Method for manufacturing a wiring harness

Abstract

A method of manufacturing a wire harness (9) including one or more electrically conductive paths (22) and a resin molded body (23) having a tubular shape that accommodates and protects the one or more electrically conductive paths (22), the manufacturing method comprising: straight extruding an extruded resin material (30) having an internal space from a resin extrusion machine (31) into a mold (38) and straight feeding the one or more electrically conductive paths (22) together with the extrusion to the internal space; and Forming an outer surface of the extruded resin material (30) to an outer configuration of the resin molded body (23) and aligning an inner surface of the extruded resin material (30) corresponding to outer surfaces of the one or more electrically conductive paths (22), wherein the resin molded body (23) includes a first part (27) having gaps (S) along a circumferential direction substantially in the entire circumference between an inner surface of the resin molded body (23) and the outer surfaces of the one or more electrically conductive paths (22), and a second part (28) having substantially no gap (S) between the inner surface of the resin molded body (23) and the outer surface of the one or more electrically conductive paths (22) in a region along the circumferential direction.

Description

Background of the invention<Gebiet der Erfindung>

[0001] The present invention relates to a wire harness including one or more electrically conductive paths and a resin molded body that houses and protects the electrically conductive paths, and to a method for manufacturing the wire harness. <Beschreibung der verwandten Technik>

[0002] A wire harness is used to electrically connect devices mounted on a motor vehicle. The wire harness includes a covering member made of a resin and having a tubular shape, and one or more electrically conductive paths housed in the covering member. For example, in a wire harness disclosed in Patent Literature 1 described below, the wire harness is arranged to pass through an underbody of a motor vehicle. In the wire harness, a portion corresponding to the underbody of the vehicle is arranged straight. Such a wire harness is formed to be long.

[0003] [Patent literature 1] JP 2014 93 799 A

[0004] Document US 2016 / 0 322 796 A1 relates to a protective tube for electrical wires comprising a straight tube portion and a flexible tube portion arranged along a longitudinal direction. An electrical wire can be arranged therein. The protective tube for electrical wires has a tubular inner shield portion made of an electrically conductive material, which forms an inner surface of the tube, and an outer portion made of resin, which forms an outer surface of the tube. The inner shield portion is configured to be firmly attached to an inner surface of the outer portion in the straight tube portion and to be separable from an inner surface of the outer portion in the flexible tube portion.

[0005] Document US 9 387 818 B2 relates to an external protection device for a wiring harness, comprising a flat bellows tube section made of synthetic resin and a flat straight tube section that is firmly connected to the flat bellows tube section. Instead of the flat bellows tube section, a round bellows tube section is provided. Instead of the flat straight tube section, a round straight tube section is provided. An inner peripheral surface of the bellows tube section and an inner peripheral surface of the straight tube section extend straight to each other without any difference in height.

[0006] Document US 2019 / 0 092 255 A1 relates to a wire harness in which a hard conductor portion is disposed within a hard outer covering portion, and the outer covering portion and the hard conductor portion are bent together to form a bent portion. The conductor includes a single core composed of a plurality of strands that come into close contact with each other and are press-fitted to a predetermined portion of the conductor, and a twisted wire that is not pressed and is left in a state where the plurality of strands are twisted together. The single core forms the hard conductor portion.

[0007] Document DE 10 2015 223 005 A1 relates to a cable that extends longitudinally and consists of a cable core and a cable sheath. The cable sheath is extruded around the cable core. The cable sheath has several chambers, and a functional material that differs from the material of the cable sheath is introduced into at least one of the chambers. The functional material is preferably a flame retardant.

[0008] Document JP H10-334746 A relates to a self-supporting cable. A wave-like deformation is created to create slack in a cable body member, and a support line and the cable body member are covered with thermoplastic resin. A cover portion for the support line is formed, and a cover portion for the cable body member is formed around the cable body member, and a neck portion is formed between these portions.

[0009] According to a related art, since a wire harness is long, a covering member and electrically conductive paths are also long. Accordingly, when the covering member is formed in a shape that does not have a slit (that is not split), problems described below arise. In particular, when the covering member has no slit and is long, the electrically conductive paths are manufactured to be inserted from one end to the other end of the covering member. Therefore, the covering member needs to ensure an internal space having a size required for inserting the electrically conductive paths. Accordingly, a problem arises in that the size of the covering member is large.To implement electrically conductive paths, when a guide cap is attached to one end of the electrical path, the thickness of the cap must be considered, so the size of the sheathing element is significantly increased. When the size of the sheathing element is increased, it is understood that the large size of the sheathing element affects its weight and cost.

[0010] In addition, if the internal space is secured with a size required for inserting the electrically conductive path, an opening space formed between an inner surface of the covering member and an outer surface of the electrically conductive path becomes large. Accordingly, when the electrically conductive path is significantly shaken due to a shock during vehicle travel, a problem also arises in that a coating of the electrically conductive path (when the coating of the electrically conductive path has a shielding function, a braided member or a metal foil on an outer side of the electrically conductive path) violently collides with an inner surface of a tube of the covering member and breaks. Overview

[0011] One or more embodiments provide a method of manufacturing a wire harness in which a covering member can be made compact, a weight can be reduced, and a cost can be reduced, and furthermore, a shock of an electrically conductive path in a covering member can be suppressed so that the electrically conductive path can be prevented from being broken.

[0012] According to one or more embodiments, in a method for manufacturing a wire harness including one or more electrically conductive paths and a resin molded body having a tubular shape that accommodates and protects the one or more electrically conductive paths, the manufacturing method includes straightly extruding an extruded resin material having an internal space from a resin extrusion machine into a mold and straightly feeding the one or more electrically conductive paths along with the extrusion to the internal space; and forming an outer surface of the extruded resin material into an outer configuration of the resin molded body and aligning an inner surface of the extruded resin material corresponding to outer surfaces of the one or more electrically conductive paths.The resin molded body includes a first part having gaps along a circumferential direction substantially in the entire circumference between an inner surface of the resin molded body and the outer surfaces of the one or more electrically conductive paths, and a second part having substantially no gap between the inner surface of the resin molded body and the outer surface of the one or more electrically conductive paths in a region along the circumferential direction.

[0013] According to one or more embodiments, a resin molded article forming a wire harness is formed in such a shape that it is divided into a part in a state where the inner surface comes into contact with the outer surface of the electrically conductive path with a gap along a circumferential direction and a part in a state where the inner surface comes into contact with the outer surface of the electrically conductive path substantially without a gap. Accordingly, in the part provided with the gap, a bending function of the wire harness can be effectively ensured. On the other hand, in the part that comes into contact with the outer surface of the electrically conductive path substantially without the gap, miniaturization can be achieved, weight can be reduced, and costs can be effectively reduced because the wire harness is compact.Furthermore, in the part that comes into contact with the outer surface of the electrically conductive path substantially without the gap, vibration of the electrically conductive path in the resin molded body can be effectively suppressed so that the damage of the electrically conductive path is prevented.

[0014] According to one or more embodiments, in a manufacturing process, an extruded resin material is extruded, and an electrically conductive path is supplied to an internal space of the extruded resin material along with the extrusion. Further, according to the manufacturing process, in the mold, the outer surface of the extruded resin material is formed into the external configuration of the resin molded body, and the inner surface of the extruded resin material is allowed to reach a position corresponding to the outer surface of the electrically conductive path. Accordingly, the electrically conductive path does not need to be subsequently inserted, as in the conventional example. In this way, a minimum internal space can be sufficiently ensured, which is as large as necessary and as small as possible. As a result, the resin molded body that accommodates and protects the electrically conductive path can be made compact.Therefore, when the manufacturing method of the present invention is applied, the resin molded body can be miniaturized, the weight can be reduced, the cost can be reduced, and operation can be effectively simplified. Furthermore, the vibration of the electrically conductive path in the resin molded body can also be effectively suppressed, thus preventing damage to the electrically conductive path.

[0015] If the resin molded body can be made compact, it is understood that a member (for example, a protector or the like) which is subsequently attached to the resin molded body can be made compact.

[0016] Furthermore, according to one or more embodiments, it is possible to make the wire harness difficult to bend when an inner surface of an extruded resin material (a resin molded body) comes into contact with an outer surface of an electrically conductive path without a gap "without a gap." When the gap is adjusted to a "minimum gap that is as large as necessary and as small as possible," the wire harness can be easily bent. Accordingly, in the manufacturing method of the present invention, difficulty in bending the wire harness can be appropriately and advantageously adjusted. Short description of the drawings Fig. 1A and Fig. 1B are diagrams illustrating a wire harness manufactured by a manufacturing method of the present invention. Fig. 1A is a schematic diagram showing an arrangement state of a high-voltage wire harness. Fig. 1B is a schematic diagram showing an arrangement state of a low-voltage wire harness different from that of Fig. 1A differs. Fig. 2 is a diagram showing a path arrangement state and a structure of the Fig. 1A. Fig. 3A and Fig. 3B are cross-sectional views of the Fig. 2 shown wiring harness. Fig. Figure 3A is a cross-sectional view taken along line AA. Fig. Figure 3B is a cross-sectional view taken along a line BB. Fig. 4 relates to the manufacturing method of the present invention and is a schematic diagram showing a manufacturing apparatus to which the method is applied. Method for carrying out the invention

[0017] In a wire harness, a covering member is formed as a resin molded body in such a shape that it is divided into a part in a state where an inner surface of the covering member contacts an outer surface of an electrically conductive path with a gap along a circumferential direction, and a part in a state where an inner surface of the covering member contacts an outer surface of an electrically conductive path substantially without a gap. Furthermore, a method for manufacturing a wire harness is a manufacturing method in which an extruded resin material is extruded, and one or more electrically conductive paths are supplied to an inner space of the extruded resin material along with the extrusion of the extruded resin material.Furthermore, according to the manufacturing method, in a mold, an outer surface of the extruded resin material is formed into an outer configuration of the resin molded body, and an inner surface of the extruded resin material is allowed to reach a position corresponding to an outer surface of the electrically conductive path. Exemplary embodiment

[0018] A first exemplary embodiment of the present invention will now be described with reference to the drawings. Fig. 1A and Fig. 1B are diagrams illustrating a wire harness manufactured by a manufacturing method of the present invention. Fig. 1A is a schematic diagram showing an arrangement state of a high-voltage wire harness. Fig. 1B is a schematic diagram showing an arrangement state of a low-voltage wire harness different from that of Fig. 1A differs. Fig. 2 is a diagram showing a path arrangement state and a structure of the Fig. 1A. Fig. 3 is a cross-sectional view of the Fig. 2 shown wiring harness. Fig. Figure 3A is a cross-sectional view taken along line AA. Fig. Figure 3B is a cross-sectional view taken along a line BB. Fig. 4 relates to the manufacturing method of the present invention and is a schematic diagram showing a manufacturing apparatus to which the method is applied.

[0019] In the present exemplary embodiment, the present invention is applied to a wire harness mounted in a hybrid vehicle (an electric vehicle or a conventional vehicle driven by an internal combustion engine may be used). <Aufbau eines Hybridkraftfahrzeugs 1 >

[0020] In Fig. In FIG. 1A, reference numeral 1 denotes a hybrid vehicle 1. The hybrid vehicle 1 is a vehicle driven by combining two powers of an engine 2 and a motor unit 3. Electric power from a battery 5 (a battery pack) is supplied to the motor unit 3 through an inverter unit 4. In the present exemplary embodiment, the engine 2, the motor unit 3, and the inverter unit 4 are mounted in an engine compartment 6 at a position where front wheels are provided. Furthermore, the battery 5 is mounted at a rear part 7 of the vehicle where rear wheels are provided. (The battery 5 may be mounted in an interior of the vehicle located at a rear part of the engine compartment 6.)

[0021] The motor unit 3 is connected to the inverter unit 4 through a high-voltage wire harness 8 (a motor wire for high voltage). Further, the battery 5 is connected to the inverter unit 4 through a high-voltage wire harness 9. An intermediate part 10 of the wire harness 9 is disposed in a vehicle underbody 11 in the vehicle (in a vehicle body). Furthermore, the intermediate part 10 is disposed substantially parallel along the vehicle underbody 11. The vehicle underbody 11 is a known structure (the vehicle body) and is a so-called plate member having a through-hole formed at a predetermined position. The wire harness 9 is waterproofly inserted through the through-hole.

[0022] The wire harness 9 is connected to the battery 5 through a terminal block 12 provided in the battery 5. An external connection unit, such as a shielded connector 14, disposed in a harness terminal 13 on a rear end side of the wire harness 9 is electrically connected to the terminal block 12. Furthermore, the wire harness 9 is electrically connected to the inverter unit 4 through an external connection unit, such as a shielded connector 14, disposed in a harness terminal 13 on a front end side.

[0023] The motor unit 3 includes a motor and a generator. Furthermore, the inverter unit 4 includes an inverter and a converter in its structure. The motor unit 3 is designed as a motor assembly that includes a shield case. Furthermore, the inverter unit 4 is also designed as an inverter assembly that includes a shield case. The battery 5 is a Ni-MH type or a Li-ion type and is designed as a module. For example, a storage battery such as a capacitor can be used. It is understood that the battery 5 is not particularly limited as long as the battery 5 can be used for the hybrid vehicle 1 or the electric vehicle.

[0024] In Fig. 1B, reference numeral 15 denotes a wire harness. The wire harness 15 is a low-voltage wire harness and is provided to electrically connect a low-voltage battery 16 in a rear portion 7 of a vehicle in a hybrid motor vehicle 1 to an auxiliary device 18 (a device) mounted on a front portion 17 of the motor vehicle. The wire harness 15 is connected through an underbody 11 of the vehicle, such as the one shown in Fig. 1A is arranged (an example is shown such that the wire harness can be arranged to pass through an interior side of a vehicle). Reference numeral 19 in the wire harness 15 denotes a wire harness main body. Further, reference numeral 20 denotes a connector.

[0025] As in Fig. 1A and Fig. 1B, the high-voltage wire harnesses 8 and 9 and the low-voltage wire harness 15 are arranged in the hybrid vehicle 1. Any of the wire harnesses can be applied to the present invention. However, as a representative example, the high-voltage wire harness 9 will be described below. First, a configuration and structure of the wire harness 9 will be described below. <Aufbau des Kabelbaums 9>

[0026] In Fig. 1A and Fig. 2, the long wire harness 9 arranged through the underbody 11 of the vehicle includes a wire harness main body 21 and the shielded connectors 14 (the external connection units) respectively arranged in both terminals (the wire harness terminals 13) of the wire harness main body 21. Furthermore, the wire harness 9 includes terminals C for arranging the wire harness itself at predetermined positions and water-blocking members not shown in the drawing (for example, rubber sealing rings or the like). <Aufbau des Kabelbaum-Hauptkörpers 21 >

[0027] In Fig. 2 and Fig. 3A and Fig. 3B, the wire harness main body 21 includes two long electrically conductive paths 22 and a covering member 23 (a resin molded body) that houses and protects the two electrically conductive paths 22. The number of electrically conductive paths is an example, and it may be one or three arranged side by side. <Elektrisch leitender Pfad 22>

[0028] In Fig. 2 and Fig. 3A and Fig. 3B, the electrically conductive path 22 includes an electrically conductive conductor 24, an insulating insulator 25 covering the conductor 24, and a braided portion 26 (a shielding member) that performs a shielding function. Specifically, the electrically conductive path 22 is taken as an example without a cover. Since the electrically conductive path 22 has no cover, it is understood that the electrically conductive path is lighter (since the electrically conductive path 22 is long, it is understood that the electrically conductive path 22 can be made significantly lighter than the usual example). <Leiter 24>

[0029] In Fig. 3A and Fig. 3B, the conductor 24 is formed of copper or a copper alloy, or aluminum or an aluminum alloy, and has a circular shape in cross section. The conductor 24 may have either a conductor structure formed by twisting single wires together or a rod-shaped conductor structure having a circular (round) shape in cross section (for example, a conductor structure having a round single core, and in this case, the electrically conductive path itself has a rod shape). In the conductor 24 as described above, the insulator 25 made of an insulating resin material is extruded and molded onto an outer surface thereof. <Isolator 25>

[0030] In Fig. 3A and Fig. 3B, the insulator 25 is extruded using a thermoplastic resin material and molded onto an outer peripheral surface of the conductor 24. The insulator 25 is formed as a coating having a circular shape in cross section. The insulator 25 is formed to have a predetermined thickness. Various types of known resins can be used as the thermoplastic resin described above. For example, resin materials are appropriately selected from polymer materials such as a polyvinyl chloride resin, a polyethylene resin, and a polypropylene resin.

[0031] In Fig. 3A and Fig. 3B, the braided portion 26 is provided as the outermost layer of the electrically conductive path 22. Such a braided portion 26 is formed in a tubular shape by braiding particularly thin single wires having electrical conductivity. Furthermore, the braided portion 26 is formed in such a configuration and size that it covers an entire part of an outer peripheral surface from one end to the other end of the insulator 25. Not only the braided portion 26 but also a metal foil can be used as a shielding member. <Ummantelungselement 23>

[0032] In Fig. 2 and Fig. 3A and Fig. 3B, the covering member 23 is formed into a straight tubular configuration by molding an insulating resin (just before use). Further, the covering member 23 is formed in a shape whose body is not divided (in other words, it is formed in the shape that has no slit (formed in the shape that is not a divided tube)). Furthermore, the covering member 23 is formed in an elliptical shape in a divided portion so as to achieve a transversely arranged shape of the two electrically conductive paths 22 (when the number of electrically conductive paths 22 is three, the covering member 23 is formed in an elliptical shape in a divided portion that is transversely longer. Further, when the number of electrically conductive paths is one, the covering member 23 is formed in a shape that has a circular shape in cross section).

[0033] Such a covering member 23 includes a resilient tube portion 27 having resilience, and a straight tube portion 28 as a portion that straightens the electrically conductive path 22 (this example is merely an example, and, for example, an entire portion of the covering member 23 may be formed with the resilient tube portion 27). A plurality of resilient tube portions 27 and a plurality of straight tube portions 28 are formed in an axial direction of the tube. Furthermore, the resilient tube portions 27 and the straight tube portions 28 are alternately arranged. <Nachgiebiger Röhrenteil 27>

[0034] In Fig. 2 and Fig. 3A and Fig. 3B, the compliant tube parts 27 are arranged to achieve a vehicle attachment shape (a shape to which the wire harness is attached, a shape of an object 39 described below to which the wire harness is attached). Furthermore, the compliant tube parts 27 are formed with lengths such that they achieve the vehicle attachment shape. The lengths of the compliant tube parts 27 are not fixed and are each formed in required lengths to achieve the vehicle attachment shapes. The above-described compliant tube parts 27 are formed to be bent at desired angles, respectively, depending on a packaged state of the wire harness 9, during transportation of the wire harness 9, and during arrangement of a path to the vehicle.Specifically, the compliant tube parts 27 can be appropriately bent to have a bent shape and returned to an original straight state (a state during resin molding). The compliant tube parts 27 of the present exemplary embodiment are formed into bellows tube configurations having recessed bellows parts and projecting bellows parts (this is merely an example). <Gerader Röhrenteil 28>

[0035] In Fig. 2 and Fig. 3A and Fig. 3B, the straight tube part 28 is formed as a part that does not have such compliance as the compliance tube part 27. Furthermore, the straight tube part 28 is also formed as a part that is not bent in a packaged state, during its transportation, and during path arrangement (a part that is not bent means a part that is not regularly provided with compliance). The straight tube part 28 is formed in a long, straight tube shape. An outer peripheral surface of such a straight tube part 28 is designed in the shape that has no irregularities (this is merely an example).

[0036] The straight tube part 28 is formed in a stiffer part than the flexible tube part 27. The straight tube part 28 is formed at a position or with a length that achieves the vehicle attachment shape. The longest straight tube part 28 of the plurality of straight tube parts is formed as a part disposed in the underbody 11 of the vehicle in the present exemplary embodiment. <Merkmale des Ummantelungselements 23>

[0037] In Fig. 2 and Fig. 3A and Fig. 3B, the longest straight tube part 28 arranged in the underbody 11 of the vehicle is formed with a resin in such a manner that its inner surface comes into contact with the outer surface (the braid part 26) of the electrically conductive path 22 without a gap “without a gap” (see Fig. 3A). Although not particularly limited, the compliant tube portion 27 or the short straight tube portion 28 located on both sides of the longest straight tube portion 28 is further formed of a resin in such a manner that its inner surface comes into contact with the outer surfaces (the braid portions 26) of the two electrically conductive paths 22 with a “minimum gap S that is as large as necessary and as small as possible” (see Fig. 3B). Since the longest straight tube part 28 is provided in such a manner that the inner surface contacts the outer surfaces of the two electrically conductive paths 22 without a gap, the part is formed as a solid part when the part of this area is regarded as the wire harness 9. In other words, the part of the wire harness 9 is formed as a part having high rigidity or a part that is difficult to bend (a part manufactured to be difficult to bend). If the part arranged in the underbody 11 of the vehicle has the high rigidity, it is understood that workability in the arrangement in this part is improved.The above-described "minimum clearance S as large as necessary and as small as possible" means a clearance such that bending is ensured for a space required for bending or a small space to provide a slight additional length for bending, for example, in the electrically conductive path 22. In the present exemplary embodiment, parts of a predetermined area of the wire harness 9 (parts corresponding to both sides of the longest straight tube part 28) are formed into parts that are easy to bend.

[0038] In the present exemplary embodiment, the short straight tube part 28 corresponds to a "part having no gap in a region along a circumferential direction." However, the present invention is not limited, and the short straight tube part 28 may correspond to "a part having substantially no gap." "Having substantially no gap" means the above-described "without gap." "Substantially" is boldly added to accommodate cases described below, for example, that an unexpected gap is formed in a part of a circumferential direction or a gap is inevitably generated in view of the structure. "With a gap" means the above-described "minimum gap S that is as large as necessary and as small as possible." <Fertigung des Kabelbaums 9 und zur Fertigung verwendete Fertigungsvorrichtung 29>

[0039] With the configuration and structure described above, when manufacturing the wire harness 9, the wire harness main body 21 is manufactured using the manufacturing method of the present invention. The following will be described with reference to Fig. 4, the manufacturing of the wire harness main body 21 is described, and then the manufacturing of an entire part is described below.

[0040] In Fig. 4, reference numeral 29 denotes a manufacturing device. The manufacturing device 29 is a device that extrudes an extruded resin material 30, which after molding becomes the covering member 23 (see Fig. 2 and Fig. 3A and Fig. 3B), and which supplies the two electrically conductive paths 22 together with the extrusion to an inner space of the extruded resin material 30. Furthermore, in a mold 38 of the manufacturing device 29 described below, an outer surface of the extruded resin material 30 is formed into an outer configuration of the sheathing member 23, and an inner surface of the extruded resin material 30 is located at such a position that it reaches the outer surface of the electrically conductive path 22 (see Fig. 3A and Fig. 3B. "An inner surface of the extruded resin material is located at such a position where "no gap" or a "minimum gap S that is as large as necessary and as small as possible" is formed. The above-described manufacturing apparatus 29 includes a resin extrusion machine 31, an electrically conductive path supply machine 32 arranged on an upstream side of the resin extrusion machine 31, a molding part 33 arranged on a downstream side of the resin extrusion machine 31, and a cooling part (not shown in the drawing) arranged on a downstream side of the molding part 33.

[0041] The resin extrusion machine 31 includes a hopper as a part for feeding a resin material, which is not shown in the drawing, an extrusion machine main body 34 with which the hopper is integral, and a die 35 protruding from one end part of the extrusion machine main body 34. The resin molding machine 31 is configured to extrude the extruded resin material 30 from the die 35 in a tubular shape with an elliptical cross section toward the molding part 33. The electrically conductive path feeding machine 32 is equipped with a feeding machine main body 36 that feeds the two electrically conductive paths 22 arranged transversely to the resin extrusion machine 31. The feeding machine main body 36 is configured to feed the two electrically conductive paths 22 into the internal space of the extruded resin material 30.The molding part 33 is configured to form a resin straight from an inlet to an outlet. Furthermore, the molding part 33 includes a pair of build-up molding parts 37. One pair of build-up molding parts 37 is configured to form the extruded resin material 30 with a predetermined configuration. Specifically, the one pair of build-up molding parts 37 is configured so that the extruded resin material 30, which is extruded from the extrusion machine main body 34 and in which the two electrically conductive paths 22 are arranged transversely in the internal space, can be formed by a plurality of block-shaped molds 38 with a predetermined configuration.The one pair of build-up forming parts 37 each includes two pulleys, an endless belt wound on the two pulleys, the plurality of dies 38 provided on the endless belt, and a suction mechanism (or an air blower mechanism) that draws the outer surface of the extruded resin material 30 into cavities of the dies 38. The one pair of build-up forming parts 37 is configured so that the inner surface of the extruded resin material 30 can be located at a position such that it reaches the outer surface of the electrically conductive path 22 (a position where "no gap" or a "minimum gap S that is as large as necessary and as small as possible" is formed) in accordance with an operation of the suction mechanism not shown in the drawing. The above-described configuration of the manufacturing apparatus 29 is merely an example.

[0042] In Fig. 2, the wire harness 9 is manufactured by attaching the terminals C or the rubber sealing rings, boots, or the like at predetermined positions on the outer surface of the covering member 23. Further, the wire harness 9 is manufactured by equipping the connecting parts of the electrically conductive path 22 with the shielded connectors 14. <Anordnung des Pfades des Kabelbaums 9>

[0043] After the wire harness 9 is manufactured as described above, the wire harness is bent by bending the predetermined flexible tubular parts 27. In this way, the wire harness 9 is completely packaged. The packaged wire harness 9 is compact and is transported to a vehicle mounting site in such a compact state.

[0044] At the vehicle attachment site, the wire harness 9 is first attached to the object 39 (a body) of the vehicle to which the wire harness is attached, from the long part corresponding to the underbody 11 of the vehicle (the part having the longest straight tube part 28 described above). In the wire harness 9, since the longest straight tube part 28 of the covering member 23 is disposed in the longest part corresponding to the underbody 11 of the vehicle, the wire harness 9 is attached in a state where bending is prevented. At this time, the wire harness 9 is attached with good workability. After the long part corresponding to the underbody 11 of the vehicle is attached by the clamp C or the like, while the parts of the flexible tube parts 27 in the covering member 23 are bent, remaining parts are attached.After a series of operations related to the fastening have been completed, the wire harness 9 is arranged in a desired path. <Vorteile der vorliegenden Erfindung>

[0045] As above with reference to Fig. 1A to Fig.4, in the wire harness 9 of the present invention, the covering member 23 is designed in such a shape that it is divided into a part in a state where the inner surface comes into contact with the outer surface of the electrically conductive path 22 with a gap along a circumferential direction (a part in which a "minimum gap S as large as necessary and as small as possible" is created), and a part in a state where the inner surface comes into contact with the outer surface of the electrically conductive path 22 substantially without a gap (a "no gap" part). Accordingly, in the part provided with the gap, a bending function of the wire harness 9 can be effectively ensured.On the other hand, in the part that comes into contact with the outer surface of the electrically conductive path substantially without the gap, miniaturization can be achieved, weight can be reduced, and cost can be effectively reduced because the wire harness 9 is compact. Moreover, in the part that comes into contact with the outer surface of the electrically conductive path substantially without the gap, vibration of the electrically conductive path 22 in the covering member 23 can be effectively suppressed, thus preventing damage to the electrically conductive path.

[0046] Furthermore, the manufacturing method of the present invention relates to a manufacturing method in which the extruded resin material 30 is extruded, and the two electrically conductive paths are supplied to the internal space of the extruded resin material 30 along with the extrusion. Furthermore, according to the manufacturing method, in the mold 38, the outer surface of the extruded resin material 30 is formed into the outer configuration of the covering member 23, and the inner surface of the extruded resin material 30 is allowed to reach a position corresponding to the outer surface of the electrically conductive path 22. Accordingly, the electrically conductive paths do not need to be subsequently inserted, as in the conventional example. In this way, a minimum internal space can be sufficiently ensured, which is as large as necessary and as small as possible.As a result, the covering member 23, which houses and protects the two electrically conductive paths 22, can be made compact. Therefore, when the manufacturing method of the present invention is applied, the covering member 23 can be miniaturized, the weight can be reduced, the cost can be reduced, and operation can be effectively simplified. Furthermore, the vibration of the two electrically conductive paths 22 in the covering member 23 can also be effectively suppressed, thus preventing damage to the electrically conductive paths. Description of reference signs and symbols 1 hybrid vehicle, 2 combustion engine, 3 Motor unit, 4 inverter unit, 5 battery, 6 engine compartment, 7 rear part of the motor vehicle, 8, 9 wiring harness, 10 intermediate part, 11 Underbody of the vehicle, 12 terminal block, 13 Wiring harness connection, 14 shielded connector, 15 wiring harness, 16 Low voltage battery, 17 front part of the motor vehicle, 18 auxiliary device, 19 Wiring harness main body, 20 connectors, 21 Wiring harness main body, 22 electrically conductive path, 23 Enclosure element (resin molded body), 24 conductors, 25 insulator, 26 braided part, 27 flexible tube part, 28 straight tube part, 29 manufacturing device, 30 extruded resin material, 31 resin extrusion machine, 32 Machine for supplying an electrically conductive path, 33 molding part, 34 extrusion machine main body, 37 body forming part, 38 molding tool, 39 Object to which the wiring harness is attached

Claims

[1] A method of manufacturing a wire harness (9) including one or more electrically conductive paths (22) and a resin molded body (23) having a tubular shape that accommodates and protects the one or more electrically conductive paths (22), the manufacturing method comprising: straight extruding an extruded resin material (30) having an internal space from a resin extrusion machine (31) into a mold (38) and straight feeding the one or more electrically conductive paths (22) together with the extrusion to the internal space; and Forming an outer surface of the extruded resin material (30) to an outer configuration of the resin molded body (23) and aligning an inner surface of the extruded resin material (30) corresponding to outer surfaces of the one or more electrically conductive paths (22), wherein the resin molded body (23) includes a first part (27) having gaps (S) along a circumferential direction substantially in the entire circumference between an inner surface of the resin molded body (23) and the outer surfaces of the one or more electrically conductive paths (22), and a second part (28) having substantially no gap (S) between the inner surface of the resin molded body (23) and the outer surface of the one or more electrically conductive paths (22) in a region along the circumferential direction.

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