Flat electric wire, wire harness and producing method thereof

Abstract

To provide a flat electric wire, a wire harness and a producing method thereof that are capable of suppressing an increase in the number of producing steps and an increase in a producing cost, by dispensing with dedicated components for connection between a plurality of electric wires.SOLUTION: A flat electric wire 1 comprises: a plurality of first conductors 2 arranged in parallel; and a plurality of second conductors 3 arranged in parallel so as to form a lattice-like conductive pattern together with the plurality of first conductors 2, and electrically connecting the plurality of first conductors 2 with one another. The flat electric wire 1 further comprises an insulator 4 that coats the plurality of first conductors 2 and the plurality of second conductors 3 so that one end and the other end of the first conductor 2 are exposed. The one end of the first conductor 2 exposed from the insulator 4 is electrically connected with a first terminal 5, meanwhile, the other end of the first conductor 2 exposed from the insulator 4 is electrically connected with a second terminal 6.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a flat electric wire, a wire harness, and a method for manufacturing the same. [Background technology]

[0002] Connection between multiple electric wires is generally performed via terminals, connectors, bus bars, etc. (For example, see Patent Document 1). In particular, for connectors, bus bars, etc., it has been common to set dedicated parts for each number of electric wires that need to be connected and each connection pattern. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-42943 A Summary of the Invention [Problem to be solved by the invention]

[0004] In order to connect multiple electric wires, it is necessary to prepare dedicated parts such as connectors and bus bars for each number of electric wires that need to be connected and for each connection pattern, and to assemble these dedicated parts between the multiple electric wires, which increases the number of manufacturing steps and manufacturing costs.

[0005] The present invention has been made in consideration of the problems inherent in the conventional techniques, and an object of the present invention is to provide a flat electric wire, a wire harness, and a manufacturing method thereof, which can suppress an increase in the number of manufacturing steps and an increase in manufacturing costs by eliminating the need for a dedicated part for connecting a plurality of electric wires. [Means for solving the problem]

[0006] A flat electric wire according to one embodiment of the present invention comprises a plurality of first conductors arranged in parallel, a plurality of second conductors arranged in parallel to form a lattice-shaped conductive pattern together with the plurality of first conductors and electrically connecting the plurality of first conductors, an insulator covering the plurality of first conductors and the plurality of second conductors so that one end and the other end of the first conductors are exposed, a first terminal electrically connected to one end of the first conductors exposed from the insulator, and a second terminal electrically connected to the other end of the first conductors exposed from the insulator.

[0007] A wire harness according to an embodiment of the present invention includes the flat electric wire described above, and the insulator of the flat electric wire is in a rolled or folded state, and predetermined portions of the insulator are joined together so as to maintain that state.

[0008] A wire harness according to another aspect of the present invention includes the flat electric wire described above, and insulators of a plurality of the flat electric wires are overlapped with each other.

[0009] A method for manufacturing a wire harness according to an embodiment of the present invention is a method for manufacturing a wire harness including the above-mentioned flat electric wire, and includes a step of cutting off at least one of a predetermined terminal of the first terminal and the second terminal and a predetermined portion of the plurality of first conductors and the plurality of second conductors, thereby forming a conductive path between the remaining terminal and conductor. Effect of the Invention

[0010] According to the present invention, it is possible to provide a flat electric wire, a wire harness, and a manufacturing method thereof, which can suppress an increase in the number of manufacturing steps and an increase in manufacturing costs by eliminating the need for dedicated parts for connecting multiple electric wires. [Brief description of the drawings]

[0011] [Figure 1] FIG. 2 is a schematic plan view showing an example of a flat electric wire according to the present embodiment. [Diagram 2] FIG. 2 is a cross-sectional view taken along line AA in FIG. [Diagram 3]FIG. 2 is a cross-sectional view taken along line BB in FIG. [Figure 4A] FIG. 2 is a schematic cross-sectional view showing a state in which an insulator of a flat electric wire is rolled to form a wire harness. [Figure 4B] 4 is a schematic cross-sectional view showing a state in which an insulator of a flat electric wire is folded to form a wire harness. FIG. [Figure 5A] 4A to 4C are schematic plan views illustrating an example of a manufacturing method of the wire harness according to the present embodiment. [Figure 5B] 4A to 4C are schematic plan views illustrating an example of a manufacturing method of the wire harness according to the present embodiment. [Figure 5C] 4A to 4C are schematic plan views illustrating an example of a manufacturing method of the wire harness according to the present embodiment. [Figure 6A] 11 is a schematic plan view showing another example of the method for manufacturing the wire harness according to the present embodiment. FIG. [Figure 6B] 11 is a schematic plan view showing another example of the method for manufacturing the wire harness according to the present embodiment. FIG. [Figure 6C] 11 is a schematic plan view showing another example of the method for manufacturing the wire harness according to the present embodiment. FIG. [Figure 7] FIG. 4 is a schematic plan view showing another example of the flat electric wire according to the present embodiment. [Figure 8] FIG. 4 is a schematic plan view showing another example of the flat electric wire according to the present embodiment. [Figure 9] 10 is a schematic plan view showing another example of the wire harness according to the present embodiment. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, a flat electric wire, a wire harness, and a manufacturing method thereof according to the present embodiment will be described in detail with reference to the drawings. Note that the dimensional ratios in the drawings are exaggerated for the convenience of explanation and may differ from the actual ratios.

[0013] As shown in FIGS. 1 to 3, the flat electric wire 1 includes a plurality of first conductors 2, a plurality of second conductors 3, an insulator 4, a first terminal 5, and a second terminal 6.

[0014] The first conductors 2 are arranged in parallel. That is, the first conductors 2 extend in parallel to each other. In the illustrated example, four first conductors 2 are arranged in parallel, but the present invention is not limited to this, and two or more first conductors 2 may be arranged. The first conductors 2 are formed of a conductive metal material, and are formed by twisting together a plurality of wires, for example. The first conductors 2 may be covered with an insulating coating made of resin, except for the contacts 7, the connection points with the first terminal 5, and the connection points with the second terminal 6, which will be described later.

[0015] The second conductors 3 are arranged in parallel with the first conductors 2 to form a lattice-shaped conductive pattern, and electrically connect the first conductors 2 together. That is, the second conductors 3 extend parallel to each other. In the illustrated example, six second conductors 3 are arranged in parallel. The second conductors 3 are made of a conductive metal material, and are formed by twisting together a plurality of wires, for example. The second conductors 3 may be covered with an insulating coating made of resin, except for the contacts 7 described later.

[0016] In this embodiment, the second conductors 3 are divided into conductor groups (first conductor group 31 and second conductor group 32) of half each. The first conductor group 31 including three second conductors 3 is disposed closer to one end side (first terminal 5 side) of the first conductor 2 than the intermediate position C in the long side direction of the insulator 4. On the other hand, the second conductor group 32 including the remaining three second conductors 3 is disposed closer to the other end side (second terminal 6 side) of the first conductor 2 than the intermediate position C in the long side direction of the insulator 4. Each second conductor 3 is electrically connected to each first conductor 2 via a contact 7, and the second conductors 3 and the first conductors 2 form a lattice-shaped conductive pattern.

[0017] The insulator 4 covers the first conductors 2 and the second conductors 3 so that one end and the other end of the first conductors 2 are exposed. The insulator 4 is configured to have a pair of insulating resin coating layers 41, 42 (see Figs. 2 and 3), and the above-mentioned first conductors 2, second conductors 3, and contacts 7 are disposed between the pair of insulating resin coating layers 41, 42. The insulator 4 (insulating resin coating layers 41, 42) extends in a band or tape shape along the extension direction of the first conductors 2, and is formed in a rectangular shape in a plan view (see Fig. 1).

[0018] The first terminal 5 is electrically connected to one end (the left end in FIG. 1) of the first conductor 2 exposed from the insulator 4. On the other hand, the second terminal 6 is electrically connected to the other end (the right end in FIG. 1) of the first conductor 2 exposed from the insulator 4. That is, the first terminal 5 is electrically connected to one end of the first conductor 2 exposed from the insulator 4, and the second terminal 6 is electrically connected to the other end of the first conductor 2 exposed from the insulator 4. The types of the first terminal 5 and the second terminal 6 are not particularly limited.

[0019] The flat electric wire 1 may be used as a wire harness in the flat state shown in Fig. 2, or may be processed into a shape that can be mounted in a wire harness as shown in Fig. 4A and Fig. 4B. In Fig. 4A and Fig. 4B, the insulator 4 of the flat electric wire 1 is shown generally as a single sheet, and the first conductors 2 and the like are not shown.

[0020] 4A includes a flat electric wire 1, an insulator 4 of the flat electric wire 1 is in a rolled state, and predetermined portions of the insulator 4 are joined together by crimping or the like so as to maintain the rolled state. That is, predetermined portions including the outer edge of the insulator 4 are joined via a joint 11A.

[0021] 4B includes a flat electric wire 1, an insulator 4 of the flat electric wire 1 is folded in two, and predetermined portions of the insulator 4 are joined together by crimping or the like so as to maintain the folded state. That is, predetermined portions including the outer edge of the insulator 4 are joined via a joint 11B.

[0022] An example of a method for manufacturing a wire harness will be described below.

[0023] As shown in Fig. 5A, unused terminal portions of the flat electric wire 1 are cut (removed) using, for example, an automatic machine. In Fig. 5A, the exposed portions of the three first conductors 2 on the lower side of the figure are to be removed together with the terminals of the insulators 4. The removed first conductors 2 and insulators 4 can be collected together and reused by, for example, melting them. The area of ​​the terminal of the flat electric wire 1 to be removed in this process is indicated by the symbol A1A in Fig. 5A.

[0024] As shown in FIG. 5B, the parts of the conductive pattern that are not required for connection are cut (removed) using, for example, an automatic machine. In FIG. 5B, the connection part (upper side in the figure) between the first conductors 2 of the second conductors 3 in the first conductor group 31 is removed together with the insulator 4. Also, the connection part (upper side in the figure) between the first conductors 2 of the second conductors 3 in the second conductor group 32 is removed together with the insulator 4 except for the part closest to the second terminal 6, and the connection part between the first conductors 2 and the second conductors 3 that is lower than the connection part and closer to the second terminal 6 in the figure is removed. The removed first conductors 2, second conductors 3, and insulator 4 can be collected together and reused by dissolving, etc. The area of ​​the insulator 4 to be removed in this process is indicated by the symbol A2A in FIG. 5B.

[0025] The first terminal 5 and the second terminal 6 may be connected to the end of the first conductor 2 after the above-mentioned process of cutting (removing) the first conductor 2, the second conductor 3, and the insulator 4. Also, the cut portions (cut surfaces) of the first conductor 2 and the second conductor 3 may be subjected to an insulating treatment.

[0026] In this manner, by cutting (removing) the first conductor 2, the second conductor 3, and the insulator 4 according to the required number of terminals, the circuit pattern, the length of the electric wire, etc., it is possible to obtain a wire harness 10A having a conductive path 51A as shown in Fig. 5C. The conductive path 51A is indicated by a thick line in the figure, and the through-hole portion generated by cutting the first conductor 2, the second conductor 3, and the insulator 4 is indicated by the symbol HA in the figure. In this conductive path 51A, a conductive path is formed that connects one first terminal 5 at the top in the figure to four second terminals 6.

[0027] Another example of the method for manufacturing a wire harness will be described below.

[0028] As shown in Fig. 6A, unused terminal portions of the flat electric wire 1 are cut (removed) using, for example, an automatic machine. In Fig. 6A, the exposed portions of the two first conductors 2 at the center in the vertical direction in the figure are removed together with the terminals of the insulators 4. The removed first conductors 2 and insulators 4 can be collected together and reused by, for example, melting them. The area of ​​the terminal of the flat electric wire 1 that is removed in this process is indicated by the symbol A1B in Fig. 6A.

[0029] As shown in FIG. 6B, the portions of the conductive pattern that are not required for connection are cut (removed) using, for example, an automatic machine. In FIG. 6B, the connection portions (upper and lower in the figure) between the first conductors 2 of the second conductors 3 in the first conductor group 31 are removed together with the insulator 4. In addition, the connection portions (upper and lower in the figure) between the first conductors 2 of the second conductors 3 in the second conductor group 32 are removed together with the insulator 4, except for the portions closest to the second terminal 6. Furthermore, the portions of the first conductor 2 and the second conductor 3 that are on the vertical middle side and closer to the second terminal 6 side than the connection portions are removed. The removed first conductor 2, second conductor 3, and insulator 4 can be collected together and reused by dissolving, etc. The region of the insulator 4 to be removed in this process is indicated by the symbol A2B in FIG. 6B.

[0030] The first terminal 5 and the second terminal 6 may be connected to the end of the first conductor 2 after the above-mentioned process of cutting (removing) the first conductor 2, the second conductor 3, and the insulator 4. Also, the cut portions (cut surfaces) of the first conductor 2 and the second conductor 3 may be subjected to an insulating treatment.

[0031] In this manner, the first conductor 2, the second conductor 3, and the insulator 4 are cut (removed) according to the required number of terminals, the circuit pattern, the length of the electric wire, and the like, thereby making it possible to obtain a wire harness 10B having a conductive path 51B as shown in Fig. 6C. The conductive path 51B is indicated by a thick line in the figure, and the through-hole portion formed by cutting the first conductor 2, the second conductor 3, and the insulator 4 is indicated by the symbol HB in the figure. In this conductive path 51B, a conductive path connecting one first terminal 5 at the top of the figure and two second terminals 6 at the top of the figure, and a conductive path connecting one first terminal 5 at the bottom of the figure and two second terminals 6 at the bottom of the figure are formed.

[0032] Other configuration examples of the flat electric wire and the wire harness will be described below.

[0033] As shown in FIGS. 7 and 8, the flat electric wires 1A and 1B may further include a third terminal 8. As shown in FIG.

[0034] In the flat electric wire 1A shown in Fig. 7, a plurality of (two) second conductors 3 are arranged in parallel in the longitudinal middle portion of the insulator 4, and these plurality of second conductors 3 form a third conductor group 33. In the third conductor group 33, each second conductor 3 is also electrically connected to each first conductor 2 via a contact 7, and the plurality of second conductors 3 form a lattice-shaped conductive pattern together with the plurality of first conductors 2. In the flat electric wire 1A shown in Fig. 7, one end (upper side in the figure) of the second conductor 3 is exposed from the insulator 4, and a third terminal 8 is electrically connected to the one end of the second conductor 3 exposed from the insulator 4.

[0035] In the flat electric wire 1B shown in FIG. 8, a plurality of (two) second conductors 3 are arranged in parallel in the longitudinal middle of the insulator 4, and these plurality of second conductors 3 form a third conductor group 33. In the third conductor group 33, each second conductor 3 is also electrically connected to each first conductor 2 via a contact 7, and the plurality of second conductors 3 form a lattice-shaped conductive pattern together with the plurality of first conductors 2. In the flat electric wire 1B shown in FIG. 8, one end (upper side in the figure) and the other end (lower side in the figure) of the second conductor 3 are exposed from the insulator 4, and a third terminal 8 is electrically connected to each of the one end and the other end of the second conductor 3 exposed from the insulator 4.

[0036] As shown in Fig. 9, a wire harness 20 may include a plurality of flat electric wires 1, 1B, and the insulators 4 of the plurality of flat electric wires 1, 1B may be overlapped with each other. The wire harness 20 shown in Fig. 9 is configured by including the flat electric wire 1 shown in Fig. 1 and the flat electric wire 1B shown in Fig. 8.

[0037] Thus, the flat electric wire 1 according to this embodiment includes a plurality of first conductors 2 arranged in parallel, and a plurality of second conductors 3 arranged in parallel to form a lattice-shaped conductive pattern together with the plurality of first conductors 2 and electrically connect the plurality of first conductors 2. The flat electric wire 1 also includes an insulator 4 that covers the plurality of first conductors 2 and the plurality of second conductors 3 so that one end and the other end of the first conductors 2 are exposed. Furthermore, the flat electric wire 1 includes a first terminal 5 electrically connected to one end of the first conductors 2 exposed from the insulator 4, and a second terminal 6 electrically connected to the other end of the first conductors 2 exposed from the insulator 4.

[0038] In the flat electric wire 1, a lattice-shaped conductive pattern is formed by a plurality of first conductors 2 and a plurality of second conductors 3 between the first terminal 5 and the second terminal 6. Therefore, desired conductive paths 51A, 51B can be formed by cutting (removing) predetermined terminals and conductors according to the required number of terminals, circuit pattern, electric wire length, etc. (see Figs. 5C and 6C).

[0039] As described above, according to the present embodiment, it is possible to provide a flat electric wire 1 that can suppress an increase in the number of manufacturing steps and an increase in manufacturing costs by eliminating the need for dedicated parts for connecting multiple electric wires.

[0040] In the flat electric wire 1, a predetermined one of the first terminal 5 and the second terminal 6 may be cut off, and the remaining terminal, the plurality of first conductors 2, and the plurality of second conductors 3 may form conductive paths 51A, 51B.

[0041] By cutting (removing) certain terminals of the first terminals 5 and the second terminals 6 according to the required number of terminals, circuit pattern, wire length, etc., the desired conductive paths 51A, 51B can be formed (see Figures 5C and 6C).

[0042] In the flat electric wire 1, predetermined portions of the plurality of first conductors 2 and the plurality of second conductors 3 may be cut away together with the insulator 4, and conductive paths 51A, 51B may be formed by the remaining portions of the plurality of first conductors 2 and the plurality of second conductors 3, the first terminal 5, and the second terminal 6.

[0043] Depending on the required number of terminals, circuit pattern, wire length, etc., predetermined portions of the multiple first conductors 2 and the multiple second conductors 3 together with the insulator 4 can be cut (removed) to form the desired conductive paths 51A, 51B (see Figures 5C and 6C).

[0044] In the flat electric wires 1A and 1B, at least one of one end and the other end of the second conductor 3 is exposed from the insulator 4, and a third terminal 8 may be electrically connected to one end or the other end of the second conductor 3 exposed from the insulator 4.

[0045] The flat electric wires 1A and 1B further include a third terminal 8 in addition to the first terminal 5 and the second terminal 6, thereby improving the connectivity of the flat electric wire 1 (see Figs. 7 and 8).

[0046] Moreover, the wire harnesses 10A, 10B according to this embodiment include a flat electric wire 1, and the insulator 4 of the flat electric wire 1 is in a rolled or folded state, and predetermined portions of the insulator 4 are joined together so as to maintain that state.

[0047] By configuring the flat electric wire 1 in this way, it is possible to improve the mountability of the flat electric wire 1 in a wire harness (see Figs. 4A and 4B).

[0048] Moreover, a wire harness 20 according to another aspect of the present embodiment includes flat electric wires 1, 1B, and the insulators 4 of the flat electric wires 1, 1B are overlapped with each other.

[0049] Since the wire harness 20 includes a plurality of flat electric wires 1, 1B, the connectivity of the wire harness 20 can be improved (see FIG. 9).

[0050] As described above, according to the present embodiment, a wire harness can be provided that can suppress an increase in the number of manufacturing steps and an increase in manufacturing costs by eliminating the need for dedicated parts for connecting multiple electric wires.

[0051] Furthermore, the manufacturing method of the wire harness according to the embodiment is a method for manufacturing a wire harness including the flat electric wire 1. The manufacturing method includes a step of cutting at least one of a predetermined terminal of the first terminal 5 and the second terminal 6 and a predetermined portion of the plurality of first conductors 2 and the plurality of second conductors 3 to form conductive paths 51A, 51B by the remaining terminal and conductor.

[0052] In the flat electric wire 1, a lattice-like conductive pattern is formed by a plurality of first conductors 2 and a plurality of second conductors 3 between the first terminal 5 and the second terminal 6. Therefore, by cutting (removing) predetermined portions of the flat electric wire 1 according to the required number of terminals, circuit pattern, electric wire length, etc., it is possible to form desired conductive paths 51A, 51B (see Figs. 5C and 6C).

[0053] As described above, according to the present embodiment, a manufacturing method for a wire harness can be provided that can suppress an increase in the number of manufacturing steps and an increase in manufacturing costs by eliminating the need for dedicated parts for connecting multiple electric wires.

[0054] In a method for manufacturing a wire harness, a predetermined terminal among the first terminal 5 and the second terminal 6 may be removed, so that conductive paths 51A, 51B are formed by the remaining terminal, the multiple first conductors 2, and the multiple second conductors 3.

[0055] By cutting (removing) certain terminals of the first terminals 5 and the second terminals 6 according to the required number of terminals, circuit pattern, wire length, etc., the desired conductive paths 51A, 51B can be formed (see Figures 5C and 6C).

[0056] In this manufacturing method, by removing predetermined portions of the multiple first conductors 2 and the multiple second conductors 3 together with the insulator 4, conductive paths 51A, 51B may be formed by the remaining portions of the multiple first conductors 2 and the multiple second conductors 3 and the first terminal 5 and the second terminal 6.

[0057] Depending on the required number of terminals, circuit pattern, wire length, etc., predetermined portions of the multiple first conductors 2 and the multiple second conductors 3 together with the insulator 4 can be cut (removed) to form the desired conductive paths 51A, 51B (see Figures 5C and 6C).

[0058] The manufacturing method of the wire harness may further include a step of rolling or folding the insulator 4 of the flat electric wire 1 and joining predetermined portions of the insulator 4 together so that the rolled or folded state is maintained.

[0059] By configuring the flat electric wire 1 in this way, it is possible to improve the mountability of the flat electric wire 1 in a wire harness (see Figs. 4A and 4B).

[0060] Although the present embodiment has been described above, the present embodiment is not limited to this, and various modifications are possible within the scope of the gist of the present embodiment. [Explanation of symbols]

[0061] 1,1A,1B flat wire 2 First Conductor 3 Second Conductor 4. Insulation 5 1st terminal 6 2nd terminal 8 3rd terminal 10A, 10B Wire harness 20 Wire Harness 51A, 51B Conductive path

Claims

1. A plurality of first conductors arranged in parallel; a plurality of second conductors arranged in parallel to the plurality of first conductors so as to form a lattice-shaped conductive pattern and electrically connect the plurality of first conductors; an insulator covering the first conductors and the second conductors such that one end and the other end of the first conductors are exposed; a first terminal electrically connected to one end of the first conductor exposed from the insulator; a second terminal electrically connected to the other end of the first conductor exposed from the insulator. Flat electric wire.

2. 2. The flat electric wire according to claim 1, wherein a predetermined terminal of the first terminal and the second terminal is cut off, and a conductive path is formed by the remaining terminal, the plurality of first conductors, and the plurality of second conductors.

3. 2. The flat electric wire according to claim 1, wherein predetermined portions of the plurality of first conductors and the plurality of second conductors are removed together with the insulator, and a conductive path is formed by remaining portions of the plurality of first conductors and the plurality of second conductors, the first terminal, and the second terminal.

4. 4. The flat electric wire according to claim 1, wherein at least one of one end and the other end of the second conductor is exposed from the insulator, and a third terminal is electrically connected to the one end or the other end of the second conductor exposed from the insulator.

5. The flat electric wire according to any one of claims 1 to 3, The insulator of the flat electric wire is in a rolled or folded state, and predetermined portions of the insulator are joined together so as to maintain the rolled or folded state. Wire harness.

6. The flat electric wire according to any one of claims 1 to 3, The insulators of the plurality of flat electric wires are overlapped with each other. Wire harness.

7. A method for manufacturing a wire harness including the flat electric wire according to claim 1, comprising the steps of: a step of removing at least one of a predetermined terminal of the first terminal and the second terminal and a predetermined portion of the plurality of first conductors and a predetermined portion of the plurality of second conductors to form a conductive path by the remaining terminal and conductor; A manufacturing method of a wire harness.

8. 8. The method for manufacturing a wire harness according to claim 7, wherein the conductive path is formed by removing a predetermined terminal from among the first terminal and the second terminal, the remaining terminal, the plurality of first conductors, and the plurality of second conductors.

9. 8. The method for manufacturing a wire harness according to claim 7, wherein predetermined portions of the first conductors and the second conductors are removed together with the insulator, so that the conductive path is formed by remaining portions of the first conductors and the second conductors, the first terminal, and the second terminal.

10. 10. The method for manufacturing a wire harness according to claim 7, further comprising a step of: putting the insulator of the flat electric wire in a rolled or folded state, and joining predetermined portions of the insulator to each other so that the state is maintained.

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