the flat wiring member 100. In the first forming process, the middle portion 130 is folded back along the fold-back line L1 along the extension direction X of the first portion 110.

[0074] The second forming process is the process of forming a second fold-back portion 160 on the flat wiring member 100. In the second forming process, the first housing 10 and the second housing 20 are rotated relative to each other, and the second fold-back portion 160 is formed on the second portion 120. In the second forming process, the second fold-back portion 160 is formed along a fold-back line L2 orthogonal to the extension direction X, such that a part of the second portion 120 overlaps with the middle portion 130. According to the manufacturing method of the wiring harness 1 of this embodiment, the U-shaped flat wiring member 100 can be elongated into a straight shape.

[0075] The contents disclosed in the above-described embodiments can be appropriately combined and implemented.

[0076] Explanation of reference numerals in the attached figures

[0077] 1: Wiring harness

[0078] 10: First shell

[0079] 11: Main Body

[0080] 11a: Support wall

[0081] 11e: Hinge section

[0082] 11f: Hinge section

[0083] 11g: Protective shield

[0084] 11h: Sidewall

[0085] 11j: Restriction Department

[0086] 12: First Card Combination Section

[0087] 18: Cover

[0088] 18a: Opposite wall

[0089] 18b: Restricted Section

[0090] 19A: First shaft support section

[0091] 19B: Second shaft support

[0092] 20: Second shell

[0093] 21: Main Body

[0094] 21a: Support wall

[0095] 21e: Hinge section

[0096] 22: Second Card Section

[0097] 24: Cover

[0098] 25A: First rotating axis

[0099] 25B: Second Rotation Axis

[0100] 60: Rotational Structure

[0101] 100: Flat wiring component

[0102] 110: Part One

[0103] 120: Part Two

[0104] 130: Middle section

[0105] 130a: First Zone

[0106] 130b: Second Zone

[0107] 140: Testing line

[0108] 150: First Turnback Section

[0109] 160: Second Turnback Section

[0110] 170: Branch Office

[0111] 180: Corner

[0112] 200: Busbar

[0113] 400: Busbar Module

[0114] L1, L2: Turnback lines

[0115] X: Direction of extension

[0116] Y: Width direction

[0117] Z: Height direction

Claims

1. A wire harness, characterized in that, It comprises: a flat wiring component formed in a U-shape, having a straight first portion, a straight second portion, and an intermediate portion connecting the end of the first portion to the end of the second portion; and a first housing holding the first portion. A second housing holds the second portion. The first and second housings are capable of engaging with each other to form a straight shape for the flat wiring member. In the straight-shaped flat wiring member, when viewed from above, the second portion extends along an extension of the first portion. The straight-shaped flat wiring member has a first fold-back portion and a second fold-back portion. In the first fold-back portion, the middle portion folds back along a fold-back line that extends along the direction of extension of the first portion. In the second fold-back portion, the second portion folds back along a fold-back line orthogonal to the direction of extension in such a way that a portion of the second portion overlaps with the middle portion.

2. The wire harness according to claim 1, characterized in that, The first housing has a protective cover that covers the middle portion where the first fold-back portion is formed.

3. The wire harness according to claim 2, characterized in that, The protective cover has a limiting part that supports the second part and restricts the position of the second folded-back part.

4. A method for manufacturing a wire harness, characterized in that, The process includes the following steps: accommodating a straight first portion of a U-shaped flat wiring component in a first housing; accommodating a straight second portion of the flat wiring component in a second housing; overlapping the first and second housings to form a first fold-back portion in the middle section connecting the first and second portions of the flat wiring component; rotating the first and second housings relative to each other to form a second fold-back portion in the second portion. In the step of forming the first fold-back portion, the middle portion is folded back along a fold-back line along the extension direction of the first portion. In the step of forming the second fold-back portion, the second fold-back portion is folded back along a fold-back line orthogonal to the extension direction in such a way that a portion of the second portion overlaps with the middle portion.

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