Wiring harness, and manufacturing method of wiring harness

Abstract

To improve wiring workability.SOLUTION: There are provided a plate-like bus bar 20 comprising a plurality of electric wires 10 and an electric wire installation face 21 on which the plurality of electric wires 10 are placed, that is formed into a shape obtained by being placed along a wiring route of the plurality of electric wires 10; and an adhesive sheet 30 for holding the plurality of electric wires 10 enclosed with the electric wire installation face 21 in between, to the bus bar 20. For example, the adhesive sheet 30 comprises: a bus bar coating part 31 for coating the bus bar 20; and an electric wire coating part 32 for holding the plurality of electric wires 10 enclosed with the electric wire installation face 21 in between via the bus bar coating part 31, to the bus bar 20, that allows protruding from the bus bar coating part 31.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a wire harness and a method for manufacturing a wire harness.

Background Art

[0002] Conventionally, in a wire harness, in order to protect electric wires, the electric wires are covered with exterior members such as a corrugated tube, an adhesive tape, and an adhesive sheet. In this conventional wire harness, a plurality of electric wires are bundled together in a cylindrical shape, and the wire bundle is inserted into a cylindrical corrugated tube, or an adhesive tape is wound around the wire bundle, or the wire bundle is wrapped with an adhesive sheet. For example, in the wire harnesses of Patent Documents 1 and 2 below, a self-adhesive sheet for wrapping electric wires is disclosed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in recent years, in the wire harness of a vehicle, as the number of circuits increases and the wire diameter expands, etc., the wire bundle has become thicker and its rigidity has become higher. Therefore, in the conventional wire harness, for example, it is bent while following the vehicle body, but its workability has deteriorated, and it has become difficult to follow a desired wiring route.

[0005] Therefore, an object of the present invention is to provide a wire harness and a method for manufacturing a wire harness that are excellent in wiring workability.

Means for Solving the Problems

[0006] The wire harness according to the present invention includes a plurality of electric wires, a wire installation surface on which the plurality of electric wires are placed, and a plate-shaped bus bar formed in a shape along the routing path of the plurality of electric wires, and an adhesive sheet that wraps the plurality of electric wires between the wire installation surface and holds them on the bus bar.

[0007] Further, the method for manufacturing a wire harness according to the present invention includes a bus bar forming step of forming a plate-shaped bus bar having a wire installation surface on which a plurality of electric wires are placed, a first covering step of covering the bus bar with an adhesive sheet, a bending step of bending the bus bar along the routing path of the plurality of electric wires together with the adhesive sheet, a wire installation step of placing the plurality of electric wires on the wire installation surface via the adhesive sheet, and a second covering step of wrapping the plurality of electric wires between the wire installation surface and holding them on the bus bar with the adhesive sheet.

Advantages of the Invention

[0008] In the wire harness according to the present invention, the plurality of electric wires are placed on the wire installation surface of the bus bar along the routing path of the plurality of electric wires, and the plurality of electric wires are wrapped between the wire installation surface and held on the bus bar by the adhesive sheet. Therefore, this wire harness does not need to be bent while following the vehicle body, and has excellent wiring workability. And the method for manufacturing a wire harness according to the present invention produces such a wire harness, and the same effects as those achieved by this wire harness can be obtained.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the wire harness and the method for manufacturing the wire harness according to the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to these embodiments.

[0011] [Embodiment] One embodiment of the wire harness and the method for manufacturing the wire harness according to the present invention will be described with reference to FIGS. 1 to 6.

[0012] Reference numeral 1 in FIGS. 1 and 2 indicates the wire harness of the present embodiment.

[0013] This wire harness 1 includes a plurality of electric wires 10 (FIGS. 1 and 2). All of these plurality of electric wires 10 may be of the same type, or a plurality of types of electric wires such as those having different wire diameters may be mixed.

[0014] The wire harness 1 also includes a plate-shaped bus bar 20 on which the plurality of electric wires 10 are placed (FIGS. 1 to 6). This bus bar 20 is, for example, press-formed into a desired shape using a metal plate as a base material.

[0015] The bus bar 20 has a wire installation surface 21 on which the plurality of electric wires 10 are placed (FIGS. 1 to 6). In this bus bar 20, only one of the two planes may be used as the wire installation surface 21, or both of the two planes may be used as the wire installation surface 21. In this example, one plane is used as the wire installation surface 21.

[0016] In addition, the bus bar 20 is formed into a shape along the routing path of the plurality of electric wires 10 (Fig. 5). For example, this bus bar 20 may be formed into a flat plate shape and then bent (for example, before placing the plurality of electric wires 10 thereon) into a shape along the routing path of the plurality of electric wires 10, or may be pre-formed into a shape along the routing path of the plurality of electric wires 10. The bus bar 20 shown here is formed into a rectangular flat plate shape (Fig. 3) and is bent together with the following adhesive sheet 30 into a shape along the routing path of the plurality of electric wires 10 (Fig. 5).

[0017] For example, the plurality of electric wires 10 are arranged in a direction orthogonal to the electric wire axis (so to speak, the axis of the electric wire) and placed on the electric wire installation surface 21 for each electric wire 10. That is, in this case, the plurality of electric wires 10 are placed side by side in a row in a direction orthogonal to the electric wire axis on the electric wire installation surface 21. In other words, only one layer of the following electric wire row 10A is placed on this electric wire installation surface 21.

[0018] Also, for example, the plurality of electric wires 10 are divided into a plurality of groups, and for each of the divided groups, an electric wire row 10A is formed by arranging them in a direction orthogonal to the electric wire axis along the electric wire installation surface 21 (Figs. 1, 2, 5, and 6). And in the plurality of electric wires 10, the electric wire rows 10A of each group are stacked in layers in order from the lowermost layer on the electric wire installation surface 21 side and placed on the electric wire installation surface 21. Here, an example of a plurality of electric wires 10 with the electric wire rows 10A stacked in a plurality of layers is shown.

[0019] Furthermore, this wire harness 1 includes an adhesive sheet 30 that wraps the plurality of electric wires 10 between the electric wires and the electric wire installation surface 21 and holds them on the bus bar 20 (Figs. 1 to 6). This adhesive sheet 30 may be any sheet as long as the sheets can be bonded to each other and have flexibility to be attached to the plurality of electric wires 10. The adhesive sheet 30 shown here is a so-called self-adhesive sheet. For example, this adhesive sheet 30 may be one in which an adhesive layer is laminated on one sheet surface of the base material and one sheet surface is used as the adhesive surface, or may be one in which an adhesive is applied to one sheet surface of the base material and one sheet surface is used as the adhesive surface.

[0020] This adhesive sheet 30 has a bus bar covering portion 31 that covers the bus bar 20, and a wire covering portion 32 that protrudes from the bus bar covering portion 31 and wraps around a plurality of wires 10 between the bus bar covering portion 31 and the wire installation surface 21 and holds them on the bus bar 20 (Figs. 1 to 6).

[0021] For example, the bus bar covering portion 31 covers the bus bar 20 in a circumferential direction for one full turn. The wire covering portion 32 protrudes from the bus bar covering portion 31 and wraps around a plurality of wires 10 placed on the wire installation surface 21 via the bus bar covering portion 31, thereby wrapping around the plurality of wires 10.

[0022] The wire covering portion 32 shown here protrudes one by one from each end in the direction orthogonal to the wiring path of the plurality of wires 10 in the bus bar covering portion 31. In this adhesive sheet 30, one wire covering portion 32 is wrapped around a plurality of wires 10 placed on the wire installation surface 21 via the bus bar covering portion 31, and the other wire covering portion 32 is wrapped around from above the one wire covering portion 32, so that the pair of wire covering portions 32 and the bus bar covering portion 31 wrap around the plurality of wires 10.

[0023] In addition, in this wire harness 1, fixing members such as clips (not shown) for attaching to the vehicle body are assembled to, for example, the bus bar 20 or the like.

[0024] For example, in this wire harness 1, the following manufacturing method is applied.

[0025] First, this manufacturing method has a bus bar forming step of forming the plate-shaped bus bar 20. In this bus bar forming step, the flat plate-shaped bus bar 20 is formed. Here, the rectangular flat plate-shaped bus bar 20 shown above is formed.

[0026] Next, this manufacturing method has a first covering step of covering the bus bar 20 with the adhesive sheet 30. In this first covering step, for example, the adhesive sheet 30 may be formed on the bus bar 20 installed in the mold. Also, in this first covering step, for example, the bus bar 20 may be sandwiched between two rectangular adhesive sheets 30, and the ends that will become the pair of wire covering portions 32 in each adhesive sheet 30 may be bonded together. In that case, the adhesive surface on the back surface at the end of one wire covering portion 32 is attached to the front surface at the end of the other wire covering portion 32.

[0027] Next, this manufacturing method has a bending step of bending the bus bar 20 together with the adhesive sheet 30 along the routing path of the plurality of wires 10. In this exemplary bending step, the bus bar 20 and the adhesive sheet 30 are bent into a crank shape.

[0028] Next, this manufacturing method has a cutting step of making a cut 32a (FIG. 5) in the wire covering portion 32 at the bending location. This cutting step is a preparatory step for suppressing the occurrence of wrinkles or the like at the bending location when the wire covering portion 32 is wound around the plurality of wires 10. In this exemplary cutting step, in the wire covering portion 32, a cut 32a is made at the boundary between the connecting portion and one main body portion at the crank-shaped bending location, and a cut 32a is made at the boundary between the connecting portion and the other main body portion at that bending location, separating the connecting portion from the main body portions at both ends.

[0029] Next, this manufacturing method has a wire installation step of placing the plurality of wires 10 on the wire installation surface 21 via the adhesive sheet 30. In this wire installation step, for example, the plurality of wires 10 are placed side by side in a row in a direction orthogonal to the wire axis. Also, in this wire installation step, for example, the plurality of wires 10 are divided into a plurality of groups, and for each of these divided groups, a wire row 10A is formed by arranging the wires in a direction orthogonal to the wire axis along the wire installation surface 21. And in this wire installation step, the wire rows 10A of each group are stacked and placed layer by layer in order from the lowermost layer on the wire installation surface 21 side.

[0030] Next, this manufacturing method has a second covering step of wrapping a plurality of electric wires 10 with an adhesive sheet 30 and holding them on a bus bar 20 between the electric wires and an electric wire installation surface 21. In this second covering step, by winding and attaching an electric wire covering portion 32 around the plurality of electric wires 10, the plurality of electric wires 10 are wrapped by the electric wire covering portion 32 and a bus bar covering portion 31 on the electric wire installation surface 21 and held on the bus bar 20. In this exemplary second covering step, one electric wire covering portion 32 is wound and attached around the plurality of electric wires 10, and the other electric wire covering portion 32 is wound and attached around the one electric wire covering portion 32, whereby the plurality of electric wires 10 are wrapped by a pair of electric wire covering portions 32 and a bus bar covering portion 31 on the electric wire installation surface 21 and held on the bus bar 20.

[0031] As described above, in the wire harness 1 of this embodiment, the plurality of electric wires 10 are placed on the electric wire installation surface 21 of the bus bar 20 along the wiring path of the plurality of electric wires 10, and the plurality of electric wires 10 are wrapped by an adhesive sheet 30 between the electric wires and the electric wire installation surface 21 and held on the bus bar 20. Therefore, this wire harness 1 does not need to be bent while following the vehicle body, and has excellent wiring workability.

[0032] Also, the wire harness 1 of this embodiment wraps a plurality of electric wires 10 arranged in a row in a direction orthogonal to the electric wire axis with the bus bar 20 and the adhesive sheet 30. Further, the wire harness 1 of this embodiment stacks a plurality of sets of electric wire rows 10A in which a plurality of electric wires 10 are grouped in layers on the electric wire installation surface 21 and wraps this with the bus bar 20 and the adhesive sheet 30. Therefore, the wire harness 1 of this embodiment has a low height in the direction orthogonal to the electric wire installation surface 21, and the degree of freedom of the layout with respect to the vehicle body can be increased.

[0033] The manufacturing method shown in this embodiment creates such a wire harness 1, and the same effects as those achieved by this wire harness 1 can be obtained.

Explanation of Reference Numerals

[0034] 1 Wire harness 10 Electric wire 10A Electric wire array 20 Bus bar 21 Electric wire installation surface 30 Adhesive sheet 31 Bus bar covering part 32 Electric wire covering part

Claims

1. A plurality of electric wires, a plate-shaped bus bar having a wire installation surface on which the plurality of electric wires are placed and formed in a shape along the wiring path of the plurality of electric wires, and an adhesive sheet that wraps the plurality of electric wires between the wire installation surface and holds them on the bus bar, characterized in that it comprises a wire harness.

2. The plurality of electric wires are arranged in a direction orthogonal to the wire axis for each wire and placed on the wire installation surface, or form a wire row arranged in a direction orthogonal to the wire axis along the wire installation surface for each of a plurality of groups divided into a plurality of groups, and the wire rows of each group are stacked in layers in order from the lowermost layer on the wire installation surface side and placed on the wire installation surface. The wire harness according to claim 1, characterized in that

3. The adhesive sheet has a bus bar covering portion that covers the bus bar, and a wire covering portion that protrudes from the bus bar covering portion and wraps the plurality of electric wires between the bus bar covering portion and the wire installation surface and holds them on the bus bar. The wire harness according to claim 1 or 2, characterized in that

4. The wire covering portion protrudes one by one from each end in the direction orthogonal to the wiring path in the bus bar covering portion. The wire harness according to claim 3, characterized in that

5. A bus bar forming step of forming a plate-shaped bus bar having a wire installation surface on which a plurality of electric wires are placed, a first covering step of covering the bus bar with an adhesive sheet, a bending step of bending the bus bar along the wiring path of the plurality of electric wires together with the adhesive sheet, a wire installation step of placing the plurality of electric wires on the wire installation surface via the adhesive sheet, and a second covering step of wrapping the plurality of electric wires between the wire installation surface by the adhesive sheet and holding them on the bus bar, characterized in that it has a method for manufacturing a wire harness.

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