Wire harness and wire harness manufacturing method

Abstract

To provide a wire harness which can appropriately route a wiring material and a wire harness manufacturing method.SOLUTION: A wire harness 1 includes: a wiring material 10 having conductivity; assemblies 20 constituted of a plurality of regulation members 21 which are linearly formed and are assembled in a state in which they are brought into contact with each other along an outer face 10m of the wiring material 10; and exterior members 30 which are cylindrically formed, and through which the wiring material 10 and the assemblies 20 are inserted. Rigidity of the regulation member 21 is lower than that of the wiring material 10, and rigidity of the assembly 20 is higher than that of the wiring material 10.SELECTED DRAWING: Figure 2

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 an electric wire, a path regulating member, a fixing member for fixing the electric wire to the path regulating member, and an exterior member through which the electric wire and the path regulating member are inserted. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6881263 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the wire harness described in the above-mentioned Patent Document 1 requires a processing machine such as a bender to bend the path-controlling member, which may take a long time to change the wiring path of the wire harness. Also, if a corrugated tube made of resin, for example, is used as the exterior member, it may be difficult to dissipate heat generated from the wires (wiring material) to the outside. Therefore, there is room for further improvement in terms of properly wiring 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 an assembly composed of a conductive wiring material, a plurality of linearly formed regulating members assembled in contact along the outer surface of the wiring material, and a cylindrically formed outer member into which the wiring material and the assembly are inserted, and is characterized in that the regulating members have lower rigidity than the wiring material, and the assembly has higher rigidity than the wiring material.

[0007] In order to achieve the above object, the wire harness manufacturing method of the present invention is characterized by comprising a bending process in which a linearly formed regulating member having a lower rigidity than a conductive wiring material is bent to match the shape of the wiring path of the wiring material, an assembly process in which an assembly formed by a plurality of the regulating members and having a higher rigidity than the wiring material is brought into contact with the outer surface of the wiring material and assembled, and an insertion process in which the wiring material and the assembly are inserted into the inside of an outer member formed in a tubular shape. [Effects of the Invention]

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

[0009] [Figure 1] FIG. 1 is a diagram illustrating a schematic configuration of a wire harness according to a first embodiment. [Figure 2] FIG. 2 is a cross-sectional view illustrating a schematic configuration of the wire harness according to the first embodiment. [Figure 3] FIG. 3 is a flowchart showing the wire harness manufacturing method according to the first embodiment. [Figure 4] FIG. 4 is a diagram illustrating a schematic configuration of a wire harness according to the second embodiment. [Figure 5] FIG. 5 is a cross-sectional view illustrating a schematic configuration of a wire harness according to the second embodiment. [Figure 6] FIG. 6 is a flowchart showing a wire harness manufacturing method according to the second 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] [First 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 an assembly 20 formed of a plurality of restricting members 21 attached to a wiring material 10. The wire harness 1 of this embodiment has a configuration in which the assembly 20 is inserted together with the wiring material 10 into the interior of a cylindrical exterior member 30, thereby enabling the wiring material 10 to be properly routed. The configuration of the wire harness 1 will be described in detail below with reference to Figs. 1 and 2.

[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 and 5 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 comprises a conductive wiring material 10, an assembly 20 attached to the outside of the wiring material 10, and an exterior member 30 into which the wiring material 10 and the assembly 20 are inserted.

[0016] <Routing material> The wiring material 10 is wired in a vehicle and electrically connects various devices. The wiring material 10 of this embodiment is an insulated electric wire that includes a conductive conductor portion (core wire) and an insulating insulating sheath portion, and the conductor portion is sheathed by the insulating sheath portion. The conductor portion here is a twisted wire formed by twisting together multiple conductive wires. The insulating sheath portion is formed, for example, by extrusion molding an insulating resin material (PP, PVC, cross-linked PE, etc., appropriately selected taking into consideration abrasion resistance, chemical resistance, heat resistance, etc.). The conductor portion 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) is approximately circular, and the cross-sectional shape of the insulating coating portion is approximately annular, resulting in an overall cross-sectional shape that is approximately circular.

[0018] <Assembly> The assembly 20 is composed of a plurality of regulating members 21, and is assembled to the wiring material 10 to regulate the extension direction of the wiring material 10. The assembly 20 of this embodiment is composed of two regulating members 21, as shown in Figures 1 and 2.

[0019] The restricting member 21 is a linear, cylindrical round pipe member, and therefore has a substantially annular cross-sectional shape (cross-sectional shape in a direction intersecting the extending direction of the restricting member 21) in this embodiment.

[0020] Furthermore, the restricting member 21, when used alone, 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 restricting member 21 of this embodiment, when used alone, 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. Furthermore, when the wiring path of the wiring material 10 is changed, the restricting member 21 can be bent again to match the shape of the new wiring path, thereby easily changing the shape. The rigidity of the restricting member 21 is determined using an index such as a spring constant (the strength of the repulsive force generated when the restricting member 21 is bent). Furthermore, it is preferable that the restricting member 21 be hard enough to be bent by hand by an operator. More specifically, the restricting member 21 is preferably a member such that the force applied by an operator when bending the restricting member 21 in any direction intersecting the extension direction (for example, the length direction X shown in FIG. 2) is greater than 0 N·m and less than 1 N·m, and the yield stress of the material constituting the restricting member 21 is less than the maximum bending stress generated in the restricting member 21. Furthermore, the restricting member 21 preferably has a longitudinal modulus of elasticity greater than 65 GPa and less than 210 GPa, or a transverse modulus of elasticity greater than 20 GPa and less than 80 GPa, and is smaller in diameter than the wiring material 10, preferably having a diameter of 10 mm or less.

[0021] Furthermore, the regulating member 21 is configured by combining a plurality of regulating members 21, here two regulating members 21, to form the assembly 20. In this embodiment, as shown in Fig. 2, the two regulating members 21 are each formed in a shape that follows the wiring path of the wiring material 10, and are arranged outside the wiring material 10 to sandwich the wiring material 10. In other words, the assembly 20 of this embodiment is configured by combining two regulating members 21 that are arranged so as to sandwich the wiring material 10.

[0022] Moreover, the regulating member 21 is formed of a metal material such as aluminum or copper. Therefore, the regulating member 21 of this embodiment can disperse heat by absorbing heat generated from the wiring material 10 and dissipating it to the outside. Furthermore, as shown in FIG. 2, the regulating member 21 is arranged in close contact with the outer surface 10m of the wiring material 10, so that the heat generated from the wiring material 10 can be efficiently absorbed.

[0023] 2, the regulating member 21 has a coolant C flowing into it that can cool the wiring material 10. The regulating member 21 of this embodiment can be circulated using an external pump or the like, and cooled using a radiator or the like, so that a relatively cold liquid can flow inside the regulating member 21 as the coolant C. Therefore, the regulating member 21 of this embodiment can efficiently absorb the heat generated from the wiring material 10 by exchanging heat with the wiring material 10 via the coolant C.

[0024] Furthermore, the assembly 20 formed by combining the above-described restricting members 21 has higher rigidity than the wiring material 10 and exhibits less deformation in response to external forces such as bending and twisting than the wiring material 10. Therefore, the assembly 20 of this embodiment is less likely to bend than the wiring material 10 alone and can prevent the wiring material 10 from bending in an unintended direction (a direction different from the direction along the wiring path of the wiring material 10) due to the repulsive force of the wiring material 10 inserted inside the exterior member 30. Furthermore, as shown in FIG. 2 , the assembly 20 can correct the position and direction of the wiring material 10 by sandwiching the wiring material 10 from both sides in the height direction Z using two restricting members 21 and aligning the central axis L10 of the wiring material 10 (hereinafter, the central axis will be simply referred to as the axis) with the axis L21 of the restricting members 21. Therefore, the assembly 20 can more reliably restrict the extension direction of the wiring material 10 and fix the wiring material 10 in a predetermined shape.

[0025] <Exterior materials> The exterior member 30 is inserted inside the wiring material 10 and the assembly 20 to protect both components. The exterior member 30 of this embodiment is a cylindrical corrugated tube. As shown in FIGS. 1 and 2, the corrugated tube has annular concave-convex portions 31 formed along the circumferential direction on its outer surface, and a plurality of the concave-convex portions 31 are provided along the extension direction of the exterior member 30, forming an accordion-like shape. Therefore, the exterior member 30 is configured to include, as the concave-convex portions 31, convex portions protruding toward the outer peripheral surface side and concave portions protruding toward the inner peripheral surface side. Furthermore, the exterior member 30 is flexible, and when force is applied, the convex portions and concave portions deform, allowing the exterior member 30 to bend (flex) in any direction intersecting the extension direction of the exterior member 30 (for example, the length direction X shown in FIG. 2).

[0026] Furthermore, the exterior member 30 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 30 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 30 is determined using an index such as a spring constant (the strength of the repulsive force generated when the exterior member 30 is bent). Furthermore, it is preferable that the exterior member 30 is hard enough to be bent by hand by an operator.

[0027] Furthermore, the exterior member 30 is formed of a metal material such as aluminum or copper. Therefore, the exterior member 30 of this embodiment can disperse heat by absorbing heat generated from the wiring material 10 inserted therein and dissipating the heat to the outside. Furthermore, since the exterior member 30 is formed in a bellows shape as described above, heat can be efficiently dissipated by utilizing the uneven portion 31. Note that the size of the convex and concave portions of the uneven portion 31 is not particularly limited, but it is preferable that the uneven portion 31 has a large area that comes into contact with a fluid outside the exterior member 30 (for example, wind flowing outside the exterior member 30, air present outside the exterior member 30, etc.).

[0028] The exterior member 30 includes a storage space 30S as an internal space and a pair of insertion openings 30T that open along the extension direction of the exterior member 30. The storage space 30S here is a portion defined and formed by the wall of the exterior member 30, as shown in FIGS. 1 and 2. The insertion openings 30T are portions defined and formed by the ends (edge ​​portions of the exterior member 30) of the exterior member 30, as shown in FIG. 1. The exterior member 30 can accommodate the wiring material 10 inside by inserting the wiring material 10 into the storage space 30S through the pair of insertion openings 30T. As shown in FIG. 2, the center line L30 connecting the centers of the insertion openings 30T is positioned along the axis L10 of the wiring material 10 accommodated in the storage space 30S, so that the exterior member 30 can extend along the extension direction of the wiring material 10 (the length direction X shown in FIG. 2).

[0029] In the present embodiment, a corrugated tube has been described as an example of the exterior member 30, but there is no particular limitation on the type of the exterior member 30. The exterior member 30 may be formed, for example, by a straight tube member on which the uneven portion 31 is not formed.

[0030] <Wire harness manufacturing method> Next, a method for manufacturing the wire harness 1 will be described with reference to FIG.

[0031] As shown in Fig. 3, the manufacturing method of the wire harness 1 includes a bending step (step S1), an assembling step (step S2), and an insertion step (step S3). The bending step (step S1) here is a step of bending the restricting members 21 to match the shape of the wiring path of the wiring material 10. The assembling step (step S2) is a step of assembling an assembly 20 formed by a plurality of restricting members 21 to the wiring material 10. The insertion step (step S3) is a step of inserting the wiring material 10 and the assembly 20 into the exterior member 30. This wire harness manufacturing method will be described assuming that it is performed manually by an operator.

[0032] Specifically, first, in preparation for the bending step (step S1), the worker prepares a plurality of regulating members 21 (two regulating members 21 in this embodiment). At this time, each regulating member 21 is not bent in a predetermined direction and extends linearly.

[0033] Next, in the bending process (step S1), the worker bends each of the regulating members 21 into a predetermined shape. At this time, the regulating members 21 are hard enough to be bent by the worker's hands. Therefore, the worker manually bends each of the regulating members 21 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.

[0034] Next, after the above-mentioned bending process (step S1), the worker constructs the assembly 20 by sandwiching the wiring material 10 between two regulating members 21 as an assembly process (step S2). At this time, the assembly 20 is arranged around the wiring material 10 in a state where each regulating member 21 is bent along the extension direction of the wiring material 10 and into a shape that matches the wiring path of the wiring material 10, that is, in a state where it is arranged according to a preset shape. Specifically, when the preset wiring path of the wiring material 10 is linear, the regulating member 21 extends linearly according to the shape of the wiring path of the wiring material 10, and is arranged outside the wiring material 10 in a state where the outer surface 21m of the regulating member 21 is in contact with the outer surface 10m of the wiring material 10. Furthermore, when the pre-set wiring path of the wiring material 10 is curved, the regulating member 21 extends while bending in accordance with the shape of the wiring path of the wiring material 10, and is positioned outside the wiring material 10 with the outer surface 21m of the regulating member 21 in contact with the outer surface 10m of the wiring material 10.

[0035] Then, the worker sandwiches the wiring material 10 between the two regulating members 21 and places the wiring material 10 inside the assembly 20, thereby determining the shape of the wiring material 10 and fixing the shape of the wiring material 10. For example, if the preset wiring path of the wiring material 10 is straight, the wiring material 10 is fixed in a straight shape in accordance with the shape of the wiring path. Also, if the preset wiring path of the wiring material 10 is curved, the wiring material 10 is fixed in a curved shape in accordance with the shape of the wiring path. Therefore, the extension direction of the wiring material 10 is properly regulated by the regulating members 21 that constitute the assembly 20. The assembly 20 is fixed to the wiring material 10 by being bound with a binding member such as tape, for example.

[0036] Next, after the above-described assembling process (step S2), the worker performs an insertion process (step S3) in which the wiring material 10 and the assembly 20 are inserted into the storage space 30S of the outer casing member 30, which is formed in a cylindrical shape and extends linearly, thereby storing both components inside the outer casing member 30 (see FIG. 2). At this time, the outer casing member 30 is configured to have lower rigidity than the wiring material 10. Therefore, the outer casing member 30 deforms to fit the shapes of the wiring material 10 and the assembly 20 inserted therein. Specifically, when the predetermined wiring path of the wiring material 10 is linear, the outer casing member 30 extends linearly to fit the shape of the wiring path of the wiring material 10 (see outer casing member 30A shown in FIG. 1). Furthermore, when the predetermined wiring path of the wiring material 10 is curved, the outer casing member 30 deforms to fit the shape of the wiring path of the wiring material 10 (see outer casing member 30B shown in FIG. 1). Therefore, the wire harness 1 can properly maintain the preset wiring path of the wiring material 10 by the restricting member 21 constituting the assembly 20. Furthermore, since the restricting member 21 is assembled in contact with the outer surface 10m of the wiring material 10 along the outer surface 10m of the wiring harness 1, the heat generated from the wiring material 10 can be conducted from the inside to the outside of the exterior member 30 via the assembly 20, and the heat can be dissipated to the outside. Furthermore, since the coolant C flows into the restricting member 21, the wire harness 1 can efficiently absorb the heat generated from the wiring material 10 and cool the wiring material 10.

[0037] The wire harness 1 described above comprises a conductive wiring material 10, an assembly 20 composed of a plurality of regulating members 21 formed in a linear shape and assembled in contact along the outer surface 10m of the wiring material 10, and an outer member 30 formed in a tubular shape and into which the wiring material 10 and the assembly 20 are inserted, and the regulating members 21 have lower rigidity than the wiring material 10, and the assembly 20 has higher rigidity than the wiring material 10. In addition, the wire harness manufacturing method for manufacturing the wire harness 1 described above includes a bending process (step S1) in which a linearly formed regulating member 21 having a lower rigidity than the conductive wiring material 10 is bent to match the shape of the wiring path of the wiring material 10, an assembly process (step S2) in which an assembly 20 composed of a plurality of regulating members 21 and having a higher rigidity than the wiring material 10 is brought into contact with the wiring material 10 along the outer surface 10m, and assembled, and an insertion process (step S3) in which the wiring material 10 and the assembly 20 are inserted into the inside of an outer member 30 formed in a tubular shape.

[0038] According to this configuration, the wiring harness 1 can determine and fix the shape of the wiring material 10 by restricting the extension direction of the wiring material 10 using the assembly 20 assembled to the outside of the wiring material 10. Then, the wiring harness 1 can properly maintain the wiring path of the wiring material 10 by fixing the wiring material 10 in a predetermined shape (a shape that matches the wiring path of the wiring material 10). Furthermore, according to this configuration, the wiring harness 1 can absorb heat generated from the wiring material 10 using the assembly 20 assembled to the outside of the wiring material 10 and conduct the heat to the exterior member 30. Then, the wire harness 1 can conduct the heat generated from the wiring material 10 from the inside to the outside of the exterior member 30 via the assembly 20, thereby dissipating the heat to the outside of the exterior member 30. Therefore, the wire harness 1 does not require additional equipment for dissipating heat from the interior of the exterior member 30 to the exterior of the exterior member 30 or for cooling the wiring material 10 and the exterior member 30, and can appropriately dissipate heat with a small number of parts. Furthermore, with this configuration, the restricting member 21 is easier to bend alone than the wiring material 10 and can bend without applying a large load. Therefore, the wire harness 1 allows the restricting member 21 to be bent in a simple manner, improving workability. Furthermore, the wire harness 1 can appropriately restrict the extension direction of the wiring material 10 by assembling an assembly 20 formed of multiple restricting members 21 bent into a predetermined shape (a shape corresponding to the wiring path of the wiring material 10) to the outside of the wiring material 10. Furthermore, with this configuration, if the predetermined wiring path of the wiring material 10 is changed, the shape of the restricting member 21, which is easier to bend than the wiring material 10, can be changed by adjusting the shape of the restricting member 21. Therefore, the wiring harness 1 allows the wiring route of the wiring material 10 to be easily changed, improving workability. Therefore, the wire harness 1 and the wire harness manufacturing method for manufacturing the wire harness 1 properly maintain the wiring route 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.

[0039] Here, the restricting member 21 of the wire harness 1 described above is a member that, when bent in any direction intersecting the extension direction, requires a force greater than 0 N·m and equal to or less than 1 N·m, and the yield stress of the material constituting the restricting member 21 is smaller than the maximum bending stress generated in the restricting member 21. With this configuration, the restricting member 21 can be bent manually. Furthermore, when the predetermined routing path of the wiring material 10 is changed, the shape of the restricting member 21 can be changed more easily by manually adjusting the shape of the restricting member 21. Therefore, the wire harness 1 can further improve the workability when processing the restricting member 21. Therefore, the wire harness 1 allows the wiring material 10 to be routed more appropriately.

[0040] Furthermore, the restricting member 21 of the wire harness 1 described above has a modulus of longitudinal elasticity that is higher than 65 Gpa and lower than 210 Gpa, or a modulus of transverse elasticity that is higher than 20 Gpa and lower than 80 Gpa. With this configuration, the restricting member 21 can be bent manually. Furthermore, when the predetermined routing path of the wiring material 10 is changed, the shape of the restricting member 21 can be changed more easily by manually adjusting the shape of the restricting member 21. Therefore, the wire harness 1 can further improve the workability when processing the restricting member 21. Therefore, the wire harness 1 allows the wiring material 10 to be routed more appropriately.

[0041] Furthermore, the regulating members 21 of the wire harness 1 described above are formed into a shape that follows the wiring path of the wiring material 10 and are arranged outside the wiring material 10 to sandwich the wiring material 10. In addition, in the bending step (step S1) of the wire harness manufacturing method for manufacturing the wire harness 1 described above, the linear regulating members 21 are bent along the extension direction of the wiring material 10 and into a shape that matches the wiring path of the wiring material 10, and in the assembling step (step S2), the wiring material 10 is sandwiched between the plurality of regulating members 21 bent into a shape that matches the wiring path to form an assembly 20, and the assembly 20 is arranged outside the wiring material 10. With this configuration, the assembly 20 can correct the position and direction of the axis L10 of the wiring material 10 by surrounding the wiring material 10 with the plurality of regulating members 21 bent into a predetermined shape (a shape that matches the wiring path of the wiring material 10). Furthermore, the assembly 20 allows the wiring material 10 to be routed along the extension direction of the regulating members 21. Therefore, the wire harness 1 can more appropriately maintain the routing path of the wiring material 10 by more appropriately determining the shape of the wiring material 10 and more appropriately fixing it by using the assembly 20 to regulate the extension direction of the wiring material 10. Furthermore, with this configuration, the assembly 20 can efficiently absorb heat generated from the wiring material 10 by sandwiching the wiring material 10 between the multiple regulating members 21 and efficiently conduct the heat to the exterior member 30. The assembly 20 can efficiently conduct the heat generated from the wiring material 10 from the inside to the outside of the exterior member 30, thereby efficiently dissipating the heat to the outside of the exterior member 30. Therefore, the wire harness 1 can more appropriately maintain the routing path of the wiring material 10 and more appropriately dissipate the heat generated from the wiring material 10, thereby more appropriately routing the wiring material 10.

[0042] Furthermore, the assembly 20 of the wire harness 1 described above has a shape bent along the wiring path of the wiring material 10. According to this configuration, the assembly 20 is assembled to the wiring material 10 in a predetermined shape (a shape bent according to the wiring path of the wiring material 10), thereby making it possible to properly maintain the wiring path of the wiring material 10. Therefore, the wire harness 1 allows the wiring material 10 to be properly routed.

[0043] Furthermore, the restricting member 21 of the wire harness 1 described above is formed in a cylindrical shape. With such a configuration, the restricting member 21 can absorb heat generated from the wiring material 10 and conduct the heat to the exterior member 30. The assembly 20 can conduct the heat generated from the wiring material 10 from the inside to the outside of the exterior member 30, thereby dissipating the heat to the outside of the exterior member 30. Therefore, the wire harness 1 allows the wiring material 10 to be properly routed.

[0044] Furthermore, the restricting member 21 of the wire harness 1 described above has a coolant C flowing into it, which can cool the wiring material 10. With this configuration, the restricting member 21 can exchange heat with the wiring material 10 via the coolant C. Furthermore, the restricting member 21 can efficiently absorb heat generated from the wiring material 10 by making linear contact with the wiring material 10 along the extension direction of the wiring material 10, and can efficiently radiate the heat to the outside of the exterior member 30. Therefore, the wire harness 1 allows the wiring material 10 to be properly routed.

[0045] [Second embodiment] Next, a wire harness 100 according to a second embodiment shown in Fig. 4 and Fig. 5 will be described. The wire harness 100 differs from the wire harness 1 according to the first embodiment in the shape of the restricting member 21 that constitutes the assembly 20. In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0046] Specifically, the wire harness 100 differs from the wire harness 1 in that the wire harness 100 includes an assembly 120 instead of the assembly 20. The assembly 120 also differs from the assembly 20 in that the assembly 120 is configured by a regulating member 121 instead of the regulating member 21. The regulating member 121 also differs from the regulating member 21 in terms of its shape. Other configurations of the wire harness 100, the assembly 120, and the regulating member 121 are substantially the same as those of the wire harness 1, the assembly 20, and the regulating member 21.

[0047] <Regulating member> As shown in FIGS. 4 and 5, two regulating members 121 are combined to form an assembly 120. As shown in FIG. 5, each regulating member 121 is formed in a spiral shape centered on an axis L121, and is wound around the outside of the wiring material 10. In other words, the assembly 120 of this embodiment is formed by combining two regulating members 121 arranged to sandwich the wiring material 10. In this case, the assembly 120 can correct the position and direction of the wiring material 10 by aligning the axis L10 of the wiring material 10 with the axis L121 of the regulating members 121 using the two regulating members 121 arranged to spiral around the wiring material 10. Therefore, like the assembly 20 described above, the assembly 120 can more reliably regulate the extension direction of the wiring material 10 and fix the wiring material 10 in a predetermined shape.

[0048] <Wire harness manufacturing method> Next, a method for manufacturing the wire harness 100 will be described with reference to FIG.

[0049] As shown in Fig. 6, the manufacturing method of the wire harness 100 includes a bending step (step S11), an assembling step (step S12), and an insertion step (step S13). The bending step (step S11) here is a step of bending the regulating members 121 to match the shape of the wiring path of the wiring material 10. The assembling step (step S12) is a step of assembling an assembly 120 formed by a plurality of regulating members 121 to the wiring material 10. The insertion step (step S13) is a step of inserting the wiring material 10 and the assembly 120 into the exterior member 30. This wire harness manufacturing method will be described assuming that it is performed manually by an operator.

[0050] Specifically, first, in preparation for the bending step (step S11), the worker prepares a plurality of regulating members 121 (two regulating members 121 in this embodiment). At this time, each regulating member 121 is not bent in a predetermined direction and extends linearly.

[0051] Next, as a bending process (step S11), the worker performs a first processing process (step S11a) of bending the regulating member 121 into a spiral shape and a second processing process (step S11b) of bending the axis L121 of the spiral shape into a shape that matches the wiring path of the wiring material 10. At this time, the regulating member 121 is hard enough to be bent by the worker's hand. Therefore, as the first processing process (step S11a), the worker manually bends each regulating member 121 into a spiral shape that matches the shape of the wiring material 10 (the diameter of the wiring material 10). Then, after the first processing process (step S11a), as a second processing process (step S11b), the worker bends the axis L121 of each regulating member 121 to match the shape of a preset wiring path. In addition, when the preset wiring path of the wiring material 10 is linear, the process of bending the spiral-shaped restricting member 121 to match the shape of the preset wiring path is omitted.

[0052] Next, after the above-mentioned bending process (step S11), the worker constructs the assembly 120 by inserting the wiring material 10 into the inside of two regulating members 121 formed in a spiral shape and bent into a shape that matches the wiring path of the wiring material 10 as an assembly process (step S12). At this time, the assembly 120 is placed on the outside of the wiring material 10 in a state where each regulating member 121 is bent along the extension direction of the wiring material 10 and into a shape that matches the wiring path of the wiring material 10, that is, in a state where it is arranged according to a preset shape. Specifically, when the preset wiring path of the wiring material 10 is linear, each regulating member 121 is arranged outside the wiring material 10 in a state where the axis L121 of the spiral shape extends linearly according to the shape of the wiring path of the wiring material 10, and the outer surface 121m of the regulating member 121 is in contact with the outer surface 10m of the wiring material 10. Furthermore, when the preset routing path of the wiring material 10 is curved, each regulating member 121 extends while bending in accordance with the shape of the routing path of the wiring material 10, and is arranged on the outside of the wiring material 10 with the outer surface 121m of the regulating member 121 in contact with the outer surface 10m of the wiring material 10. Therefore, the wiring material 10 is inserted into the inside (axis line L121 side) of the spiral-shaped regulating member 121, and the regulating member 121 is wound around the outer surface 10m side.

[0053] Then, the worker wraps the two regulating members 121 around the outside of the wiring material 10 and places the wiring material 10 inside the assembly 120, thereby determining the shape of the wiring material 10 and fixing the shape. For example, if the predetermined wiring path of the wiring material 10 is straight, the wiring material 10 is fixed in a straight shape in accordance with the shape of the wiring path. Also, if the predetermined wiring path of the wiring material 10 is curved, the wiring material 10 is fixed in a curved shape in accordance with the shape of the wiring path. Therefore, the extension direction of the wiring material 10 is properly regulated by the regulating members 121 that constitute the assembly 120. The assembly 120 is fixed to the wiring material 10 by being bound with a binding member such as tape, for example.

[0054] Next, after the above-described assembling process (step S12), the worker performs an insertion process (step S13) in which the wiring material 10 and the assembly 120 are inserted into the storage space 30S of the outer casing member 30, which is formed in a cylindrical shape and extends linearly, thereby accommodating both components inside the outer casing member 30 (see FIG. 5). At this time, the outer casing member 30 is configured to have lower rigidity than the wiring material 10. Therefore, the outer casing member 30 deforms to fit the shapes of the wiring material 10 and the assembly 120 inserted therein. Specifically, when the preset routing path of the wiring material 10 is linear, the outer casing member 30 extends linearly to fit the shape of the routing path of the wiring material 10 (see outer casing member 30A shown in FIG. 4). Furthermore, when the preset routing path of the wiring material 10 is curved, the outer casing member 30 deforms to a curved shape to fit the shape of the routing path of the wiring material 10 (see outer casing member 30B shown in FIG. 4). Therefore, the wire harness 100 can properly maintain the preset wiring path of the wiring material 10 by the regulating member 121 constituting the assembly 120. Furthermore, since the wire harness 100 is assembled with the regulating member 121 in contact along the outer surface 10m of the wiring material 10, heat generated from the wiring material 10 can be conducted from the inside to the outside of the exterior member 30 via the assembly 120, and the heat can be dissipated to the outside. Furthermore, since the coolant C flows into the inside of the regulating member 121, the wire harness 100 can efficiently absorb heat generated from the wiring material 10 and cool the wiring material 10.

[0055] The restricting member 121 of the wire harness 100 described above is formed in a spiral shape centered on an axis L121 extending along the wiring path of the wiring material , and is wound around the outside of the wiring material . Furthermore, the bending process (step S11) of the wire harness manufacturing method for manufacturing the wire harness 1 described above includes a first processing process (step S11a) of bending the regulating member 121 into a spiral shape, and a second processing process (step S11b) of bending the regulating member 121 bent into the spiral shape so that the axis L121 of the regulating member 121 is aligned with the extension direction of the wiring material 10 and into a shape that matches the wiring path of the wiring material 10. In the assembly process (step S12), the wiring material 10 is inserted inside the multiple regulating members 121 that are bent into a spiral shape and into a shape that matches the wiring path to form an assembly 120, and the assembly 120 is placed outside the wiring material 10. According to this configuration, the assembly 120 can correct the position and direction of the axis L10 of the wiring material 10 by covering the outside of the wiring material 10 with multiple regulating members 121 bent into a spiral shape and a predetermined shape (a shape that matches the wiring path of the wiring material 10). Furthermore, the assembly 120 can route the wiring material 10 along the extension direction of the regulating members 121. Therefore, by regulating the extension direction of the wiring material 10 with the assembly 120, the shape of the wiring material 10 can be more appropriately determined and fixed more appropriately, thereby more appropriately maintaining the wiring path of the wiring material 10. Furthermore, according to this configuration, the assembly 120 can efficiently absorb heat generated from the wiring material 10 and efficiently conduct the heat to the exterior member 30 by inserting the wiring material 10 inside the multiple regulating members 121 bent into a spiral shape. The assembly 120 can efficiently conduct the heat generated from the wiring material 10 from the inside to the outside of the exterior member 30, thereby efficiently dissipating the heat to the outside of the exterior member 30. Therefore, similar to the wire harness 1 described above, the wire harness 100 can more appropriately maintain the wiring path of the wiring material 10 and more appropriately dissipate the heat generated from the wiring material 10, thereby allowing the wiring material 10 to be more appropriately routed.

[0056] The wire harnesses 1, 100 and the wire harness manufacturing method (steps S1 to S3, steps S11 to S13) according to the above-described embodiments of the present invention are not limited to the above-described embodiments, and various modifications are possible within the scope of the claims.

[0057] For example, although the regulating members 21, 121 have been described as being cylindrically formed round pipe members, they may also be solid round bar members, and the cross-sectional shape (cross-sectional shape in a direction intersecting the extension direction of the regulating members 21, 121) may be approximately circular.

[0058] Furthermore, the regulating members 21, 121 may be hollow and may not contain a cooling liquid capable of cooling the wiring material 10. Furthermore, the type of liquid that is allowed to flow into the regulating members 21, 121 is not particularly limited.

[0059] Furthermore, although it has been described that the regulating member 21 is linear and the regulating member 121 is spiral-shaped, the regulating members 21, 121 are not particularly limited as long as they have a shape that allows at least partial contact of the outer surfaces 21m, 121m with the outer surface 10m of the wiring material 10.

[0060] Furthermore, as long as the regulating members 21, 121 are stiff enough to be bent by the worker's hands, the force that the worker applies when bending the regulating members 21, 121 by 1 radian in any direction intersecting the extension direction is not particularly limited, and the values ​​of the longitudinal elastic modulus and transverse elastic modulus are also not particularly limited.

[0061] Furthermore, although the assemblies 20 and 120 have been described as being configured by two restriction members 21 and 121, the number of restriction members 21 and 121 is not particularly limited as long as there are a plurality of restriction members.

[0062] Moreover, the exterior member 30 may be made of an insulating resin material.

[0063] Furthermore, the wire harnesses 1, 100 and the wire harness manufacturing method (steps S1 to S3, steps S11 to S13) according to the present embodiment may be configured by appropriately combining the components of the embodiments described above. [Explanation of symbols]

[0064] 1,100 Wire harness 10 Routing material 10m Outer surface of cable 20, 120 assembly 21, 121 Regulatory members 30 Exterior materials L10 Axis of cable L21, L121 Axis of the restricting member L30 Center line of exterior material S1, S11 bending process S2, S12 assembly process S3, S13 Insertion process X length direction Y width direction Z height direction

Claims

1. A conductive wiring material; An assembly including a plurality of linearly formed restricting members assembled in contact with each other along the outer surface of the wiring material; an exterior member formed in a cylindrical shape and into which the wiring material and the assembly are inserted, The restricting member has a lower rigidity than the wiring material, The assembly has a higher rigidity than the wiring material. Wire harness.

2. The regulating member is a member to which a force of 1 N m or less is applied when bending in a direction intersecting with the extension direction, and the yield stress of the material constituting the regulating member is smaller than the maximum bending stress generated in the regulating member. The wire harness according to claim 1 .

3. The regulating member has a longitudinal elastic modulus higher than 65 Gpa and lower than 210 Gpa, or a transverse elastic modulus higher than 20 Gpa and lower than 80 Gpa. The wire harness according to claim 1 or 2.

4. The restricting member is formed in a shape that follows the routing path of the wiring material, and is arranged outside the wiring material to sandwich the wiring material. The wire harness according to claim 1 or 2.

5. The regulating member is formed in a spiral shape centered on an axis extending along the wiring path of the wiring material and is wound around the outside of the wiring material. The wire harness according to claim 1 or 2.

6. The assembly has a shape bent along the wiring path of the wiring material. The wire harness according to claim 1 or 2.

7. The regulating member is formed in a cylindrical shape. The wire harness according to claim 1 or 2.

8. The regulating member has a coolant capable of cooling the wiring material flowing into it. The wire harness according to claim 7.

9. a bending step of bending a linearly formed restricting member having a lower rigidity than a conductive wiring material to conform to the shape of a wiring path of the wiring material; an assembly process in which an assembly formed by a plurality of the restricting members and having a rigidity higher than that of the wiring material is brought into contact with the outer surface of the wiring material and assembled; and an insertion step of inserting the wiring material and the assembly into an exterior member formed in a cylindrical shape. Wire harness manufacturing method.

10. In the bending step, the linear regulating member is bent along the extension direction of the wiring material and into a shape that matches the wiring path of the wiring material, In the assembling step, the wiring material is sandwiched between the plurality of restricting members bent into a shape that matches the wiring path to form the assembly, and the assembly is disposed outside the wiring material. The method for manufacturing a wire harness according to claim 9.

11. The bending process includes a first processing step of bending the regulating member into a spiral shape, and a second processing step of bending the regulating member bent into the spiral shape so that the axis of the regulating member is along the extension direction of the wiring material and is in accordance with the wiring path of the wiring material, In the assembling step, the wiring material is inserted into the inside of the plurality of restricting members which are spirally shaped and bent into a shape that matches the wiring path to form the assembly, and the assembly is disposed outside the wiring material. The method for manufacturing a wire harness according to claim 9.

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