Wire harness

Abstract

To provide a wire harness in which a processing work on an exterior member can be lessened.SOLUTION: A wire harness WH includes: an exterior member 1 having a wiring material bundle WT, an exterior main body 10 that is formed so as to extend in an axis direction X and have an arc shape in cross section when viewed from the axis direction X, and an opening 11 that is formed so as to extend in the axis direction X from one end to the other end of the exterior main body 10; and a filling member 2 that fills at least a part of the interior of the opening 11 in a state where the wiring material bundle WT is accommodated in the exterior main body 10.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a wire harness. [Background technology]

[0002] BACKGROUND ART Conventionally, a corrugated tube has been used as an exterior member for protecting a wire harness (see, for example, Patent Document 1). The corrugated tube can be bent to fit the wiring route, for example. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-115229 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional exterior members have slits in the axial direction, and the wire harness is housed inside the slit and needs to be wrapped with tape. However, the speed and appearance of this tape wrapping vary depending on the level of skill, so improvements are needed.

[0005] An object of the present invention is to provide a wire harness that can reduce the amount of processing work required for an exterior member. [Means for solving the problem]

[0006] In order to achieve the above object, the wire harness of the present invention is characterized by comprising a wiring material, an exterior body extending along an axial direction and having a cross-sectional shape formed in an arc when viewed from the axial direction, an exterior member having an opening formed extending from one end to the other end of the exterior body along the axial direction, and a filling member that fills at least a portion of the inside of the opening when the wiring material is housed in the exterior body. [Effects of the Invention]

[0007] The wire harness according to the present invention has an effect of reducing the processing work required for the exterior member. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic diagram showing a schematic configuration of a wire harness according to an embodiment. [Figure 2] FIG. 2 is a cross-sectional view taken along the line AA in FIG. [Figure 3] FIG. 3 is a schematic diagram of the exterior body and the filling member in a straight portion of the exterior member. [Figure 4] FIG. 4 is a schematic diagram of a curved portion of an exterior member. [Figure 5] FIG. 5 is a schematic diagram of the exterior body and the filling member at the curved portion of the exterior member. [Figure 6] FIG. 6 is a schematic diagram showing a schematic configuration of a wire harness according to a first modified example of the embodiment. [Figure 7] FIG. 7 is a schematic diagram showing a schematic configuration of a wire harness according to a second modified example of the embodiment. [Figure 8] FIG. 8 is a cross-sectional view taken along the arrow BB in FIG. [Figure 9] FIG. 9 is a schematic diagram showing a schematic configuration of a wire harness according to a third modified example of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the following embodiments. That is, the components in the following embodiments include those that can be easily imagined by a person skilled in the art or those that are substantially the same, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention.

[0010] In the following description, the illustrated X direction is used. The axial direction X corresponds to the extending direction of the wiring material W, the wiring material bundle WT, and the exterior member 1.

[0011] [Embodiment] The wire harness WH in this embodiment is, for example, a component in which a plurality of wiring materials W used for power supply and signal communication are bundled together as a wiring material bundle WT to connect various devices mounted on a vehicle, and the wiring materials W are connected to the devices using connectors or the like (not shown). As shown in Figures 1 and 2, the wire harness WH includes a wiring material bundle WT, an exterior member 1 that houses and protects the wiring material bundle WT, and a filling member 2. The wire harness WH may also include grommets, protectors, fixtures, and the like (not shown).

[0012] The wiring material W is composed of, for example, a conductive linear core wire and an insulating covering portion that covers the outside of the core wire. The wiring material W is, for example, an insulated electric wire in which the core wire is covered with a covering portion. The core wire is composed of a plurality of wires made of a conductive metal, such as copper, copper alloy, aluminum, or aluminum alloy, bundled together. The core wire may also be a twisted core wire in which a plurality of wires are twisted together. The covering portion is an electric wire covering that covers the outer side of the core wire. The covering 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.).

[0013] The exterior member 1 is, for example, a processed cylindrical corrugated tube that covers the wiring material bundle WT. Like the corrugated tube, the exterior member 1 is made of an insulating resin material or the like. The exterior member 1 has an exterior body 10 and an opening 11.

[0014] The exterior body 10 extends along the axial direction X, and has an arc-shaped cross section when viewed from the axial direction X. The exterior body 10 of this embodiment has a shape obtained by cutting a cylindrical corrugated tube in half, and has a semicircular cross section when viewed from the axial direction X.

[0015] 1, the exterior body 10 has a plurality of peaks 12 formed in an arc shape around a central axis O along the axial direction X and protruding in one radial direction intersecting the axial direction X, and a plurality of valleys 13 formed in an arc shape around the central axis O and recessed in the other radial direction, which are arranged alternately along the axial direction X. The intervals between adjacent peaks 12 and valleys 13 among the plurality of peaks 12 and valleys 13 shown in FIG. 3 are the same interval L when the exterior body 10 is in a straight state.

[0016] The opening 11 is formed in the exterior body 10 and extends from one end to the other end of the exterior body 10 along the axial direction X. The wiring material bundle WT is accommodated in the exterior body 10 through the opening 11.

[0017] The filling member 2 fixes the exterior member 1 to the wiring material bundle WT when the wiring material bundle WT is housed in the exterior body 10. The filling member 2 is a hot melt adhesive that is heated and melted to bond objects together. The filling member 2 is filled inside the opening 11 when the wiring material bundle WT is housed in the exterior body 10. The filling members 2 are filled, for example, at intervals along the axial direction X of the exterior body 10. In the example shown in FIG. 1 , there are three filling points where filling members 2 are provided in the axial direction X for a certain length of the exterior body 10, but the number is not limited to this.

[0018] Next, a brief description will be given of a manufacturing method of the wire harness WH. An assembly worker prepares a wiring material bundle WT by bundling a plurality of wiring materials W, and then assembles the exterior member 1 to the wiring material bundle WT. Specifically, the assembly worker places the wiring material bundle WT inside the exterior body 10 through the opening 11.

[0019] Next, with the wiring material bundle WT housed in the exterior body 10, the assembly worker fills the inside of the opening 11 of the exterior body 10 with the filling material 2. For example, the assembly worker uses a gun-type adhesive injection device to fill the inside of the opening 11 with the filling material 2 at intervals along the axial direction X, thereby fixing the exterior member 1 to the wiring material bundle WT. The assembly worker uses a gun-type adhesive injection device to apply the filling material 2 to the inside of the opening 11 at intervals along the axial direction X, thereby fixing the exterior member 1 to the wiring material bundle WT. Furthermore, by using a gun-type adhesive injection device for each placement location of the filling material 2, the amount of filling material 2 used can be reduced. Furthermore, the filling material 2 serves both as a fixing member for fixing the exterior member 1 to the wiring material bundle WT and as a protective material for the wiring material bundle WT, thereby enabling the same all-around protection as a conventional cylindrical corrugated tube. In addition, since the application of the filling material 2 is performed by equipment rather than by hand, there is no difference in work speed or appearance due to differences in the proficiency level of the assembly worker. In addition, application of the filling material 2 reduces contact between the wiring material bundle WT and the exterior body 10, and the generation of abnormal noise due to such contact can be suppressed compared to conventional cylindrical corrugated tubes.

[0020] As described above, the wire harness WH of this embodiment comprises a wiring material bundle WT, an exterior body 10 extending along the axial direction X and having an arc-shaped cross-sectional shape when viewed from the axial direction X, an exterior member 1 having an opening 11 formed extending from one end to the other end of the exterior body 10 along the axial direction X, and a filling member 2 that fills at least a portion of the inside of the opening 11 when the wiring material bundle WT is housed in the exterior body 10.

[0021] Compared to conventional cylindrical corrugated tubes, the wire harness WH uses protective material only in areas that require protection, reducing the amount of protective material used and eliminating the need for tape wrapping or mounting jigs, thereby shortening processing time. Conventional cylindrical corrugated tubes provide full-circumference protection due to their cylindrical shape, and the protective material that makes up the corrugated tube is used in areas that do not require protection, resulting in a greater amount of protective material used overall.

[0022] Furthermore, compared to conventional cylindrical corrugated tubes, wire harnesses WH allow for easier addition of wiring material W to the wire harness WH. This eliminates the need for careful checking for damage to the sheath caused by the wiring material W getting caught. This allows for consistent processing speeds regardless of the operator, resulting in less variation in quality. The process of attaching a conventional cylindrical corrugated tube to a wiring material bundle WT involves delicate work, such as threading tape through pre-drilled slits in the corrugated tube, which tends to result in longer processing times. Furthermore, when a corrugated tube is to be attached to a wiring material bundle WT, the time required for wrapping the tape around the corrugated tube and threading the corrugated tube through the wiring material bundle WT increases, resulting in longer processing times. Furthermore, when using an attachment jig to thread the wiring material bundle WT through the corrugated tube, the use of the jig can be difficult when the position of the jig plate or fork or the installation space is limited, resulting in longer processing times.

[0023] Furthermore, compared to a conventional cylindrical corrugated tube, the wiring harness WH can easily have a wiring material W added to it later. With a conventional cylindrical corrugated tube, if a wiring material W is to be added to a wire harness WH later, it is necessary to remove all the corrugated tubes from the wiring material bundle WT, add the wiring material W, and then reattach the corrugated tube.

[0024] Furthermore, compared to conventional cylindrical corrugated tubes, the wire harness WH reduces the amount of work required by workers to process the exterior materials. When attaching a conventional cylindrical corrugated tube to a bundle of wiring material WT, careful work is required to check for scratches on the sheath of the wiring material W caused by edges in the slits of the corrugated tube or by the wiring material W getting caught in the slits. In addition, when wrapping tape around the corrugated tube, the speed of work and the appearance vary depending on the worker's level of skill.

[0025] Furthermore, in the wire harness WH according to this embodiment, the filling members 2 are filled at intervals along the axial direction X of the exterior body 10. This makes it possible to minimize the use of the filling members 2 compared to a wire harness WH in which the filling members 2 are filled without any intervals along the axial direction X of the exterior body 10, thereby reducing material costs and the weight of the wire harness WH.

[0026] In the above embodiment, the case where the exterior body 10 is attached to the straight wiring material bundle WT and fixed with the filling member 2 has been described, but the present invention is not limited to this, and the exterior body 10 may be attached to the curved wiring material bundle WT and fixed with the filling member 2. When the wiring harness WH is curved together with the exterior body 10 after the exterior body 10 is attached to the wiring material bundle WT, the wiring harness WH has a curved portion 21 that is different from the straight portion 20 (see FIG. 1) in the straight state, as shown in FIG. 4. In the curved portion 21, the distance L between adjacent peaks 12 and valleys 13 among the plurality of peaks 12 and the plurality of valleys 13 becomes a distance L1 that is different from the distance L when the exterior body 10 is straight. When the filling member 2 is filled into the curved portion 21 of the wire harness WH, the filling member 2 covers the adjacent peaks 12 to fix the interval L1 therebetween and fills the adjacent valleys 13 to fix the interval L1 therebetween, thereby maintaining the curved state of the curved portion 21. In other words, with the filling member 2 filled into the opening 11, the exterior member 1 maintains a curved shape in which the exterior body 10 is curved to match the wiring path of the wiring material bundle WT. This curved shape is the shape of the curved portion 21, and the interval L between the peaks 12 and the valleys 13 is widened or narrowed.

[0027] The assembly worker holds the wire harness WH, which has the outer casing member 1 attached to the wiring material bundle WT, in a path-regulated shape, and then fills the curved portion 21 of the wire harness WH with the filling member 2 to fix the outer casing member 1 to the wiring material bundle WT.

[0028] Conventionally, when assembling a wire harness WH to a vehicle, clamps or the like are used to install the wire harness WH while avoiding any interfering objects. The wire harness WH of this embodiment can be fixed in a manner that avoids interfering objects and maintains its shape, eliminating the need for clamps during vehicle assembly and reducing the number of clamps required. As a result, parts costs can be reduced and vehicle assembly can be improved. Furthermore, the wire harness WH of this embodiment can eliminate the need for tape wrapping or band fastening work required for clamp installation. Furthermore, if a corrugated tube is set up to the clamp position to attach a clamp to the wire harness WH, the clamp is no longer necessary, so protective material only needs to be installed in the interfering area, reducing the amount of protective material used.

[0029] In the wire harness WH of the present embodiment, when the filling member 2 is filled in the openings 11 at the curved portion 21 of the exterior member 1, the spacing L1 at the curved portion 21 is fixed by the filling member 2, and the curved portion 21 is maintained in a curved shape. More specifically, the wire harness WH includes an exterior main body 10 including a curved portion 21 in which a plurality of peaks 12 formed in an arc shape around a central axis O along the axial direction X and protruding in one radial direction intersecting the axial direction X, and a plurality of valleys 13 formed in an arc shape around the central axis O and recessed in the other radial direction are alternately arranged along the axial direction X, and the spacing between adjacent peaks 12 and valleys 13 among the plurality of peaks 12 and the plurality of valleys 13 is different from the spacing L when the exterior main body 10 is in a straight state. In the exterior member 1, in a state where the filling member 2 is filled in the opening 11 at the curved portion 21, the gap L1 at the curved portion 21 is fixed by the filling member 2, and the curved portion 21 is maintained in a bent shape.

[0030] Compared to conventional wire harnesses WH, the above-described configuration of the wire harness WH eliminates the need for clamps or the like to maintain the regulated path, and the shape of the curved portion 21 can be easily maintained along the regulated path. Furthermore, the wire harness WH facilitates the path regulation and shape maintenance of the wiring material bundle WT and the exterior member 1, improving the ease of vehicle assembly of the wire harness WH. Furthermore, by reducing the number of clamps used in the wire harness WH, it is possible to reduce the number of clamp fixing holes provided on the vehicle body, for example, and to reduce processing work such as tape wrapping for clamp installation. Furthermore, the wire harness WH allows the protective material set to match the length of the clamps to be shortened, thereby reducing material costs.

[0031] In addition, the curved portion 21 shown in Figure 5 has the exterior body 10 positioned on the inner side of the curved wiring material bundle WT, as shown in Figure 4, but this is not limited to this, and the exterior body 10 may also be positioned on the outer side of the curved wiring material bundle WT.

[0032] Furthermore, the filling members 2 are filled at intervals along the axial direction X of the exterior body 10, but this is not limited to this, and the filling members 2 may extend from one end to the other end of the exterior body 10 along the axial direction X of the exterior body 10 and be filled so as to block the opening 11.

[0033] [First Modification of the Embodiment] In the above embodiment, the exterior body 10 has a shape obtained by cutting a cylindrical corrugated tube in half, and has a semicircular cross-section when viewed from the axial direction X, but this is not limited to this. For example, in the wire harness WHA shown in FIG. 6, the cross-section of the exterior body 10A when viewed from the axial direction X is not a semicircle but a partial circle. In the illustrated example, the circumferential length of the exterior body 10A is 2 / 3 of the entire circumference, but this is not limited to this and may be, for example, more than 1 / 2 and not more than 2 / 3 of the entire circumference. For example, by changing the position of a slit added to the cylindrical slit corrugated tube, the circumferential length of the exterior body 10A can be adjusted to match the diameter of the wiring material bundle WT or the position of an obstruction.

[0034] In the wire harness WHA according to the first modification of the present embodiment, the cross section of the exterior body 10A is formed in an arc shape when viewed from the axial direction X, and the circumferential length of the exterior body 10A is more than 1 / 2 and not more than 2 / 3 of the entire circumference. This makes it possible to adjust the circumferential length of the wire harness WHA in accordance with the bundle diameter of the wiring material bundle WT and the position of an obstruction.

[0035] [Second Modification of the Embodiment] In the above embodiment, the filling member 2 is filled using a gun-type adhesive injection device when assembling the wire harness WH, but this is not limited to this. For example, in the wire harness WHB shown in FIGS. 7 and 8, the filling member 2 has a sheet-shaped filling sheet 3. The filling sheet 3 is formed in a rectangular shape and is made of, for example, a thermoplastic resin, similar to a hot melt adhesive. The filling sheet 3 is arranged at the same position as the filling position of the filling member 2. In other words, the filling sheets 3 are arranged at intervals along the axial direction X of the exterior body 10.

[0036] With the wiring material bundle WT housed in the exterior body 10, the assembly worker arranges multiple filler sheets 3 at intervals along the axial direction X inside the opening 11 of the exterior body 10. Next, the assembly worker heats each of the multiple arranged filler sheets 3 with a gun-type heating device to melt the filler sheets 3 and secure the exterior member 1 to the wiring material bundle WT. In this case, by simultaneously heating each of the multiple arranged filler sheets 3 with a gun-type heating device to melt the filler sheets 3, it is possible to simultaneously secure multiple locations that require fixation with filler members 2. As a result, even if the length of the exterior member 1 in the axial direction X of the wire harness WHB is increased, the exterior member 1 can be secured to the wiring material bundle WT without changing the processing time. Furthermore, the wire harness WHB requires fewer installation steps for the exterior member 1 than conventional methods, thereby shortening the installation time and facilitating automation.

[0037] [Third Modification of the Embodiment] In the third modified example of the above embodiment, the filling sheets 3 are arranged at intervals along the axial direction X of the exterior body 10, but this is not limited to this. For example, the wire harness WHC shown in FIG. 9 has a sheet-shaped filling sheet 3A that connects multiple filling members 2. The filling sheet 3A extends from one end to the other end of the exterior body 10 along the axial direction X of the exterior body 10 and is formed so as to close the opening 11. The filling sheet 3A connects the filling points of adjacent filling members 2 so as to cover the wiring material bundle WT exposed from the opening 11.

[0038] With the wiring material bundle WT housed in the exterior body 10, the assembly worker places a filler sheet 3A inside the opening 11 of the exterior body 10. Next, the assembly worker heats the placed filler sheet 3A with a gun-type heating device at intervals along the extension direction of the exterior body 10 to melt parts of the filler sheet 3A and secure the exterior member 1 to the wiring material bundle WT. In this case, by simultaneously heating multiple parts of the placed filler sheet 3A with the gun-type heating device to melt the filler sheet 3A, it is possible to simultaneously secure multiple parts that require fixation with the filler member 2. Furthermore, the wire harness WHC can secure a wide area inside the opening 11 of the exterior body 10 with the filler sheet 3A. Furthermore, the wire harness WHC connects the filled parts of adjacent filler members 2 so that the filler sheet 3A covers the wiring material bundle WT exposed from the opening 11. This allows the wire harness WHC to prevent the wiring material bundle WT and the wiring material W from protruding from the opening 11, and improves the protection of the wiring material bundle WT housed in the exterior body 10 by the filling member 2. [Explanation of symbols]

[0039] 1 Exterior materials 2 Filler material 10 Exterior body 11 Opening 12 Yamabe 13 Valley 20 Straight section 21 Curved section WH Wire Harness WT wiring material bundle W Routing material

Claims

1. The wiring material, an exterior member having an exterior main body whose cross section when viewed from the axial direction is formed in an arc shape and which extends along the axial direction, and an opening formed to extend from one end to the other end of the exterior main body along the axial direction; a filling member that fills at least a part of the inside of the opening when the wiring material is housed in the exterior body; A wire harness comprising:

2. The filling member is The outer casing body is filled with the outer casing at intervals along the axial direction. The wire harness according to claim 1 .

3. The exterior member is With the filling member filled in the opening, the exterior body is maintained in a curved shape that matches the routing path of the routing material. The wire harness according to claim 1 or 2.

4. The exterior body includes: a curved portion in which a plurality of peaks are formed in an arc around a central axis along the axial direction and protrude in one radial direction intersecting with the axial direction, and a plurality of valleys are formed in an arc around the central axis and recessed in the other radial direction, are alternately arranged along the axial direction, and the curved portion is curved so that the intervals between adjacent peaks and valleys among the plurality of peaks and valleys are different from the intervals when the exterior main body is in a straight state, The exterior member is In the state where the filling member is filled in the opening in the curved portion, the gap in the curved portion is fixed by the filling member, and the curved portion is maintained in a bent shape. The wire harness according to claim 1 or 2.

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