Wire harness and manufacturing method for the same

Abstract

To provide a wire harness capable of properly routing wiring materials and a manufacturing method for the same.SOLUTION: A wire harness 1 includes a conductive wiring material 10, an outer casing member 20 formed in a tubular shape with the wiring material 10 inserted therein, and a resin filling material 30 filled inside the outer casing member 20. Furthermore, the outer casing member 20 has a resin inlet 22 that connects the interior and exterior and allows the resin filling material 30 to be filled.SELECTED DRAWING: Figure 3

Description

[Technical Field]

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

[0002] For example, Patent Document 1 discloses a wire harness including a high-voltage cable and a metal protective pipe through which the high-voltage cable is inserted. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2004-224156 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the wire harness described in the above-mentioned Patent Document 1 may be subjected to various processes, such as bending, while the high-voltage cable (wiring material) is inserted into the protective pipe, which may result in a large load being applied during the process. Furthermore, when dissipating heat generated from the wiring material to the outside, a device for circulating a coolant may be placed in the gap between the wiring material and the protective pipe, which may increase the number of parts. Therefore, there is room for further improvement in terms of properly routing the wiring material.

[0005] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a wire harness that allows wiring materials to be properly routed, and a method for manufacturing the wire harness. [Means for solving the problem]

[0006] In order to achieve the above object, the wire harness of the present invention comprises a conductive wiring material, a cylindrical outer casing member through which the wiring material is inserted, and a resin filler material filled inside the outer casing member, and the outer casing member has a resin injection port that connects the inside to the outside and through which the resin filler material can be filled.

[0007] In order to achieve the above object, the wire harness manufacturing method of the present invention is characterized by comprising an insertion step of inserting a conductive wiring material into the inside of a cylindrically formed and linearly extending outer member, a bending step of bending the wiring material and the outer member to match the shape of the wiring path of the wiring material, and a fixing step of filling a resin filler through a resin injection port that connects the inside and outside of the outer member and fixing the position of the wiring material relative to the outer member. [Effects of the Invention]

[0008] The wire harness according to the present invention has an effect of enabling the wiring material to be properly routed. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram showing a schematic configuration of a wire harness according to the present embodiment. [Figure 2] FIG. 2 is a cross-sectional view showing a schematic configuration of the wire harness according to the present embodiment. [Figure 3] FIG. 3 is a cross-sectional view showing a schematic configuration of the wire harness according to the present embodiment. [Figure 4] FIG. 4 is a flowchart showing the wire harness manufacturing method according to the present embodiment. [Figure 5] FIG. 5 is a schematic view for explaining the insertion step in the wire harness manufacturing method according to the present embodiment. [Figure 6] FIG. 6 is a schematic view for explaining the fixing step in the wire harness manufacturing method according to the present embodiment. [Figure 7]FIG. 7 is a schematic view for explaining the fixing step in the wire harness manufacturing method according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the present invention is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially the same.

[0011] [Embodiment] The wire harness 1 shown in Figure 1 is, for example, a collection of multiple wiring materials 10 used for power supply and signal communication, bundled together to form an assembly component for connecting various devices installed in a vehicle, and the multiple wiring materials 10 are connected to each device using connectors or the like.

[0012] The wire harness 1 has a cylindrical exterior member 20 into which a wiring material 10 is inserted, and the interior of the exterior member 20 is filled with a resin filler 30. The wire harness 1 of this embodiment has a configuration in which the shape of the exterior member 20 is fixed by the resin filler 30 filled inside the exterior member 20, thereby enabling the wiring material 10 to be properly routed. Hereinafter, the configuration of the wire harness 1 will be described in detail with reference to Figs. 1 to 3.

[0013] In the following description, of the first, second, and third directions that intersect with one another, the first direction will be referred to as the "length direction X," the second direction will be referred to as the "width direction Y," and the third direction will be referred to as the "height direction Z." Here, the length direction X, width direction Y, and height direction Z are perpendicular to one another. Furthermore, the length direction X shown in Figures 2, 3, and 5 to 7 typically corresponds to the extension direction (axial direction) of the wiring material 10. Unless otherwise specified, each direction used in the following description will be described as the direction in a state in which each part of the wire harness 1 is assembled.

[0014] Furthermore, the wire harness 1 may further include a protector, a grommet, a fixture, a connector, and the like.

[0015] The wire harness 1 includes a conductive wiring material 10, an exterior member 20 provided on the wiring material 10, and a resin filler 30 filled inside the exterior member 20.

[0016] <Routing material> The wiring material 10 is arranged in a vehicle and electrically connects various devices. As shown in FIG. 2, the wiring material 10 of this embodiment is an insulated electric wire that includes a conductive conductor portion 10a (core wire) and an insulating insulating sheath portion 10b, and the conductor portion 10a is sheathed by the insulating sheath portion 10b. The conductor portion 10a here is a twisted wire formed by twisting together multiple conductive wires. The insulating sheath portion 10b is formed, for example, by extrusion molding an insulating resin material (PP, PVC, cross-linked PE, etc., appropriately selected in consideration of abrasion resistance, chemical resistance, heat resistance, etc.). The conductor portion 10a may also be a bundle of multiple wires.

[0017] In addition, the cross-sectional shape of the wiring material 10 (cross-sectional shape in a direction intersecting the extension direction of the wiring material 10) of the conductor portion 10a is approximately circular, and the cross-sectional shape of the insulating coating portion 10b is approximately annular, so that the overall cross-sectional shape is approximately circular (see Figure 3).

[0018] <Exterior materials> The exterior member 20 has the wiring material 10 inserted therethrough and protects the wiring material 10. The exterior member 20 of this embodiment is a cylindrical corrugated tube. As shown in FIGS. 1 and 2 , the corrugated tube has annular concave-convex portions 21 formed along the circumferential direction on its outer surface, and a plurality of the concave-convex portions 21 are provided along the extension direction of the exterior member 20, thereby forming an accordion-like shape. Therefore, the exterior member 20 is configured to include, as the concave-convex portions 21, convex portions 211 that protrude toward the outer peripheral surface side and concave portions 212 that protrude toward the inner peripheral surface side. Furthermore, the exterior member 20 is flexible, and when a force is applied, the convex portions 211 and the concave portions 212 deform, allowing the exterior member 20 to bend (flex) in any direction intersecting the extension direction of the exterior member 20 (for example, the length direction X shown in FIG. 2 ).

[0019] Furthermore, the exterior member 20 has lower rigidity than the wiring material 10, and its deformation amount in response to external forces such as bending and twisting is greater than that of the wiring material 10. Therefore, the exterior member 20 of this embodiment is more flexible than the wiring material 10, and when bent in any direction together with the wiring material 10 inserted therein, it can bend to match the shape of the wiring path of the wiring material 10. The rigidity of the exterior member 20 is determined using indicators such as a spring constant (the strength of the repulsive force generated when the exterior member 20 is bent). Furthermore, the exterior member 20 is preferably stiff enough to be bent by an operator's hand. More specifically, it is preferable that the force applied when an operator bends the exterior member 20 by 1 radian in any direction intersecting the extension direction (e.g., the length direction X shown in FIG. 2) be 0.5 N·m or less.

[0020] The exterior member 20 is formed of a metal material such as aluminum or copper. Therefore, the exterior member 20 of this embodiment can dissipate heat by absorbing heat generated from the wiring material 10 inserted therein and dissipating the heat to the outside. Since the exterior member 20 is formed in a bellows shape as described above, the uneven portion 21 can efficiently dissipate heat. While the sizes of the convex portions 211 and concave portions 212 of the uneven portion 21 are not particularly limited, it is preferable that the uneven portion 21 have a large contact area with a fluid outside the exterior member 20 (e.g., wind flowing outside the exterior member 20, air present outside the exterior member 20, etc.). More specifically, the height 211a (see FIG. 2 ) of the convex portions 211 of the exterior member 20 is preferably relatively large. For example, the height 211a of the convex portions 211 is preferably 25% or more of the minimum outer diameter portion of the exterior member 20 (the minimum outer diameter portion 212a of the concave portions 212). Furthermore, it is preferable that the spacing between the protrusions 211 (pitch 211b, see FIG. 2) of the exterior member 20 is relatively small, and it is more preferable that the pitch 211b of the protrusions 211 is three times or more the width 211c of the protrusions 211.

[0021] The exterior member 20 is configured to include a storage space 20S as an internal space and a pair of insertion openings 20T that open along the extension direction of the exterior member 20. The storage space 20S here is a portion defined and formed by the wall of the exterior member 20, as shown in FIGS. 1 to 3. The insertion openings 20T are portions defined and formed by the ends (edge ​​portions of the exterior member 20) of the exterior member 20, as shown in FIG. 1. The exterior member 20 can accommodate the wiring material 10 inside by inserting the wiring material 10 into the storage space 20S through the pair of insertion openings 20T. As shown in FIG. 2, the center line L20 connecting the centers of the insertion openings 20T is positioned along the central axis L10 of the wiring material 10 accommodated in the storage space 20S, so that the exterior member 20 can extend along the extension direction of the wiring material 10 (the length direction X shown in FIG. 2).

[0022] In the present embodiment, a corrugated tube has been described as an example of the exterior member 20, but there is no particular limitation on the type of the exterior member 20. The exterior member 20 may be configured, for example, by a straight tube member on which the uneven portion 21 is not formed.

[0023] <Resin filler> The resin filler 30 is filled into the storage space 20S of the exterior member 20 in a state in which the wiring material 10 is inserted into the storage space 20S, and is interposed between the wiring material 10 located on the inside and the exterior member 20 located on the outside. The resin filler 30 of this embodiment is filled so as to eliminate any gap between the wiring material 10 inserted into the storage space 20S and the exterior member 20. Therefore, as shown in Figures 2 and 3, the resin filler 30 is filled so as to entirely fill the storage space 20S of the exterior member 20, and is in contact with both the wiring material 10 and the exterior member 20.

[0024] The resin filler 30 is made of a thermosetting resin such as an epoxy resin. The thermosetting resin is solidified by a chemical reaction when a curing agent is mixed with a prepolymer, which is the main component, and a heat curing process is performed. Therefore, when the resin filler 30 is filled inside the exterior member 20 and then hardened, it can fix the position of the wiring material 10 relative to the exterior member 20.

[0025] Furthermore, the resin filler 30 has a thermosetting resin whose hardening temperature is lower than the sheath melting point (melting point of the insulating sheath portion 10b) of the wiring material 10, or the thermosetting resin whose hardening temperature is lower than the sheath heat resistance temperature (heat resistance temperature of the insulating sheath portion 10b) of the wiring material 10. Therefore, for example, if the sheath melting point of the wiring material 10 is 180°C, the resin filler 30 is made of a thermosetting resin whose hardening temperature is about 150°C, or, for example, if the sheath heat resistance temperature of the wiring material 10 is 120°C, the resin filler 30 is made of a thermosetting resin whose hardening temperature is about 100°C. As a result, the resin filler 30 of this embodiment can prevent the insulating sheath portion 10b of the wiring material 10 from melting due to the heat generated when the thermosetting resin solidifies. Furthermore, the resin filler 30 can prevent a decrease in the electrical conductivity of the wiring material 10 due to a decrease in the durability of the insulating sheath portion 10b of the wiring material 10.

[0026] Furthermore, the thermal conductivity of the thermosetting resin in the resin filler 30 is higher than that of air, which is 0.03 W / (m·K). Therefore, the resin filler 30 is made of a thermosetting resin with a higher thermal conductivity than general thermosetting resins, more specifically, a thermosetting resin with a thermal conductivity of approximately 0.2 W / (m·K) to 3 W / (m·K). This allows the resin filler 30 of this embodiment to absorb heat generated from the wiring material 10 inserted inside the exterior member 20 and conduct the heat to the exterior member 20. Furthermore, as shown in FIGS. 2 and 3 , the resin filler 30 is in close contact with both the wiring material 10 located inside and the exterior member 20 located outside, so that it can efficiently absorb heat from the outer circumferential surface of the wiring material 10 and efficiently conduct the heat to the inner circumferential surface of the exterior member 20.

[0027] In this embodiment, a thermosetting resin has been described as an example of the resin filler 30, but the type of resin filler 30 is not particularly limited. The resin filler 30 may be composed of a thermoplastic resin such as PE. The thermoplastic resin melts when the temperature reaches or exceeds its melting point and solidifies when cooled. Therefore, the softening temperature of the thermoplastic resin (the temperature at which the thermoplastic resin begins to soften when heated) of the resin filler 30 is lower than the coating melting point of the wiring material 10 inserted inside the exterior member 20, or the softening temperature of the thermoplastic resin is lower than the coating heat resistance temperature of the wiring material 10. Therefore, for example, if the coating melting point of the wiring material 10 is 180°C, the resin filler 30 is composed of a thermoplastic resin with a softening temperature of approximately 150°C. Alternatively, for example, if the coating heat resistance temperature of the wiring material 10 is 120°C, the resin filler 30 is composed of a thermoplastic resin with a softening temperature lower than 120°C. Furthermore, the resin filler 30 is made of a general thermoplastic resin having a thermal conductivity of about 0.3 W / (m·K) to 0.5 W / (m·K), which is higher than the thermal conductivity of air, 0.03 W / (m·K), or a thermoplastic resin having a thermal conductivity higher than that of general thermoplastic resin.

[0028] Moreover, the exterior member 20 configured as described above includes a resin injection port 22 and a filling check port 23.

[0029] <Resin injection port> The resin injection port 22 is a portion into which the resin filler 30 is injected from a resin injection nozzle M (see FIG. 6). As shown in FIG. 2, two resin injection ports 22 are provided in this embodiment. Each resin injection port 22 is provided at an end 20a of the exterior member 20, and is thereby spaced apart along the extension direction of the exterior member 20 (the length direction X shown in FIG. 2). As shown in FIG. 3, each resin injection port 22 is formed on the upper side of the exterior member 20, and opens along a direction intersecting the extension direction of the exterior member 20 (the height direction Z shown in FIG. 3), thereby connecting the inside and outside of the exterior member 20.

[0030] Resin injection port 22 is formed in a substantially circular shape and is sized to allow the tip of resin injection nozzle M to be inserted therein (see FIG. 6). Therefore, resin injection port 22 of this embodiment can efficiently inject resin filler 30 from the tip of resin injection nozzle M toward the inside of exterior member 20.

[0031] Furthermore, the exterior body 40 (see FIGS. 1 to 3) formed by filling the exterior member 20 with the resin filler 30 through the resin injection port 22 is fixed in a shape that follows the predetermined wiring path of the wiring material 10 as the resin filler 30 solidifies. For example, if the predetermined wiring path of the wiring material 10 is straight (linear), the exterior member 20 and the wiring material 10 inserted inside the exterior member 20 are each adjusted to the shape of the wiring path, and the resin filler 30 is filled into the exterior member 20. Therefore, an exterior body 40A is formed that is fixed in a straight shape along the wiring path of the wiring material 10 (see FIG. 1). Similarly, if the predetermined wiring path of the wiring material 10 is curved, the exterior member 20 and the wiring material 10 are each adjusted to the shape of the wiring path, and the resin filler 30 is filled into the exterior member 20. Therefore, an outer casing 40B is formed that is fixed in a curved shape along the routing path of the wiring material 10 (see FIG. 1). The outer casing 40 configured in this manner has higher rigidity than the wiring material 10, and its deformation amount against external forces such as bending and twisting is smaller than that of the wiring material 10. Therefore, the outer casing 40 of this embodiment is less likely to bend than the wiring material 10 alone, and can be prevented from bending in an unintended direction (a direction different from the routing path of the wiring material 10) due to the repulsive force of the wiring material 10 inserted inside the outer casing member 20.

[0032] There are no particular limitations on the number of resin injection ports 22 or the positions at which the resin injection ports 22 are provided. There are also no particular limitations on the shape of the resin injection ports 22, and the resin injection ports 22 may be formed in a polygonal shape such as a rectangle.

[0033] <Filling confirmation port> The filling check opening 23 is a portion where it is possible to check the state of filling of the resin filler 30 into the exterior member 20. In this embodiment, one filling check opening 23 is provided in the recess 212 of the exterior member 20. As shown in FIG. 3 , the filling check opening 23 is formed on the left side of the exterior member 20 and opens along a direction intersecting the extension direction (length direction X) of the exterior member 20, thereby communicating the inside and outside of the exterior member 20.

[0034] 3, the opening direction of filling confirmation opening 23, which connects the inside and outside of exterior member 20, intersects with the opening direction of resin injection opening 22. Furthermore, the opening direction of filling confirmation opening 23 is perpendicular to the opening direction of resin injection opening 22, and the angle θ1 formed between the center line L23 of filling confirmation opening 23 and the center line L22 of resin injection opening 22 is 90°. Therefore, in this embodiment, when resin filler 30 injected from resin injection opening 22 accumulates at bottom 20b of exterior member 20 and fills recess 212, which is the minimum inner diameter portion of exterior member 20, by 50% or more of the cross-sectional area as viewed from the extension direction (length direction X shown in FIG. 3), part of resin filler 30 flows into filling confirmation opening 23. Therefore, an operator can visually check the state of resin filler 30 filling exterior member 20 from the outside through filling confirmation opening 23.

[0035] There are no particular limitations on the number of filling confirmation ports 23 or the positions at which the filling confirmation ports 23 are provided. There are also no particular limitations on the shape of the filling confirmation ports 23, and the ports may be formed in, for example, a circular shape or a polygonal shape such as a rectangle.

[0036] <Wire harness manufacturing method> Next, a method for manufacturing the wire harness 1 will be described with reference to FIGS.

[0037] As shown in Fig. 4, the manufacturing method of the wire harness 1 includes an insertion step (step S1), a bending step (step S2), and a fixing step (step S3). The insertion step (step S1) here is a step of inserting the wiring material 10 into the interior of the exterior member 20. The bending step (step S2) is a step of bending the wiring material 10 and the exterior member 20 to match the shape of the wiring path of the wiring material 10. The fixing step (step S3) is a step of filling a resin filler 30 through a resin injection port 22 of the exterior member 20 and fixing the position of the wiring material 10 relative to the exterior member 20. Note that this wire harness manufacturing method will be described as being performed manually by an operator.

[0038] Specifically, first, in preparation for the insertion step (step S1), the worker prepares the wiring material 10 and the exterior member 20. At this time, the wiring material 10 and the exterior member 20 are not bent in a predetermined direction and extend linearly. Therefore, in the insertion step (step S1), the worker inserts the wiring material 10 into the storage space 20S of the exterior member 20, which is formed in a cylindrical shape and extends linearly, thereby storing the wiring material 10 inside the exterior member 20 (see FIG. 5).

[0039] Next, after the above-mentioned insertion process (step S1), the worker bends the exterior member 20 together with the wiring material 10 as a bending process (step S2). At this time, the exterior member 20 is hard enough to be bent by the worker's hand. Therefore, the worker manually bends the wiring material 10 and the exterior member 20 to match the shape of the predetermined wiring path of the wiring material 10. Note that if the predetermined wiring path of the wiring material 10 is linear, this bending process is omitted.

[0040] Next, after the bending step (step S2), the worker fills the interior of the exterior member 20 with the resin filler 30 as a fixing step (step S3). At this time, the interior of the exterior member 20 is filled with the resin filler 30 in a state where the exterior member 20 is adjusted to match the shape of the predetermined wiring path of the wiring material 10. Specifically, when the predetermined wiring path of the wiring material 10 is linear, the interior of the exterior member 20 is filled with the resin filler 30 in a state where the exterior member 20 and the wiring material 10 inserted inside the exterior member 20 each extend linearly to match the shape of the wiring path of the wiring material 10. Furthermore, when the predetermined wiring path of the wiring material 10 is curved, the interior of the exterior member 20 is filled with the resin filler 30 in a state where the exterior member 20 and the wiring material 10 inserted inside the exterior member 20 each extend curved to match the shape of the wiring path of the wiring material 10. Furthermore, the resin filler 30 is filled into the interior of the exterior member 20 through the resin injection port 22 by inserting the tip of the resin injection nozzle M into the resin injection port 22 of the exterior member 20 (see FIG. 6). Furthermore, the resin filler 30 filled into the interior of the exterior member 20 accumulates at the bottom 20b of the exterior member 20, and when it fills 50% or more of the cross-sectional area of ​​the recess 212, which is the smallest inner diameter portion of the exterior member 20, as viewed from the extension direction (the length direction X shown in FIG. 3), it flows into the filling confirmation port 23 and leaks out from the filling confirmation port 23 (see FIG. 7). Therefore, when the worker visually confirms through the filling confirmation port 23 that the resin filler 30 has filled more than half of the capacity of the exterior member 20, the worker ends the operation of filling the resin filler 30.

[0041] Then, the worker attaches a sealing member such as a rubber plug to the insertion opening 20T of the exterior member 20, thereby sealing the resin filler 30 inside the exterior member 20. This makes it possible to prevent the resin filler 30 from leaking out from the insertion opening 20T of the exterior member 20.

[0042] Then, the worker solidifies the resin filler 30 filled inside the exterior member 20, thereby fixing the position of the wiring material 10 relative to the exterior member 20. Then, the worker determines the shape of the wiring material 10 and the exterior member 20 using the resin filler 30 solidified inside the exterior member 20, and fixes the shape. Therefore, the exterior body 40 formed by filling the exterior member 20 with the resin filler 30 can properly maintain the predetermined wiring path of the wiring material 10 using the resin filler 30. For example, if the predetermined wiring path of the wiring material 10 is linear, the exterior body 40 is fixed linearly along the wiring path of the wiring material 10 (see exterior body 40A in FIG. 1). Furthermore, if the predetermined wiring path of the wiring material 10 is curved, the exterior body 40 is fixed in a curved shape along the wiring path of the wiring material 10 (see exterior body 40B in FIG. 1). Furthermore, since the resin filler 30 of the outer casing 40 is in contact with both the wiring material 10 and the outer casing member 20, the heat generated from the wiring material 10 can be conducted from the inside to the outside of the outer casing member 20 via the resin filler 30, and the heat can be dissipated to the outside.

[0043] The wire harness 1 described above includes a conductive wiring material 10, a cylindrical exterior member 20 through which the wiring material 10 is inserted, and a resin filler 30 filled inside the exterior member 20. The exterior member 20 has a resin injection port 22 that connects the interior to the exterior and can be filled with the resin filler 30. A wire harness manufacturing method for manufacturing the wire harness 1 described above includes an insertion step (step S1) of inserting the conductive wiring material 10 into the cylindrical exterior member 20 that extends linearly, a bending step (step S2) of bending the wiring material 10 and the exterior member 20 to match the shape of the wiring path of the wiring material 10, and a fixing step (step S3) of filling the resin filler 30 through the resin injection port 22 that connects the interior to the exterior of the exterior member 20 and fixing the position of the wiring material 10 relative to the exterior member 20.

[0044] According to this configuration, the wire harness 1 can fix the position of the wiring material 10 relative to the exterior member 20 by the resin filler 30 filled inside the exterior member 20, and can determine the shapes of the wiring material 10 and the exterior member 20. The wiring harness 1 can properly maintain the routing path of the wiring material 10 by fixing the wiring material 10 and the exterior member 20 in a predetermined shape (a shape that matches the routing path of the wiring material 10). Furthermore, according to this configuration, the wire harness 1 can absorb heat generated from the wiring material 10 by the resin filler 30 filled inside the exterior member 20 and conduct the heat to the exterior member 20. The wire harness 1 can conduct the heat generated from the wiring material 10 from the inside to the outside of the exterior member 20 via the resin filler 30, and thereby dissipate the heat to the outside of the exterior member 20. Therefore, the wire harness 1 can properly dissipate heat with a small number of parts, without the need to prepare new equipment for dissipating heat inside the exterior member 20 to the outside of the exterior member 20 or for cooling the wiring material 10 or the exterior member 20. Therefore, the wire harness 1 and the wire harness manufacturing method for manufacturing the wire harness 1 properly maintain the wiring path of the wiring material 10 and properly dissipate heat generated from the wiring material 10, thereby allowing the wiring material 10 to be properly routed.

[0045] Furthermore, the exterior member 20 of the wire harness 1 described above has lower rigidity than the wiring material 10, while the exterior body 40, which is obtained by filling the exterior member 20 with the resin filler 30, has higher rigidity than the wiring material 10. With this configuration, the exterior member 20 is more flexible than the wiring material 10 and can bend without applying a large load. Therefore, when the exterior member 20 is bent in any direction together with the wiring material 10 inserted therein, it can bend to match the shape of the wiring path. Furthermore, the exterior body 40 formed by filling the exterior member 20 with the resin filler 30 is less flexible than the wiring material 10 and prevents the exterior member 20 from bending in an unintended direction (a direction different from the wiring path of the wiring material 10) due to the repulsive force of the wiring material 10, thereby more appropriately maintaining the wiring path of the wiring material 10. Therefore, the wire harness 1 allows the wiring material 10 to be routed more appropriately.

[0046] Furthermore, the exterior body 40 (exterior body 40B shown in FIG. 1 ) in which the resin filler 30 is filled in the exterior member 20 of the wire harness 1 described above has a shape curved along the wiring path of the wiring material 10. According to this configuration, the exterior body 40 is fixed in a predetermined shape (a shape curved according to the wiring path of the wiring material 10) by filling the interior of the exterior member 20 with the resin filler 30, and thus the wiring path of the wiring material 10 can be properly maintained. Therefore, the wire harness 1 allows the wiring material 10 to be properly routed.

[0047] Furthermore, the resin filler 30 of the wire harness 1 described above is a thermosetting resin whose hardening temperature is lower than the melting point of the insulating coating portion 10b of the wiring material 10, or a thermoplastic resin whose softening temperature is lower than the melting point of the insulating coating portion 10b of the wiring material 10. With this configuration, the resin filler 30 can prevent the insulating coating portion 10b of the wiring material 10 from melting due to the heat generated when the thermosetting resin or thermoplastic resin solidifies. Furthermore, the resin filler 30 can suppress a decrease in the electrical conductivity of the wiring material 10, which would otherwise be caused by a decrease in the durability of the insulating coating portion 10b of the wiring material 10. Therefore, the wire harness 1 allows the wiring material 10 to be routed more appropriately.

[0048] Furthermore, the exterior member 20 of the wire harness 1 described above is formed in a bellows shape and has convex portions 211 protruding toward the outer circumferential surface side and concave portions 212 protruding toward the inner circumferential surface side. The resin filler 30 fills the concave portions 212 to 50% or more of the cross-sectional area as viewed from the extending direction of the exterior member 20. With this configuration, the resin filler 30 fills more than half of the capacity of the exterior member 20, thereby fixing a half-periphery of the wiring material 10 to a half-periphery of the exterior member 20. Therefore, in the wire harness 1, the wiring material 10 and the exterior member 20 are fixed in a predetermined shape (a shape corresponding to the wiring path of the wiring material 10), thereby more appropriately maintaining the wiring path of the wiring material 10. Furthermore, with this configuration, the exterior member 20 is formed in a bellows shape, which increases the area in contact with an external fluid, and the convex portions 211 and the concave portions 212 can be used as heat dissipation fins. Therefore, the wire harness 1 can efficiently dissipate heat generated from the wiring material 10 to the outside of the exterior member 20, and can further prevent heat from being trapped inside the exterior member 20, thereby preventing the current-carrying performance of the wiring material 10 from being reduced due to heat. Therefore, the wire harness 1 can more properly maintain the wiring path of the wiring material 10 and more properly dissipate heat generated from the wiring material 10, thereby allowing the wiring material 10 to be properly routed.

[0049] Furthermore, the exterior member 20 of the wire harness 1 described above further has a filling confirmation opening 23 through which the filling state of the resin filler 30 can be visually confirmed, and the opening direction of the filling confirmation opening 23 intersects with the opening direction of the resin injection opening 22. With this configuration, when the exterior member 20 is filled with the resin filler 30, the resin filler 30 flows into the filling confirmation opening 23. Therefore, the wire harness 1 can ensure that the appropriate amount of resin filler 30 is filled relative to the capacity of the exterior member 20. Therefore, the wire harness 1 can more appropriately fix the wiring material 10 to the exterior member 20, and more appropriately route the wiring material 10.

[0050] Furthermore, the exterior member 20 of the wire harness 1 described above is made of metal, and the resin filler 30 is a resin having a thermal conductivity higher than that of air. With this configuration, the resin filler 30 can absorb heat generated from the wiring material 10 more quickly and conduct the heat to the exterior member 20 more quickly. Therefore, the wire harness 1 can dissipate heat generated from the wiring material 10 to the outside of the exterior member 20 more quickly, and can further prevent heat from being trapped inside the exterior member 20. Therefore, the wire harness 1 can prevent the current-carrying performance of the wiring material 10 from being reduced due to heat, and the wiring material 10 can be routed more appropriately.

[0051] The wire harness 1 according to the embodiment of the present invention and the wire harness manufacturing method (steps S1 to S3) described above are not limited to the above embodiment, and various modifications are possible within the scope of the claims.

[0052] For example, the material that constitutes the exterior member 20 may be made of an insulating resin material.

[0053] Furthermore, the positional relationship between the resin injection port 22 and the filling check port 23 provided in the exterior member 20 is not limited to the form shown in FIG.

[0054] There are no particular limitations on the hardening temperature of the thermosetting resin or the softening temperature of the thermoplastic resin used as the resin filler 30. There are no particular limitations on the type of resin used as the resin filler 30.

[0055] Furthermore, the amount and position of the resin filler 30 are not particularly limited.

[0056] Furthermore, the wire harness 1 according to the present embodiment and the wire harness manufacturing method (steps S1 to S3) may be configured by appropriately combining the components of the embodiments described above. [Explanation of symbols]

[0057] 1 Wire harness 10 Routing material 10a Conductor 10b Insulation coating 20 Exterior materials 21 Uneven part 211 Convex 212 recess 22 Resin injection port 23 Filling confirmation port 30 Resin filler 40 Exterior body S1 Insertion process S2 bending process S3 Fixed process X length direction Y width direction Z height direction

Claims

1. A conductive wiring material; an exterior member formed in a cylindrical shape and through which the wiring material is inserted; a resin filler filled inside the exterior member, The exterior member is characterized in that it has a resin injection port that communicates the inside with the outside and can fill the resin filler. Wire harness.

2. The exterior member has a lower rigidity than the wiring material, The exterior body in which the resin filler is filled into the exterior member has a higher rigidity than the wiring material. The wire harness according to claim 1 .

3. The exterior body in which the resin filler is filled into the exterior member has a curved shape along the wiring path of the wiring material. The wire harness according to claim 1 or 2.

4. The resin filler is a thermosetting resin having a hardening temperature lower than the melting point of the insulating coating of the wiring material, or a thermoplastic resin having a softening temperature lower than the melting point of the insulating coating of the wiring material. The wire harness according to claim 1 or 2.

5. the exterior member is formed in a bellows shape and has a convex portion protruding toward an outer circumferential surface side and a concave portion protruding toward an inner circumferential surface side, The resin filler fills 50% or more of a cross-sectional area of ​​the recess when viewed from the extending direction of the exterior member. The wire harness according to claim 1 or 2.

6. the exterior member further has a filling check port through which a filling state of the resin filler can be visually confirmed, an opening direction of the filling confirmation port, which communicates the inside and the outside of the exterior member, intersects with an opening direction of the resin injection port; The wire harness according to claim 1 or 2.

7. the exterior member is made of metal, The resin filler is a resin having a thermal conductivity higher than that of air. The wire harness according to claim 1 or 2.

8. an insertion step of inserting a conductive wiring material into an interior of an exterior member formed in a tubular shape and extending linearly; A bending process of bending the wiring material and the exterior member according to the shape of the wiring path of the wiring material; and a fixing step of filling a resin filler material from a resin injection port that communicates with the inside and outside of the exterior member and fixing the position of the wiring material relative to the exterior member. Wire harness manufacturing method.

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