Protective metal fitting for joint portion and wire harness

Abstract

To provide a joint protective metal fitting capable of adequately protecting a joint portion between electric wires having conductor materials different from each other, and a wire harness.SOLUTION: A joint protective metal fitting 1 is fixed to an electric wire W having a joint portion WS formed between a first conductor W1a and a second conductor W2a that are made of different materials, and includes a plate-shaped metal fitting body 2 for protecting the joint portion WS, and a pair of electric wire clamping portions 3 that are provided at both ends of the metal fitting body 2 in an extension direction X and fix the metal fitting body 2 to each of a first insulating coating portion W1b and a second insulating coating portion W2b of the electric wire W. The metal fitting body 2 is fixed to the electric wire W in an assembled state in which the joint portion WS is interposed between the pair of wire clamping portions 3 in the extension direction X.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a protective fitting for a joint and a wire harness.

Background Art

[0002] For an electric wire having a joint formed between conductors of different materials, for example, after inserting an aluminum conductor of a coated aluminum electric wire between copper conductors of a coated copper electric wire, a copper strand is interposed and the copper strand and the aluminum strand are ultrasonically welded with a welding horn of an ultrasonic welder (see, for example, Patent Document 1).

[0003] Also, an aluminum conductor is joined to a non-molded portion of an aluminum plate, and a copper conductor is joined to a non-molded portion of a copper plate, respectively, and the joint portion between the conductor and the plate is bent toward the joint portion between the molded plates (see, for example, Patent Document 2).

[0004] Also, there is one in which a curved portion is provided in the electric wire so that no force is applied to the joint portion between the joined electric wires (see, for example, Patent Document 3).

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0006] By the way, at the joint where an electric wire having an aluminum conductor and an electric wire having a copper conductor are joined, a hard and brittle intermetallic compound is formed at the joint interface. Since an external force may be applied to the electric wire or the wire harness, it is necessary to protect the joint against the external force.

[0007] Therefore, an object of the present invention is to provide a protective fitting for a joint that can appropriately protect the joint between electric wires having different conductor materials, and a wire harness.

Means for Solving the Problems

[0008] In order to achieve the above object, a protective fitting for a joint according to the present invention is fixed to an electric wire having a joint formed between conductors of different materials, and includes a plate-shaped fitting body that protects the joint, and is provided at both ends in the extending direction of the fitting body. A pair of wire clamping portions for fixing the fitting body to the insulating coating portion of the electric wire, and the fitting body is fixed to the electric wire in an assembled state in which the joint is sandwiched in the extending direction between the pair of wire clamping portions.

Effects of the Invention

[0009] According to the protective fitting for a joint and the wire harness according to the present invention, there is an effect that the joint between electric wires having different conductor materials can be appropriately protected.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

[0011] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited by the following embodiments. That is, the constituent elements in the following embodiments include those that can be easily assumed by those skilled in the art or those that are substantially the same, and various omissions, replacements, and changes can be made without departing from the gist of the invention.

[0012] [Embodiment] FIG. 1 is a perspective view showing a schematic configuration of a wire harness including a protective fitting for a joint portion according to an embodiment. FIG. 2 is a top view showing a schematic configuration of a wire harness including a protective fitting for a joint portion according to an embodiment. FIG. 3 is a side view showing a schematic configuration of a wire harness including a protective fitting for a joint portion according to an embodiment. FIG. 4 is a top view showing a schematic configuration of a protective fitting for a joint portion according to an embodiment.

[0013] The protective fitting 1 for a joint portion shown in FIGS. 1 to 4 is fixed to an electric wire W having a joint portion WS between conductors of different materials and protects the joint portion WS. The protective fitting 1 for a joint portion is incorporated into a wire harness WH that is routed in a vehicle such as an automobile in a state of being fixed to the electric wire W. Here, the wire harness WH is, for example, a collective component in which a plurality of electric wires W used for power supply, communication, etc. are bundled for connection between each device mounted on the vehicle, and the electric wires W are connected to each device with a connector or the like. Note that the wire harness WH may further include grommets, fixtures, connectors, etc. The wire harness WH of the present embodiment includes, for example, one or a plurality of electric wires W and the protective fitting 1 for a joint portion.

[0014] In the following description, for convenience, among the illustrated X direction, Y direction, and Z direction, the X direction is defined as the "extending direction X", the Y direction is defined as the "width direction Y", and the Z direction is defined as the "plate thickness direction Z". The extending direction X, the width direction Y, and the plate thickness direction Z intersect each other. The extending direction X corresponds to the extending direction of the joint protection fitting 1 and the axial direction of the electric wire W. In the following description, each direction used is described as the direction in the state where the joint protection fitting 1 is assembled to the electric wire W unless otherwise specified.

[0015] First, the electric wire W in the present embodiment will be described. The electric wire W is composed of a first electric wire W1, a second electric wire W2, and a joint portion WS between the first electric wire W1 and the second electric wire W2.

[0016] The first electric wire W1 is a copper electric wire having a copper conductor. The first electric wire W1 has, for example, a conductive first conductor W1a formed by a plurality of strands and an insulating first insulation coating portion W1b covering the outer peripheral side of the first conductor W1a. The first conductor W1a is composed of a metal member having flexibility and conductivity. The first conductor W1a is formed to extend with substantially the same diameter with respect to the axial direction extending linearly. The strands constituting the first conductor W1a are manufactured from a conductive metal, such as copper, a copper alloy, etc. Here, the first conductor W1a is a simple bundle of a plurality of strands, but may be formed by twisting a plurality of strands.

[0017] The first insulating coating portion W1b is an electric wire coating that covers the outer peripheral side of the first conductor W1a. The first insulating coating portion W1b is provided in contact with the outer peripheral surface of the first conductor W1a. The first insulating coating portion W1b is formed, for example, by extrusion molding an insulating resin material (including PP, PVC, cross-linked PE, etc., and appropriately selected in consideration of abrasion resistance, chemical resistance, heat resistance, etc.). The first insulating coating portion W1b is formed from one end to the other end of the first conductor W1a in the axial direction. At the end of the first conductor W1a of the first electric wire W1, the first insulating coating portion W1b is peeled off, and the end of the first conductor W1a is exposed from the first insulating coating portion W1b. At the end of the first conductor W1a of the first electric wire W1, the end of the second conductor W2a of the second electric wire W2 described later is physically and electrically joined. As an example, the first electric wire W1 has a substantially circular cross-sectional shape in the axial direction of the first conductor W1a, and the first insulating coating portion W1b has a substantially annular cross-sectional shape in the axial direction, and the overall cross-sectional shape is substantially circular.

[0018] The second electric wire W2 is an aluminum electric wire having a conductor made of aluminum or an aluminum alloy. The second electric wire W2 has, for example, a conductive second conductor W2a formed by a plurality of strands and an insulating second insulating coating portion W2b that covers the outer peripheral side of the second conductor W2a. The second conductor W2a is composed of a metal member having flexibility and conductivity. The second conductor W2a is formed to extend with substantially the same diameter with respect to the axial direction in which it linearly extends. The strands constituting the second conductor W2a are manufactured from a conductive metal, for example, aluminum, an aluminum alloy, etc. Here, the second conductor W2a is a simple bundle of a plurality of strands, but may be formed by twisting a plurality of strands.

[0019] The second insulating coating portion W2b is an electric wire coating that covers the outer peripheral side of the second conductor W2a. The second insulating coating portion W2b is provided in contact with the outer peripheral surface of the second conductor W2a. The second insulating coating portion W2b is formed, for example, by extrusion molding an insulating resin material (including PP, PVC, cross-linked PE, etc., which is appropriately selected in consideration of abrasion resistance, chemical resistance, heat resistance, etc.). The second insulating coating portion W2b is formed from one end to the other end of the second conductor W2a in the axial direction. At the end of the second conductor W2a of the second electric wire W2, the second insulating coating portion W2b is peeled off, and the end of the second conductor W2a is exposed from the second insulating coating portion W2b. At the end of the second conductor W2a of the second electric wire W2, the end of the second conductor W2a of the second electric wire W2 described below is physically and electrically joined. As an example, the second electric wire W2 has a substantially circular cross-sectional shape in the axial direction of the second conductor W2a, and the second insulating coating portion W2b has a substantially annular cross-sectional shape in the axial direction, and the overall cross-sectional shape is substantially circular.

[0020] The joint portion WS is a portion where the first conductor W1a and the second conductor W2a are joined. The joint portion WS is formed by butting and joining the ends of the first conductor W1a and the second conductor W2a in the axial direction with each other, for example, by laser welding, resistance welding, arc welding, etc. The outer diameter of the joint portion WS in this embodiment is set to be relatively larger than the outer diameters of the first conductor W1a and the second conductor W2a respectively, but it is not limited thereto. Also, in the state where the joint protection fitting 1 is fixed to the electric wire W, the joint portion WS in this embodiment is in contact with the joint protection fitting 1 in the plate thickness direction Z, but it is not limited thereto.

[0021] Next, the joint protection fitting 1 in this embodiment will be described.

[0022] The protective fitting 1 for the joint part has a structure in which the first electric wire W1 is clamped and fixed to one end in the extending direction X, and the second electric wire W2 having a second conductor W2a made of a material different from the first conductor W1a of the first electric wire W1 is clamped and fixed to the other end. The protective fitting 1 for the joint part is made of, for example, a metal with thermal conductivity and electrical conductivity, such as copper or the like. The protective fitting 1 for the joint part is protected, for example, in a state where the protective fitting 1 for the joint part is fixed to the electric wire W, by covering the entire protective fitting 1 for the joint part and a part of the first electric wire W1 and the second electric wire W2 with the heat shrinkable tube 30. The protective fitting 1 for the joint part is installed in the wiring path of the wire harness WH, inside the power box, inside the junction block, and the like. In this case, the protective fitting 1 for the joint part is preferably arranged at a position where it is not affected by vibrations received from the outside as much as possible. The protective fitting 1 for the joint part has a fitting body 2 and a pair of wire clamping parts 3.

[0023] The fitting body 2 is fixed to the electric wire W having the joint part WS and is a part that protects the joint part WS. As shown in FIG. 3, the fitting body 2 is formed to extend in the extending direction X along the electric wire W in a state where the protective fitting 1 for the joint part is fixed to the electric wire W, and has a uniform plate thickness in the plate thickness direction Z. Further, as shown in FIGS. 2 and 4, the fitting body 2 has a uniform width in the width direction Y except for four notches 21 described later. The cross-sectional shape of the fitting body 2 as viewed from the plate thickness direction Z is formed in a substantially rectangular shape with the extending direction X as the long side and the width direction Y as the short side.

[0024] A pair of wire clamping parts 3 are provided at both ends of the fitting body 2 in the extending direction X, and are parts for fixing the fitting body 2 to the first insulating covering part W1b and the second insulating covering part W2b of the wire W respectively. That is, the fitting body 2 is fixed to the wire W in an assembled state where the joint part WS is sandwiched in the extending direction X between the pair of wire clamping parts 3. The pair of wire clamping parts 3 are each formed to extend along the width direction Y in a state before the protection fitting 1 for joint part shown in Fig. 4 is fixed to the wire W. When viewed from the plate thickness direction Z, the wire clamping part 3 is formed such that the width in the width direction Y is relatively longer than the width in the width direction Y of the fitting body 2 in a state before the protection fitting 1 for joint part is fixed to the wire W. The wire clamping part 3 is a part that is bent by an assembler using a jig or the like and clamped against each of the first insulating covering part W1b and the second insulating covering part W2b of the wire W in a state where the joint part WS is placed on the placing part 10 of the protection fitting 1 for joint part described later.

[0025] The fitting body 2 of the present embodiment has a placing part 10 and a pair of bending deformation absorbing parts 11.

[0026] The placing part 10 is a part where the joint part WS is placed facing the plate thickness direction Z orthogonal to the extending direction X in an assembled state where the joint part WS is sandwiched in the extending direction X between the pair of wire clamping parts 3 with respect to the wire W. The placing part 10 contacts the joint part WS in the plate thickness direction Z and supports the joint part WS in a state where the protection fitting 1 for joint part is fixed to the wire W. That is, the placing part 10 is not provided with a through hole 20 or a notch 21 described later.

[0027] The pair of bending deformation absorbing parts 11 are parts provided on both sides of the placing part 10 in the extending direction X with the placing part 10 interposed therebetween. Each bending deformation absorbing part 11 is provided between the wire clamping part 3 and the placing part 10 along the extending direction X. The bending deformation absorbing part 11 has a through hole 20 and a pair of notches 21.

[0028] The through-hole 20 is a through-hole that penetrates the fitting body 2 in the plate thickness direction Z. When viewed from the plate thickness direction Z of the fitting body 2, the through-hole 20 is provided at two locations along the extending direction X with respect to the fitting body 2. The two through-holes 20 are provided on both sides of the mounting portion 10 along the extending direction X with the mounting portion 10 interposed therebetween. In a state where the joint portion protection fitting 1 is fixed to the electric wire W, one through-hole 20 is positioned to face the portion where the first conductor W1a is exposed to the outside in the plate thickness direction Z, and the other through-hole 20 is positioned to face the portion where the second conductor W2a is exposed to the outside in the plate thickness direction Z. The through-hole 20 is formed in a rectangular or oblong shape when viewed from the plate thickness direction Z. The through-hole 20 is formed such that the opening width in the width direction Y is substantially the same as the outer diameter width of the joint portion WS.

[0029] The pair of notches 21 are notches provided at both ends of the fitting body 2 in the width direction Y. The notches 21 are respectively provided on both sides of the fitting body 2 in the width direction Y with the through-hole 20 interposed therebetween. That is, the notches 21 are formed so as to be recessed inward (toward the through-hole 20 side) from each end surface on both sides of the fitting body 2 in the width direction Y. The notches 21 are formed in a semi-circular cross-sectional shape when viewed from the plate thickness direction Z.

[0030] In the joint portion protection fitting 1 of the present embodiment, since the bending deformation absorbing portion 11 has the through-hole 20 and the pair of notches, the bending deformation absorbing portion 11 has a structure that is easily bent with respect to an external force.

[0031] Further, in the joint portion protection fitting 1 of the present embodiment, by providing the bending deformation absorbing portion 11 at a position facing each of the first conductor W1a and the second conductor W2a in the plate thickness direction Z, the bending deformation absorbing portion 11 deforms prior to the mounting portion 10 with respect to an external force applied to the joint portion protection fitting 1. Then, as the bending deformation absorbing portion 11 bends, the first conductor W1a having relatively higher flexibility than the first electric wire W1 and the second conductor W2a having relatively higher flexibility than the second electric wire W2 bend. As a result, in the joint portion protection fitting 1, each of the bending deformation absorbing portion 11, the first conductor W1a, and the second conductor W2a absorbs the external force, and it becomes possible to protect the joint portion WS.

[0032] In addition, the protective fitting 1 for the joint portion of the present embodiment clamps and fixes the electric wire W by a pair of wire clamping portions 3 provided at both ends in the extending direction X of the fitting main body 2. Thereby, even when a tensile load acts on the electric wire W in the axial direction, the protective fitting 1 for the joint portion receives the tensile load, so that the joint portion WS of the electric wire W can be prevented from being damaged. In this case, the degree to which the protective fitting 1 for the joint portion can withstand bending and tensile loads can be adjusted by the plate thickness, width of the fitting main body 2, the shape of the through hole 20, and the shape of the notch 21.

[0033] In addition, the protective fitting 1 for the joint portion of the present embodiment has a structure in which the bending deformation absorbing portion 11 starts to bend before the mounting portion 10 even when an external force accompanied by bending deformation is applied to the fitting main body 2. Therefore, compared with the case where the rigidity of the entire protective fitting 1 for the joint portion is increased, the volume of the fitting itself can be reduced. Further, in the protective fitting 1 for the joint portion, the pair of wire clamping portions 3 have the minimum required height in the plate thickness direction Z in the clamped state, and the exclusive area of the space associated with the installation of the protective fitting 1 for the joint portion can be small. Further, since the joint portion WS is formed by the sum of the volumes of the aluminum conductor and the copper conductor, there is no reduction in the cross-sectional area of the joint portion WS. Further, since the joint portion WS is in contact with the mounting portion 10, the conductivity of the protective fitting 1 itself contributes when the electric wire W is energized, so that there is no reduction in electrical performance due to the joint between conductors of different materials.

[0034] As described above, the protective fitting 1 for the joint portion and the wire harness WH according to the present embodiment include the fitting main body 2 and a pair of wire clamping portions 3 provided at both ends in the extending direction X of the fitting main body 2 for fixing the fitting main body 2 to the first insulating coating portion W1b and the second insulating coating portion W2b of the electric wire W, respectively. The fitting main body 2 is fixed to the electric wire W in an assembled state in which the joint portion WS is sandwiched in the extending direction X between the pair of wire clamping portions 3.

[0035] With the above configuration, even when a tensile load acts on the electric wire W in the axial direction, the protective fitting 1 for the joint portion receives the tensile load, so that the joint portion WS of the electric wire W can be prevented from being damaged. As a result, the protective fitting 1 for the joint portion and the wire harness WH can appropriately protect the joint portion between the first electric wire W1 and the second electric wire W2 whose conductor materials are different from each other.

[0036] Further, in the protective fitting 1 for the joint portion and the wire harness WH according to the present embodiment, the metal fitting main body 2 has a mounting portion 10 on which the joint portion WS is placed facing in the plate thickness direction Z in the assembled state, and a pair of bending deformation absorbing portions 11 provided on both sides in the extending direction X with the mounting portion 10 interposed therebetween. The bending deformation absorbing portion 11 is formed with a through hole 20 penetrating the metal fitting main body 2 in the plate thickness direction Z and a pair of notches 21 provided at both ends in the width direction Y of the metal fitting main body 2.

[0037] With the above configuration, in the protective fitting 1 for the joint portion and the wire harness WH, with respect to the external force applied to the protective fitting 1 for the joint portion, the bending deformation absorbing portion 11 that is more easily bent than the mounting portion 10 deforms first, so that it is possible to protect the joint portion WS located on the mounting portion 10.

[0038] In the above embodiment, the protective fitting 1 for the joint portion is formed of a conductive metal member, but is not limited thereto, and may be formed of, for example, an insulating metal member.

[0039] Further, in the above embodiment, the joint portion WS may be formed by other methods such as ultrasonic bonding or brazing in addition to fusion bonding such as laser welding, resistance welding, and arc welding.

[0040] In the above-described embodiment, the joint portion WS is formed by abutting and joining the end portion of the first conductor W1a and the end portion of the second conductor W2a in the axial direction. However, the present invention is not limited to this. For example, the joint portion WS may be formed by arranging and joining the first conductor W1a and the second conductor W2a in the width direction Y, or may be formed by dividing the first conductor W1a and the second conductor W2a and sandwiching them with each other.

[0041] In the above-described embodiment, the bending deformation absorbing portion 11 is formed with the through hole 20 and the pair of notches 21. However, the present invention is not limited to this, and at least one of the through hole 20 and the pair of notches 21 may be formed. Further, the bending deformation absorbing portion 11 may be formed by integrally forming the through hole 20 and the notch 21 on the premise that it deforms prior to the mounting portion 10 by an external force, or may have a curved shape or a wavy shape.

[0042] In the above-described embodiment, the wire clamping portion 3 is clamped by an operator using a jig or the like. However, the present invention is not limited to this, and for example, clamping may be performed on a clamping device after the joining process of the first conductor W1a and the second conductor W2a.

[0043] In the above-described embodiment, the protective fitting 1 for the joint portion has been described in a form protected by the heat shrinkable tube 30. However, the present invention is not limited to this. For example, the protective fitting 1 for the joint portion may be, for example, a form in which the entire protective fitting 1 for the joint portion and a part of the first wire W1 and the second wire W2 are covered by a flexible resin by molding, potting, or the like, or may be covered by a resin case. Thereby, the protective fitting 1 for the joint portion can prevent corrosion of the joint portion WS.

Explanation of Reference Numerals

[0044] 1 Protective fitting for joint portion 2 Fitting body 3 Wire clamping portion 10 Mounting portion 11 Bending deformation absorbing portion W Wire W1 First wire W2 Second wire W1a First conductor W1b First insulating coating W2a Second conductor W2b Second insulating coating WS Joint WH Wire harness

Claims

1. It is fixed to a wire having a joint formed between conductors of different materials, and includes a plate-shaped fitting body that protects the joint; A pair of wire clamping portions provided at both ends in the extending direction of the fitting body, for fixing the fitting body to the insulating coating portion of the wire; The fitting body: Is fixed to the wire in an assembled state in which the joint is sandwiched in the extending direction between the pair of wire clamping portions; A protective fitting for a joint, characterized in that.

2. The fitting body: A placement portion on which the joint is placed facing each other in the plate thickness direction orthogonal to the extending direction in the assembled state; A pair of bending deformation absorbing portions provided on both sides in the extending direction with the placement portion interposed therebetween; The bending deformation absorbing portion: At least one of a through hole penetrating the fitting body in the plate thickness direction and a pair of notches provided at both ends in the width direction orthogonal to the extending direction and the plate thickness direction of the fitting body is formed; The protective fitting for a joint according to Claim 1.

3. A wire having a joint between conductors of different materials; A plate-shaped fitting body fixed to the wire to protect the joint; A pair of wire clamping portions provided at both ends in the extending direction of the fitting body, for fixing the fitting body to the insulating coating portion of the wire; The fitting body: Is fixed to the wire in an assembled state in which the joint is sandwiched in the extending direction between the pair of wire clamping portions; A wire harness, characterized in that.

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