Wire harness and manufacturing method of wire harness

Abstract

To provide a wire harness in which a flat wiring member formed in a U-shape can be elongated in a linear shape.SOLUTION: A wire harness 1 includes: a flat wiring member 100 formed in a U-shape having a straight first part 110, a straight second part 120, and an intermediate part 130 connecting an end part of the first part and an end part of the second part; a first case holding the first part; and a second case holding the second part. The first case and the second case are engageable with each other with the shape of the flat wiring member being a straight shape. The straight flat wiring member has a first folded part 150 and a second folded part 160. In the first folded part, the intermediate part is folded along a folded line L1 along an extending direction X in which the first part extends, and in the second folded part, the second part is folded along a folded line L2 orthogonal to the extending direction so that a part of the second part overlaps the intermediate part.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] Conventionally, there are flat wiring materials such as flexible printed circuit boards. Patent Document 1 discloses a flexible printed circuit board that can easily realize long wiring. The flexible printed circuit board of Patent Document 1 includes a first strip-shaped member and a second strip-shaped member each having a conductive portion and an insulating portion covering the conductive portion, and a first connecting member that connects a first end of the first strip-shaped member to a first end of the second strip-shaped member. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-170699 Summary of the Invention [Problem to be solved by the invention]

[0004] It is desirable to be able to make a U-shaped flat wiring material into a long, straight line.Using a U-shaped flat wiring material can reduce the manufacturing and installation costs of the flat wiring material.

[0005] An object of the present invention is to provide a wire harness in which a flat wiring material formed in a U-shape can be elongated into a straight shape, and a method for manufacturing the wire harness. [Means for solving the problem]

[0006] The wire harness of the present invention comprises a flat wiring material formed in a U-shape having a linear first portion, a linear second portion, and an intermediate portion connecting an end of the first portion and an end of the second portion, a first case holding the first portion, and a second case holding the second portion, wherein the first case and the second case are capable of engaging with each other so that the shape of the flat wiring material is linear, and in the linear-shaped flat wiring material, the second portion extends on an extension line of the first portion in a planar view, and the linear-shaped flat wiring material has a first fold portion and a second fold portion, and in the first fold portion, the intermediate portion is folded along a fold line along the extension direction in which the first portion extends, and in the second fold portion, the second portion is folded along a fold line perpendicular to the extension direction so that a part of the second portion overlaps the intermediate portion.

[0007] The method for manufacturing a wire harness of the present invention includes the steps of: accommodating a first linear portion of a flat wiring material formed into a U-shape in a first case; accommodating a second linear portion of the flat wiring material in a second case; stacking the first case and the second case and forming a first fold portion in an intermediate portion connecting the first portion and the second portion of the flat wiring material; and rotating the first case and the second case relative to each other to form a second fold portion in the second portion, wherein in the step of forming the first fold portion, the intermediate portion is folded along a fold line along the extension direction of the first portion, and in the step of forming the second fold portion, the second fold portion is folded along a fold line perpendicular to the extension direction so as to overlap a part of the second portion with the intermediate portion. [Effects of the Invention]

[0008] The wire harness according to the present invention includes a flat wiring material formed in a U-shape having a linear first portion, a linear second portion, and an intermediate portion connecting the end of the first portion and the end of the second portion, a first case for holding the first portion, and a second case for holding the second portion, and the first case and the second case can be engaged with each other while the shape of the flat wiring material is linear. The wire harness according to the present invention has the effect of enabling the flat wiring material formed in a U-shape to be elongated in a linear shape.

[0009] The method for manufacturing a wire harness according to the present invention includes the steps of: accommodating a first linear portion of a U-shaped flat wiring material in a first case; accommodating a second linear portion of the flat wiring material in a second case; stacking the first case and the second case to form a first folded portion in an intermediate portion connecting the first portion and the second portion of the flat wiring material; and rotating the first case and the second case relative to each other to form a second folded portion in the second portion. The method for manufacturing a wire harness according to the present invention has the effect of enabling the flat wiring material formed in a U-shape to be elongated into a linear shape. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view of a wire harness according to an embodiment. [Figure 2] FIG. 2 is a perspective view showing a linear flat wiring material according to the embodiment. [Figure 3] FIG. 3 is a plan view of the flat wiring material according to the embodiment. [Figure 4] FIG. 4 is a plan view of the case according to the embodiment. [Figure 5] FIG. 5 is a perspective view of the case according to the embodiment. [Figure 6] FIG. 6 is a plan view of the wire harness according to the embodiment. [Figure 7] FIG. 7 is a plan view of the wire harness according to the embodiment. [Figure 8]FIG. 8 is a plan view of the wire harness according to the embodiment. [Figure 9] FIG. 9 is a cross-sectional view of the wire harness according to the embodiment. [Figure 10] FIG. 10 is a perspective view of a flat wiring material on which a first folded portion is formed. [Figure 11] FIG. 11 is a cross-sectional view of the wire harness according to the embodiment. [Figure 12] FIG. 12 is a perspective view of the wire harness according to the embodiment. [Figure 13] FIG. 13 is a cross-sectional view of the wire harness according to the embodiment. [Figure 14] FIG. 14 is a perspective view of the wire harness according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, a wire harness and a method for manufacturing the wire harness according to an embodiment of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiment. Furthermore, 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.

[0012] [Embodiment] An embodiment will be described with reference to Fig. 1 to Fig. 14. The embodiment relates to a wire harness and a manufacturing method of the wire harness. Fig. 1 is a perspective view of the wire harness according to the embodiment, Fig. 2 is a perspective view showing a linear flat wiring material according to the embodiment, Fig. 3 is a plan view of the flat wiring material according to the embodiment, Fig. 4 is a plan view of a case according to the embodiment, Fig. 5 is a perspective view of the case according to the embodiment, Figs. 6 to 8 are plan views of the wire harness according to the embodiment, Fig. 9 is a cross-sectional view of the wire harness according to the embodiment, and Fig. 10 is a perspective view of the flat wiring material on which a first folded portion is formed.

[0013] Fig. 11 is a cross-sectional view of the wire harness according to the embodiment, Fig. 12 is a perspective view of the wire harness according to the embodiment, Fig. 13 is a cross-sectional view of the wire harness according to the embodiment, and Fig. 14 is a perspective view of the wire harness according to the embodiment. Figs. 9 and 11 show a cross section taken along line IX-IX in Fig. 8. Fig. 13 shows a cross section taken along line XIII-XIII in Fig. 1.

[0014] As shown in Fig. 1, the wire harness 1 of the embodiment has a flat wiring material 100, a first case 10, and a second case 20. As will be described below, the first case 10 and the second case 20 of the present embodiment can deform the flat wiring material 100 formed in a U-shape into a linear shape and hold it. The first case 10 and the second case 20 are configured to engage with each other while holding the linearly shaped flat wiring material 100. The flat wiring material 100 of Fig. 1 is held in a linear shape by the two cases 10 and 20.

[0015] Figure 2 shows a main part of the flat wiring material 100 held in a linear shape as in Figure 1. Figure 3 shows the U-shaped flat wiring material 100 before being deformed into a linear shape. The flat wiring material 100 is, for example, an FPC (flexible printed circuit board). The flat wiring material 100 of this embodiment is arranged in a battery module and detects the voltage and temperature of the battery cells of the battery module.

[0016] When the flat wiring material 100 is an FPC, the flat wiring material 100 has a base film, a conductive layer, and a coverlay. The conductive layer is sandwiched and protected between the base film and the coverlay. The conductive layer is, for example, a conductive metal foil and has a circuit pattern including multiple detection lines 140. The flat wiring material 100 is flexible and can be bent when being wired.

[0017] The flat wiring material 100 shown in Figure 3 has a substantially U-shape in plan view. The flat wiring material 100 has a first portion 110, a second portion 120, and an intermediate portion 130. The first portion 110 and the second portion 120 have substantially rectangular shapes in plan view. The flat wiring material 100 has a slit 100s formed between the first portion 110 and the second portion 120.

[0018] The intermediate portion 130 connects the end of the linear first portion 110 and the end of the linear second portion 120. The shape of the intermediate portion 130 in a planar view is approximately trapezoidal. The intermediate portion 130 has a tapered shape in which its width narrows as it moves away from the first portion 110 and the second portion 120 along the extension direction X. The extension direction X is the direction in which the first portion 110 extends, and is the longitudinal direction of the first portion 110. In the flat wiring material 100 in its initial shape before deformation, the first portion 110 and the second portion 120 extend in the same extension direction X and are aligned in the width direction Y. The width direction Y is a direction perpendicular to the extension direction X and is the width direction of the first portion 110 and the second portion 120.

[0019] The flat wiring material 100 of this embodiment is provided with branch portions 170 connected to the bus bar 200. The branch portions 170 extend from the first portion 110 and the second portion 120 in the width direction Y. The tip portions of the branch portions 170 are connected to the bus bar 200 by solder or the like.

[0020] Figures 4 and 5 show the first case 10 and the second case 20 of this embodiment. The first case 10 and the second case 20 are molded, for example, from an insulating synthetic resin. The first case 10 has a main body 11 and a cover 18. The main body 11 and the cover 18 are molded, for example, as a single unit. In the first case 10 of this embodiment, the main body 11 and the cover 18 are connected via a hinge portion 11e. The main body 11 has a support wall 11a that supports the first portion 110 of the flat wiring material 100. The support wall 11a is formed in a straight line along the extension direction X. The cover 18 has an opposing wall 18a that covers the support wall 11a. The first portion 110 of the flat wiring material 100 is accommodated and held between the support wall 11a and the opposing wall 18a.

[0021] A first shaft support portion 19A and a second shaft support portion 19B are provided at an end portion of the main body 11 in the extension direction X. The first shaft support portion 19A rotatably supports a first rotating shaft 25A of the second case 20. The second shaft support portion 19B rotatably supports a second rotating shaft 25B of the second case 20.

[0022] The second case 20 according to the embodiment has a main body 21 and a cover 24. The main body 21 and the cover 24 are, for example, molded integrally. In the second case 20 according to the embodiment, the main body 21 and the cover 24 are connected via a hinge portion 21e. The main body 21 has a support wall 21a that supports the second portion 120 of the flat wiring material 100. The support wall 21a is formed in a straight line along the extension direction X. The cover 24 has an opposing wall 24a that covers the support wall 21a. The second portion 120 of the flat wiring material 100 is accommodated and held between the support wall 21a and the opposing wall 24a.

[0023] A first rotation shaft 25A is provided at an end of the main body 21 in the extension direction X. A second rotation shaft 25B is provided at an end of the cover 24 in the extension direction X. The first rotation shaft 25A protrudes from a side surface of the main body 21 in the width direction Y. The second rotation shaft 25B extends in the width direction Y so as to cross the end of the cover 24. Both end portions of the second rotation shaft 25B are supported by second bearing portions 19B.

[0024] In the wire harness 1 according to the embodiment, the rotation structure 60 is configured by the two pivotal support portions 19A, 19B of the first case 10 and the two rotation shafts 25A, 25B of the second case 20. The rotation structure 60 enables the two cases 10, 20 to rotate relative to each other as shown in FIG.

[0025] As shown in Fig. 5, the first case 10 has a first engagement portion 12, and the second case 20 has a second engagement portion 22. The first engagement portion 12 is disposed at an end of the main body 11 in the extension direction X. The second engagement portion 22 is disposed at an end of the main body 21 in the extension direction X. The two engagement portions 12, 22 engage with each other at a second relative position shown in Fig. 1.

[0026] Fig. 6 shows the flat wiring material 100 assembled to the first case 10 and the second case 20. The first case 10 and the second case 20 shown in Figs. 4 and 6 are arranged side by side in the width direction Y. In this specification, with respect to the first case 10 and the second case 20, the relative position in which the two cases 10, 20 are arranged side by side in the width direction Y is referred to as a first relative position. As shown in Fig. 4, when the two cases 10, 20 are arranged in the first relative position, the support wall 11a of the first case 10 and the support wall 21a of the second case 20 are arranged side by side in the width direction.

[0027] The first portion 110 of the flat wiring material 100 is accommodated in the main body 11 of the first case 10 and is supported by the support wall 11a. The process of accommodating the first portion 110 in the first case 10 is performed, for example, by a worker. The second portion 120 of the flat wiring material 100 is accommodated in the main body 21 of the second case 20 and is supported by the support wall 21a. The process of accommodating the second portion 120 in the second case 20 is performed, for example, by a worker. The two accommodation processes are performed, for example, with the two cases 10, 20 held by a jig plate.

[0028] Once the flat wiring material 100 is housed in the two cases 10, 20, a closing process is performed to close the covers 18, 24. In the closing process, the cover 18 of the first case 10 is assembled to the main body 11 while bending the hinge portion 11e. In the closing process, the cover 24 of the second case 20 is assembled to the main body 21 while bending the hinge portion 21e. The two closing processes are performed, for example, by a worker. Figure 7 shows the covers 18, 24 in a closed state. The opposing wall 18a of the cover 18 covers the first portion 110 of the flat wiring material 100. The opposing wall 24a of the cover 24 covers the second portion 120 of the flat wiring material 100.

[0029] A first rotation step is performed to rotate the second case 20 relative to the first case 10 from the state shown in FIG. 7. In the first rotation step, the second case 20 is rotated relative to the first case 10 around a rotation axis Cx shown in FIG. 7 as the rotation center. The rotation axis Cx is, for example, a straight line extending in the extension direction X between the two covers 18, 24. This rotation may be performed using, for example, a jig plate. In this case, the jig plate may have a main body that supports the first case 10 and a support member that supports the second case 20. The support member is supported by the main body so as to be rotatable around the rotation axis Cx.

[0030] The second case 20 is rotated relative to the first case 10 around the rotation axis Cx as the center of rotation, and the second case 20 is overlapped on the first case 10. As a result, the second portion 120 of the flat wiring material 100 overlaps with the first portion 110 and faces the first portion 110.

[0031] 8 shows the state in which the second case 20 is stacked on the first case 10 after the first rotation process is completed. In this specification, with respect to the first case 10 and the second case 20, the relative position in which the two cases 10, 20 overlap in the height direction Z is referred to as the intermediate relative position. In the intermediate relative position, the second portion 120 of the flat wiring material 100 overlaps with the first portion 110 and faces the first portion 110. The height direction Z is a direction perpendicular to both the extension direction X and the width direction Y.

[0032] When the two cases 10, 20 rotate around the rotation axis Cx and are positioned at an intermediate relative position, the middle portion 130 of the flat wiring material 100 is bent along the rotation axis Cx. Figure 9 shows a cross section IX-IX of Figure 8, and Figure 10 shows the flat wiring material 100 in the state of Figure 8. As shown in Figures 9 and 10, a first folded portion 150 is formed in the middle portion 130 of the flat wiring material 100.

[0033] In the first folded portion 150, the intermediate portion 130 is folded along a folding line L1 along the extension direction X. The folding line L1 is, for example, a straight line extending in the extension direction X between the two covers 18, 24. The intermediate portion 130 has a first region 130a connected to the first portion 110 and a second region 130b connected to the second portion 120. The intermediate portion 130 is folded so that the first region 130a and the second region 130b face each other in the height direction Z.

[0034] 11 , the first folded portion 150 is formed so as to sandwich the cover 18 of the first case 10 between the intermediate portion 130. That is, the first region 130a and the second region 130b of the intermediate portion 130 face each other in the height direction Z with the opposing wall 18a of the cover 18 interposed therebetween. The opposing wall 18a has a restricting portion 18b that protects the first folded portion 150.

[0035] As shown in FIG. 11 , the restricting portion 18b is disposed at the end of the opposing wall 18a in the width direction Y. The restricting portion 18b is a portion where the thickness of the end of the opposing wall 18a is increased, and extends in the extension direction X. The cross-sectional shape of the restricting portion 18b is substantially circular. The restricting portion 18b protrudes in the height direction Z toward the side opposite to the support wall 11a. The restricting portion 18b supports the first folded portion 150 from the inside so that the bending radius R of the first folded portion 15 does not become too small.

[0036] The opposing wall 18a can achieve both a low profile of the first case 10 and protection of the first folded portion 150. The opposing wall 18a is thin-walled except for the restricting portion 18b. This reduces the distance H1 between the first region 130a and the second region 130b in the height direction Z, thereby reducing the profile of the first case 10. Furthermore, by supporting the intermediate portion 130 in the first rotation step, an appropriate bend radius R can be formed in the first folded portion 150. The restricting portion 18b and the first folded portion 150 are positioned offset in the width direction Y from the first portion 110 and the second portion 120. This allows the distance H1 between the two regions 130a and 130b to be reduced while still ensuring sufficient space to form an appropriate bend radius R in the first folded portion 150.

[0037] As shown in Figures 9 and 11, the first case 10 has a protective cover 11g that protects the middle portion 130 of the flat wiring material 100. The protective cover 11g is connected to the support wall 11a via a hinge portion 11f. The protective cover 11g engages with the support wall 11a after the first rotation process is performed. The first case 10 accommodates the middle portion 130, which is folded back in a U-shape, between the support wall 11a and the protective cover 11g. The opposing wall 18a of the cover 18 is sandwiched inside the folded back middle portion 130. The hinge portion 11f covers the first folded back portion 150 and protects the first folded back portion 150.

[0038] 9, the first rotating shaft 25A of the second case 20 is rotatably supported by a first pivotal support portion 19A of the first case 10. The first pivotal support portion 19A has a piece portion 19c standing in the height direction Z and a locking portion 19d. The piece portion 19c has a slit 19e extending in the height direction Z. An end of the first rotating shaft 25A is inserted into the slit 19e and locked by the locking portion 19d.

[0039] The second rotating shaft 25B of the second case 20 is rotatably supported by the second pivotal support portion 19B of the first case 10. The second pivotal support portion 19B has a slit 19f formed in the side wall 11h. The side wall 11h is disposed on both sides of the support wall 11a in the width direction Y. An end of the second rotating shaft 25B is inserted into the slit 19f and rotatably supported by the side wall 11h. The two rotating shafts 25A, 25B are inserted into the two pivotal support portions 19A, 19B, thereby rotatably connecting the first case 10 and the second case 20. This forms a bus bar module 400. The bus bar module 400 includes a plurality of bus bars 200 and the wire harness 1 of the embodiment.

[0040] 12 is a diagram illustrating the second rotation process. The second rotation process is performed, for example, in a factory where the busbar module 400 is assembled to a vehicle or the like. As shown in FIG. 12, in the second rotation process, the second case 20 is rotated relative to the first case 10 from an intermediate relative position toward a second relative position, which will be described later. In the second rotation process, the second case 20 rotates relative to the first case 10 around the central axes of the two rotation shafts 25A, 25B as the rotation center.

[0041] FIG. 1 shows a state in which the two cases 10, 20 are positioned at a second relative position after the second rotation process is completed. In the second relative position, the first case 10 and the second case 20 are aligned linearly along the extension direction X. In this state, the first portion 110 and the second portion 120 of the flat wiring material 100 are aligned linearly. In other words, the second portion 120 is positioned on an extension of the first portion 110 in a plan view. Furthermore, the multiple bus bars 200 are aligned linearly along the extension direction X. The cover 18 of the first case 10 covers the first portion 110 with the opposing wall 18a, protecting it. The cover 24 of the second case 20 covers the second portion 120 with the opposing wall 24a, protecting it.

[0042] By performing the second rotation process, a second folded portion 160 is formed in the flat wiring material 100. As shown in Figures 2 and 13, the second folded portion 160 is a portion folded along a folding line L2 perpendicular to the extension direction X. In the second folded portion 160, the second portion 120 is folded along the folding line L2 so that a part of the second portion 120 overlaps with the middle portion 130. In this embodiment, the folding line L2 is a straight line along the width direction Y. When the second folded portion 160 is formed, the second region 130b of the middle portion 130 and the base end portion 120a of the second portion 120 face each other. The base end portion 120a is the end portion of the second portion 120 closer to the middle portion 130.

[0043] 13, the base end 120a and the second region 130b face each other in the height direction Z with the protective cover 11g therebetween. In the portion where the protective cover 11g is arranged, the first region 130a of the intermediate portion 130, the second region 130b of the intermediate portion 130, and the base end 120a are aligned in the height direction Z.

[0044] The first portion 110 of the flat wiring material 100 extends from the second folded portion 160 to a first side X1 in the extension direction X. The second portion 120 extends from the second folded portion 160 to a second side X2 in the extension direction X. Therefore, in the linear flat wiring material 100 shown in Figures 2 and 13, the second portion 120 extends on an extension line of the first portion 110 in a planar view.

[0045] As shown in FIG. 13, the protective cover 11g has a restricting portion 11j that protects the second folded portion 160. The restricting portion 11j is located at the end of the protective cover 11g on the first side X1 in the extension direction X. The restricting portion 11j is a portion where the thickness of the end of the protective cover 11g is increased, and extends in the width direction Y. The cross-sectional shape of the restricting portion 11j is approximately circular. The restricting portion 11j protrudes in the height direction Z toward the side opposite to the support wall 11a. The restricting portion 11j supports the second folded portion 160 from the inside so that the bending radius R of the second folded portion 160 does not become too small.

[0046] The protective cover 11g of this embodiment can regulate the bending starting point during the second rotation process. If the protective cover 11g is not provided, stress concentration may occur at the corner 180 in Figure 10 during the second rotation process. The corner 180 is the boundary between the intermediate portion 130 and the second portion 120, where the edges of the flat wiring material 100 intersect at approximately right angles. The regulating portion 11j of the protective cover 11g can regulate the lifting of the second portion 120 so that force is less likely to act on the corner 180 when the two cases 10, 20 rotate relative to each other.

[0047] Figure 15 shows the flat wiring material 100 in the middle of deformation in the second rotation process. The protective cover 11g holds down the middle portion 130 of the flat wiring material 100, thereby suppressing deformation of the middle portion 130. Furthermore, the regulating portion 11j holds down the base end portion 120a of the second portion 120, thereby suppressing lifting of the base end portion 120a. This suppresses stress concentration on the corner portion 180, thereby protecting the corner portion 180. Furthermore, the regulating portion 11j supports the base end portion 120a, allowing the second folded portion 160 to be formed at a desired position.

[0048] As described above, the wire harness 1 of this embodiment includes the flat wiring material 100, the first case 10, and the second case 20. The flat wiring material 100 includes a linear first portion 110, a linear second portion 120, and an intermediate portion 130. The intermediate portion 130 is a portion that connects an end of the first portion 110 and an end of the second portion 120. The first case 10 holds the first portion 110, and the second case 20 holds the second portion 120.

[0049] The first case 10 and the second case 20 can be engaged with each other while the shape of the flat wiring material 100 is linear. In the linear flat wiring material 100, the second portion 120 extends on an extension line of the first portion 110 in a plan view. The linear flat wiring material 100 has a first folded portion 150 and a second folded portion 160. In the first folded portion 150, the middle portion 130 is folded back along a folding line L1 along the extension direction X in which the first portion 110 extends. In the second folded portion 160, the second portion 120 is folded back along a folding line L2 perpendicular to the extension direction X so that a part of the second portion 120 overlaps with the middle portion 130.

[0050] The two cases 10, 20 of this embodiment can engage with each other by linearizing the U-shaped flat wiring material 100. Therefore, the wire harness 1 of this embodiment can elongate the U-shaped flat wiring material 100 in a linear shape.

[0051] The first case 10 of this embodiment has a protective cover 11g that covers the middle portion 130 where the first folded portion 150 is formed. Therefore, the protective cover 11g can cover and protect the middle portion 130. In addition, the protective cover 11g can suppress deformation of the middle portion 130 and promote deformation of the flat wiring material 100 into a linear shape.

[0052] The protective cover 11g of this embodiment has a restricting portion 11j. The restricting portion 11j supports the second portion 120 and restricts the position of the second folded portion 160. By restricting the position of the second folded portion 160, the restricting portion 11j can stabilize the shape of the flat wiring material 100 when it is deformed in the second rotation process.

[0053] The manufacturing method of the wire harness 1 according to this embodiment includes a first accommodating step, a second accommodating step, a first forming step, and a second forming step. The first accommodating step is a step of accommodating a linear first portion 110 of the flat wiring material 100 formed into a U-shape in a first case 10. The second accommodating step is a step of accommodating a linear second portion 120 of the flat wiring material 100 in a second case 20. The first accommodating step and the second accommodating step may be performed simultaneously, or one accommodating step may be performed after the other accommodating step.

[0054] The first forming process is a process of forming a first folded portion 150 in the flat wiring material 100. In the first forming process, the first case 10 and the second case 20 are stacked, and the first folded portion 150 is formed in the middle portion 130 of the flat wiring material 100. In the first forming process, the middle portion 130 is folded along a folding line L1 along the extension direction X of the first portion 110.

[0055] The second forming process is a process of forming the second folded portion 160 in the flat wiring material 100. In the second forming process, the first case 10 and the second case 20 are rotated relative to each other, and the second folded portion 160 is formed in the second portion 120. In the second forming process, the second folded portion 160 is formed along the folding line L2 perpendicular to the extending direction X so that a part of the second portion 120 overlaps with the middle portion 130. According to the manufacturing method of the wire harness 1 according to this embodiment, it is possible to elongate the U-shaped flat wiring material 100 into a linear shape.

[0056] The contents disclosed in the above embodiments can be implemented in appropriate combinations. [Explanation of symbols]

[0057] 1: Wire harness 10: First case 11: Main body 11a: Support wall, 11e: Hinge portion, 11f: Hinge portion, 11g: Protective cover, 11h: Side wall, 11j: Restriction portion 12:First engaging part 18: Cover; 18a: Opposing wall; 18b: Restricting portion 19A: First axis branch, 19B: Second axis branch 20: Second case 21: Main body 21a: Support wall, 21e: Hinge portion 22:Second engagement part 24: Cover, 25A: First rotating shaft, 25B: Second rotating shaft 60: Rotating structure 100: Flat wiring material, 110: First part, 120: Second part 130: Middle part, 130a: First area, 130b: Second area 140: Detection line 150: first folded portion, 160: second folded portion, 170: branch portion 180: Corner 200: Bus bar 400: Busbar module L1, L2: Folding lines X: Extension direction, Y: Width direction, Z: Height direction

Claims

1. A flat wiring material formed in a U-shape having a linear first portion, a linear second portion, and an intermediate portion connecting an end of the first portion and an end of the second portion; a first case for holding the first portion; a second case for holding the second part; Equipped with The first case and the second case are engageable with each other while the shape of the flat wiring material is linear, In the linear flat wiring material, the second portion extends on an extension line of the first portion in a plan view, The linear flat wiring material has a first folded portion and a second folded portion, In the first folded portion, the intermediate portion is folded along a folding line along an extension direction in which the first portion extends, In the second folded portion, the second portion is folded along a folding line perpendicular to the extending direction so as to overlap a part of the second portion with the intermediate portion. A wire harness characterized by:

2. The first case has a protective cover that covers the middle portion where the first folded portion is formed. The wire harness according to claim 1 .

3. The protective cover has a restricting portion that supports the second portion and restricts the position of the second folded portion. The wire harness according to claim 2 .

4. A step of accommodating a first linear portion of the flat wiring material formed into a U-shape in a first case; A step of accommodating a linear second portion of the flat wiring material in a second case; A step of stacking the first case and the second case and forming a first folded portion in an intermediate portion connecting the first portion and the second portion of the flat wiring material; forming a second folded portion in the second portion by rotating the first case and the second case relative to each other; Including, In the step of forming the first folded portion, the intermediate portion is folded along a folding line extending in an extension direction of the first portion, In the step of forming the second folded portion, the second folded portion is folded along a folding line perpendicular to the extending direction so as to overlap a part of the second portion with the intermediate portion. A method for manufacturing a wire harness.

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