Wire harness

Abstract

To stabilize the quality of a wire harness and improve production efficiency.SOLUTION: A method for producing a wire harness 50 including a plurality of electric wires 61,62,70, a sheath 80 collectively covering the plurality of electric wires 61,62,70, and a connector 51 provided at an end portion of the plurality of electric wires 61,62,70 extending from the sheath 80 includes a step of covering at least only the plurality of electric wires 110 extending from the sheath 80 between the sheath 80 and the connector 51 with a protective member 52, and a step of covering an end portion of the sheath 80, an end portion of the connector 51, and the plurality of electric wires 110 with an adhesive tape 90 so as to wrap around the protective member 52 from both sides in a circumferential direction.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a method for producing a wire harness including a plurality of electric wires. [Background technology]

[0002] Wire harnesses in which a plurality of electric wires are covered with a common sheath and wire harnesses in which a plurality of electric wires are bundled together are known. Such wire harnesses are mounted on vehicles such as automobiles. An example of a wire harness mounted on a vehicle (vehicle wire harness) is described in Patent Document 1.

[0003] Vehicle wire harnesses are required to be durable against vibrations and shocks that occur when the vehicle is running, as well as bends and friction.

[0004] Therefore, the vehicle wire harness described in Patent Document 1 includes a reinforcing member that protects a part of the electric wires extending from the sheath. One longitudinal side of the reinforcing member surrounds the end of the sheath, and the other longitudinal side of the reinforcing member surrounds the electric wires extending from the end of the sheath.

[0005] Furthermore, in the vehicle wire harness described in Patent Document 1, a series of adhesive tapes are spirally wound around the entire reinforcing member, the outer periphery of the sheath extending from one side of the reinforcing member, and the outer periphery of the electric wires extending from the other side of the reinforcing member. This adhesive tape is wound mainly to protect the electric wires and to fix the reinforcing member. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-135804 Summary of the Invention [Problem to be solved by the invention]

[0007] The task of spirally winding a series of adhesive tapes is laborious and time-consuming. Furthermore, the quality of the work may vary depending on the worker's level of skill. For example, if the worker's level of skill is low, the tape overlap width may be uneven, or gaps may appear between the front and rear tapes.

[0008] An object of the present invention is to stabilize the quality of wire harnesses and improve production efficiency. [Means for solving the problem]

[0009] In one embodiment, a method for producing a wire harness includes a plurality of electric wires, a sheath that collectively covers the plurality of electric wires, and a connector provided at ends of the plurality of electric wires extending from the sheath, and includes a step of covering at least only the plurality of electric wires extending from the sheath between the sheath and the connector with a protective member, and a step of covering the ends of the sheath, the ends of the connector, and the plurality of electric wires with adhesive tape so as to wrap around the protective member from both circumferential sides. [Effects of the Invention]

[0010] According to the present invention, it is possible to stabilize the quality of wire harnesses and improve production efficiency. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic diagram showing an electric brake device connected to a wire harness and its surroundings; [Figure 2] FIG. 2 is a schematic diagram showing the structure of an electric brake device. [Figure 3] FIG. [Figure 4] FIG. 2 is a cross-sectional view schematically showing the structure of the wire harness. [Figure 5] FIG. 4 is another cross-sectional view schematically showing the structure of the wire harness. [Figure 6A]1 is a cross-sectional view schematically showing an example of a joining mode between a first end portion and a second end portion of an adhesive tape. [Figure 6B] 10 is another cross-sectional view schematically showing one example of a joining mode between the first end and the second end of the adhesive tape. FIG. [Figure 7A] 1 is a cross-sectional view schematically showing an example of a joining mode between a first end portion and a second end portion of an adhesive tape. [Figure 7B] 10 is another cross-sectional view schematically showing one example of a joining mode between the first end and the second end of the adhesive tape. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, an example of an embodiment of a wire harness of the present invention will be described in detail with reference to the drawings. In all drawings referred to for describing the embodiment, the same or substantially the same configurations and elements are designated by the same reference numerals, and, in principle, repeated description will not be provided.

[0013] (Outline of electric brake device) FIG. 1 is a schematic diagram showing an electric brake device to which a wire harness according to this embodiment is connected and its surroundings.

[0014] The electric brake device 1 is attached to a suspension system 20 that connects a vehicle body 10 and wheels 11. The suspension system 20 is made up of an upper arm 21, a lower arm 22, a shock absorber 23, a suspension spring 24, and the like.

[0015] The upper arm 21 and the lower arm 22 are connected to a knuckle 25. More specifically, the upper arm 21 is connected to a first mounting portion 26a of the knuckle 25 via a bearing, and the lower arm 22 is connected to a second mounting portion 26b of the knuckle 25 via a bearing. In addition to the upper arm 21, a shock absorber 23 is connected to the first mounting portion 26a.

[0016] A hub unit 27 is fixed to the knuckle 25. The hub unit 27 has a flange 27a, and a disc rotor 28 is fixed to the flange 27a. The disc rotor 28 rotates together with the wheel 11 (wheel 11a and tire 11b mounted on the wheel 11a) fixed to the flange 27a.

[0017] The electric brake device 1 is fixed to the third mounting portion 26c of the knuckle 25. The electric brake device 1 presses brake pads 29a, 29b against the disc rotor 28 to slow down or stop the vehicle while it is moving. The electric brake device 1 also has a parking brake function that keeps the brake pads 29a, 29b pressed against the disc rotor 28.

[0018] (Details of the electric brake device) 2 is a schematic diagram showing the structure of the electric brake device 1. The electric brake device 1 is composed of a housing 30, an electric motor 31, a reduction mechanism 32, a thrust generating mechanism 33, a caliper 34, a parking brake mechanism 40, etc.

[0019] The electric motor 31 is a DC motor. The reduction mechanism 32 is a planetary gear type reduction mechanism that reduces the speed of the output of the electric motor 31. The thrust generating mechanism 33 includes a pair of output members 33a, 33b that are slidable in the axial direction of a shaft 35. The shaft 35 is the output shaft of the electric motor 31.

[0020] The caliper 34 includes an inner support portion 34a, an outer support portion 34b, and a connecting portion 34c. The inner support portion 34a and the outer support portion 34b face each other and are connected to each other via the connecting portion 34c. Furthermore, the caliper 34 is slidable in the axial direction of the shaft 35.

[0021] The output member 33a, the output member 33b, the brake pad 29a, the disc rotor 28, and the brake pad 29b are arranged in this order between the inner support portion 34a and the outer support portion 34b of the caliper 34.

[0022] The thrust generating mechanism 33 is a ball ramp mechanism that includes a ball groove and balls that roll in the ball groove. The thrust generating mechanism 33 converts the rotational driving force output from the speed reducing mechanism 32 into a linear driving force, and drives the pair of output members 33a, 33b in directions that separate them from each other.

[0023] The output member 33a, which is driven in a direction away from the output member 33b, presses the inner support portion 34a of the caliper 34 inward (in the direction of arrow a). This causes the caliper 34 to slide inward along the shaft 35. As a result, the brake pad 29b is pressed against the outer surface of the disc rotor 28 by the outer support portion 34b of the caliper 34. Meanwhile, the output member 33b, which is driven in a direction away from the output member 33a, presses the brake pad 29a against the inner surface of the disc rotor 28.

[0024] (Parking brake mechanism) The parking brake mechanism 40 is composed of engaging members 41 and 42, a solenoid actuator 43, a coil spring 44, and the like.

[0025] The engaging member 41 is fixed to one end of the shaft 35. The engaging member 42 is disposed in a position opposite to the engaging member 41 and is supported so as not to rotate. However, the engaging member 42 is slidable in the axial direction of the shaft 35. In other words, the engaging member 42 is capable of moving close to the engaging member 41 and moving away from the engaging member 41.

[0026] The solenoid actuator 43 includes an annular electromagnetic coil 43a. When power is supplied to the electromagnetic coil 43a, the solenoid actuator 43 moves the engaging member 42 in a direction approaching the engaging member 41.

[0027] The electric power supplied to the electromagnetic coil 43a is supplied to the electric brake device 1 via a wire harness 50 shown in Fig. 1. More specifically, the electric power is supplied to the electric brake device 1 from the controller 12 via the wire harness 50.

[0028] 2 moves in a direction approaching the engaging member 41, the coil spring 44 is pulled and expanded. The expanded coil spring 44 urges (pulls) the engaging member 42 in a direction away from the engaging member 41. However, the driving force of the solenoid actuator 43 is greater than the urging force of the coil spring 44. Therefore, as long as power is supplied to the electromagnetic coil 43a, the engaging member 42 will not be pulled back by the coil spring 44.

[0029] An engagement protrusion having a substantially triangular cross section is formed on each of the engagement members 41 and 42. As described above, the engagement member 42 is supported so as not to rotate. Therefore, when the engagement member 42 is driven by the solenoid actuator 43 and the engagement protrusion of the engagement member 42 engages with the engagement protrusion of the engagement member 41, the rotation of the shaft 35 is restricted.

[0030] Here, the side surface (engagement surface) of the engagement protrusion formed on engagement member 41 and the side surface (engagement surface) of the engagement protrusion formed on engagement member 42 are inclined in opposite directions. Therefore, once engagement members 41, 42 are engaged, the engagement between engagement members 41, 42 will not be released unless shaft 35 is rotated in a predetermined direction that releases the engagement between engagement members 41, 42.

[0031] When the electric motor 31 presses the brake pads 29a, 29b against the disc rotor 28, the electromagnetic coil 43a is energized to engage the engaging members 41, 42, restricting the rotation of the shaft 35. As a result, the brake pads 29a, 29b are maintained pressed against the disc rotor 28. In other words, the parking brake is applied.

[0032] On the other hand, when the electromagnetic coil 43a is de-energized and the shaft 35 of the electric motor 31 is rotated in a direction in which the brake pads 29a, 29b are pressed against the disc rotor 28, the engagement members 41, 42 are disengaged. When the engagement members 41, 42 are disengaged, the engagement member 42 is moved away from the engagement member 41 by the bias of the coil spring 44. In other words, the parking brake is released.

[0033] (Wire harness) 1, one end (base end) of the wire harness 50 is connected to the controller 12, and the other end (tip end) of the wire harness 50 is connected to the electric brake device 1. More specifically, the tip end of the wire harness 50 is connected to a connector 13 (FIG. 2) provided in the electric brake device 1.

[0034] Fig. 3 is a side view of the wire harness 50. Figs. 4 and 5 are cross-sectional views schematically showing the structure of the wire harness 50. More specifically, Fig. 4 is a cross-sectional view of the wire harness 50 taken along line AA in Fig. 3. Fig. 5 is a cross-sectional view of the wire harness 50 taken along line BB in Fig. 3.

[0035] The wire harness 50 includes a plurality of twisted electric wires 61, 62, and 70 and a sheath 80 that collectively covers the electric wires 61, 62, and 70. From another perspective, the wire harness 50 includes a composite electric wire and a sheath that covers the composite electric wire. In the following description, the sheath 80 may be referred to as an "outer sheath 80."

[0036] As shown in FIG. 3, the wire harness 50 further includes a connector 51 connected to the ends of the electric wires 61, 62, and 70 extending from the outer sheath 80, and a protective member 52 covering the electric wires 61, 62, and 70 extending from the outer sheath 80.

[0037] As shown in Figures 4 and 5, the electric wires 61 and 62 are insulated electric wires including a central conductor 63 and an insulator 64 covering the central conductor 63, and supply electric power to the electric brake device 1 (Figure 1). In other words, the electric wires 61 and 62 are power cables. More specifically, the electric wires 61 and 62 are power cables that supply electric power to the electromagnetic coil 43a (Figure 2) of the parking brake mechanism 40. Therefore, in the following description, the electric wire 61 may be referred to as the "EPB cable 61," and the electric wire 62 may be referred to as the "EPB cable 62." Furthermore, the EPB cables 61 and 62 may be collectively referred to as the "EPB cable 60."

[0038] The electric wire 70 is a signal cable that transmits a signal output from the wheel speed sensor 36 (FIG. 2) to the controller 12 (FIG. 1). The wheel speed sensor 36 is disposed near the electric brake device 1, and outputs a signal corresponding to the rotational status (rotational speed, rotational angle, etc.) of the wheel 11. In the following description, the electric wire 70 may be referred to as a "WSS cable 70." The signal output from the wheel speed sensor 36 is used, for example, to control an antilock brake system (ABS). For this reason, the electric wire 70 may also be referred to as an "ABS cable."

[0039] The WSS cable 70 includes two twisted core cables 71, 72 and a sheath 73 that collectively covers these core cables 71, 72. In the following description, the sheath 73 may be referred to as the "inner sheath 73" to distinguish it from the outer sheath 80. The core cables 71, 72 are insulated wires that include a center conductor 74 and an insulator 75 that covers the center conductor 74.

[0040] 3, longitudinal portions of the EPB cable 60 and the WSS cable 70 extend from the end of the outer sheath 80. Most of the EPB cable 60 and the WSS cable 70 covered by the outer sheath 80 are twisted together. On the other hand, portions (exposed portions) of the EPB cable 60 and the WSS cable 70 extending from the end of the outer sheath 80 are not twisted together (untwisted).

[0041] Furthermore, longitudinal portions of the core cables 71, 72 extend from the end of the inner sheath 73. The core cables 71, 72 extending from the end of the inner sheath 73 are covered with a heat-shrinkable tube 76. One longitudinal side of the heat-shrinkable tube 76 overlaps the core cables 71, 72, and the other longitudinal side of the heat-shrinkable tube 76 overlaps the inner sheath 73. In other words, the heat-shrinkable tube 76 spans the inner sheath 73 and the core cables 71, 72 extending from the inner sheath 73.

[0042] The heat shrinkable tube 76 overlaps the core cables 71 and 72 and the inner sheath 73 by 10 mm or more, respectively, and serves to improve the waterproofing of the WSS cable 70.

[0043] The connector 51 is provided at the end of the EPB cable 60 and the WSS cable 70 extending from the end of the outer sheath 80, and is connected to a connector 13 (FIG. 2) provided in the electric brake device 1. Specifically, the respective ends of the EPB cables 61, 62 and the core cables 71, 72 are connected to the connector 51.

[0044] More specifically, connection terminals crimped onto the ends of the center conductors 63 of the EPB cables 61, 62 are inserted into connection holes formed in the connector 51. Furthermore, connection terminals crimped onto the ends of the center conductors 74 of the core cables 71, 72 are inserted into connection holes formed in the connector 51. The ends of the respective center conductors 63, 74 are provided with waterproof plugs that are inserted into the connection holes together with the connection terminals.

[0045] The protective member 52 is made of resin and has a cylindrical shape, and is flexible. More specifically, the protective member 52 is a bellows-shaped tube (corrugated tube) in which a plurality of large diameter portions and small diameter portions are alternately formed. Examples of materials for the protective member 52 include polypropylene, flame-retardant polypropylene, polyamide, etc.

[0046] The protective member 52 is disposed between the outer sheath 80 and the connector 51, and covers a portion of the longitudinal direction of the EPB cable 60 and the WSS cable 70 extending from the outer sheath 80. In other words, the exposed portions of the EPB cable 60 and the WSS cable 70 extending from the outer sheath 80 are inserted into the protective member 52, which is shorter than the exposed portions.

[0047] Focusing on the WSS cable 70, a portion of the heat-shrinkable tube 76 and substantially all of the core cables 71, 72 extending from the heat-shrinkable tube 76 are covered by the protective member 52. As a result, the core cables 71, 72 are protected from chipping and the like. Not only the core cables 71, 72 but also the EPB cable 60 are protected by the protective member 52, but the core cables 71, 72, which are thinner than the EPB cable 60, are in particular in need of protection.

[0048] From the viewpoint of adequately protecting the core cables 71, 72, it is preferable that the length of the protective member 52 be 10 mm or more. However, the length of the protective member 52 can be changed as appropriate depending on the length of the core cables 71, 72 extending from the heat-shrinkable tube 76, etc. Also, the protective member 52 may be extended to a length that can cover all of the exposed portions of the WSS cable 70, including the inner sheath 73. In this case, the entire exposed portion of the EPB cable 60 is also covered by the protective member 52.

[0049] A small gap 53 is provided between the protective member 52 and the connector 51. This allows the connector 51 to swivel, making it easier to align the connector 51 with the connector 13. From the perspective of protecting the core cables 71 and 72, it is preferable that the gap 53 be 10 mm or less. Alternatively, to prioritize protection of the core cables 71 and 72, the gap 53 may be eliminated. In other words, the protective member 52 may be butted against the connector 51.

[0050] (adhesive tape) 3, at least the area from the end of the outer sheath 80 to the end of the connector 51 is covered with adhesive tape 90. More specifically, the area including the end of the outer sheath 80, the exposed portions of the EPB cable 60 and the WSS cable 70, the heat shrink tube 76, the protective member 52, and the end of the connector 51 is covered with adhesive tape 90. In the following description, the area covered with adhesive tape 90 may be referred to as the "covered area."

[0051] From another perspective, the adhesive tape 90 fixes and binds together the outer sheath 80, the exposed portions of the EPB cable 60 and the WSS cable 70, the heat shrink tube 76, the protective member 52, and the connector 51.

[0052] 4 and 5, the adhesive tape 90 has a sheet-like substrate 91 and an adhesive layer 92 formed on one surface of the substrate 91. From another perspective, the adhesive layer 92 forms the inner surface of the adhesive tape 90, and the substrate 91 forms the outer surface of the adhesive tape 90. The substrate 91 is made of a resin material such as polyester or polypropylene, and has tensile elasticity.

[0053] Here, for convenience of explanation, the circumferential direction of the protective member 52 is defined as the width direction of the adhesive tape 90, and the axial direction of the protective member 52 is defined as the length direction of the adhesive tape 90. According to these definitions, the length (L1) shown in Fig. 3 is approximately 10 mm, and the length (L2) is approximately 5 mm.

[0054] The length (L1) shown in Fig. 3 is the length of the portion of the adhesive tape 90 that covers the end of the outer sheath 80. The length (L2) shown in Fig. 3 is the length of the portion of the adhesive tape 90 that covers the end of the connector 51.

[0055] However, the lengths (L1) and (L2) can be increased or decreased as appropriate. On the other hand, in order to bond the adhesive tape 90 to the outer sheath 80 with necessary and sufficient strength, it is preferable that the length (L1) be 10 mm or more. Similarly, in order to bond the adhesive tape 90 to the connector 51 with necessary and sufficient strength, it is preferable that the length (L2) be 5 mm or more.

[0056] The total length (L) of the adhesive tape 90 shown in Fig. 3 is approximately 600 mm. The total width of the adhesive tape 90 is greater (wider) than the maximum perimeter of the covering area. Specifically, the total width of the adhesive tape 90 is approximately 300 mm. However, the total length (L) and total width of the adhesive tape 90 can be increased or decreased as appropriate depending on the size of the covering area.

[0057] 4 and 5, the adhesive tape 90 covers the covering region with the adhesive layer 92 facing inward. More specifically, the adhesive tape 90 covers the covering region so as to enclose it from both sides in the circumferential direction of the protective member 52.

[0058] Furthermore, a first end 93 at one end in the width direction of the adhesive tape 90 and a second end 94 at the other end in the width direction of the adhesive tape 90 are bonded to each other. More specifically, the adhesive layer 92 formed at the first end 93 and the adhesive layer 92 formed at the second end 94 are bonded to each other.

[0059] In order to bond the first end 93 and the second end 94 with sufficient strength, it is preferable that the overlap width (W) between them is 10 mm or more. Therefore, in this embodiment, the overall width of the adhesive tape 90 is set so that an overlap width (W) of 10 mm or more is ensured over the entire length of the covering region.

[0060] If a part of the adhesive layer 92 formed on the first end 93 or the second end 94 protrudes, dirt, dust, etc. will adhere to the protruding portion. Therefore, when joining the first end 93 and the second end 94, it is preferable to limit the protruding width of the adhesive layer 92 to 10 mm or less.

[0061] As described above, the adhesive tape 90 covers the end of the outer sheath 80, the exposed portions of the EPB cable 60 and the WSS cable 70, the heat shrink tube 76, the protective member 52, and the end of the connector 51. Therefore, the inner surface (adhesive layer 92) of the adhesive tape 90 is in contact with these.

[0062] However, the contact state between the adhesive layer 92 of the adhesive tape 90 and the member covered by the adhesive tape 90 is not uniform throughout the entire covered area. For example, as shown in Fig. 4, the adhesive layer 92 is in contact with the entire periphery of the protective member 52. On the other hand, as shown in Fig. 5, the adhesive layer 92 is in contact with only part of the outer periphery of the EPB cable 60 and the heat-shrinkable tube 76.

[0063] Furthermore, the adhesive layer 92 is in contact with the large diameter portion but not with the small diameter portion of the protective member 52. Also, as shown in Fig. 3, the adhesive tape 90 covers the core cables 71 and 72 passing through the gap 53 but is not in contact with these core cables 71 and 72.

[0064] In the wire harness 50 of this embodiment, the area from the end of the outer sheath 80 to the end of the connector 51 is covered with a single strip-shaped adhesive tape 90. Furthermore, the adhesive tape 90 covers the above area so as to enclose both sides of the protective member 52 in the circumferential direction. In other words, the manufacturing process of the wire harness 50 does not include a process of spirally winding adhesive tape around the EPB cable 60, the WSS cable 70, the protective member 52, etc. to protect and fix them. As a result, the quality of the wire harness 50 is stable and production efficiency is improved.

[0065] From another perspective, the task of applying a single piece of adhesive tape 90 to the covered area so as to enclose the covered area from both circumferential sides of the protective member 52 is extremely easy. Therefore, there is little possibility that the finish will differ depending on the skill level of the worker. Furthermore, the time required for this task is extremely short compared to the time required for spirally winding a continuous piece of adhesive tape around the covered area.

[0066] The joining mode between the first end 93 and the second end 94 of the adhesive tape 90 is not limited to the mode shown in Figures 4 and 5. Therefore, other joining modes between the first end 93 and the second end 94 will be described. In the following description, unless otherwise specified, "the outer surface of the adhesive tape 90" means the outer surface of the adhesive tape 90 excluding the first end 93 and the second end 94.

[0067] (Jointing mode 1) 6A and 6B, the first end 93 and the second end 94 joined to each other are folded to one circumferential side (the right side of the drawing) of the protective member 52. Furthermore, the adhesive layer 92 formed on the first end 93 extends over the second end 94 and is joined to the outer surface of the adhesive tape 90.

[0068] Viewed from another perspective, a portion of the first end 93 is overlapped on top of the folded second end 94, and another portion of the first end 93 extends beyond the folded second end 94 and protrudes from the second end 94.

[0069] Furthermore, the adhesive layer 92 formed on a portion (overlapping portion 93a) of the first end portion 93 overlapping the second end portion 94 is bonded to the adhesive layer 92 formed on the second end portion 94. Meanwhile, the adhesive layer 92 formed on another portion (protruding portion 93b) of the first end portion 93 protruding from the second end portion 94 is bonded to the outer surface of the adhesive tape 90. In order to bond the protruding portion 93b to the outer surface of the adhesive tape 90 with sufficient strength, it is preferable that the width of the protruding portion 93b be 10 mm or more. From another perspective, it is preferable that the height difference (H) between the first end portion 93 and the second end portion 94 shown in FIG. 6A be 10 mm or more.

[0070] It should be noted that the outer surface of the second end 94 shown in FIG. 6B is in contact with the outer surface of the adhesive tape 90 but is not joined thereto.

[0071] 6A and 6B, the first end 93 is joined to two different locations (the second end 94 and the outer surface of the adhesive tape 90), which makes the adhesive tape 90 less likely to peel off or come off.

[0072] 6A and 6B, a gap 95 may be formed between the protruding portion 93b of the first end portion 93 and the outer surface of the adhesive tape 90. The size of this gap 95 can be increased or decreased by changing the width of the protruding portion 93b. From another perspective, the gap 95 can be increased or decreased by changing the height difference (H) between the first end portion 93 and the second end portion 94 shown in FIG. 6A.

[0073] By enlarging the gap 95, it is possible to make the outer shape of the adhesive tape 90 uniform. For example, the outer shape of the adhesive tape 90 can be made closer to a circle than the roughly triangular shape shown in FIG.

[0074] The first end 93 and the second end 94 may be reversed. Specifically, the width of the second end 94 shown in FIG. 6A may be wider than the width of the first end 93 (the height of the second end 94 shown in FIG. 6A may be higher than the height of the first end 93). In this case, the first end 93 and the second end 94 joined to each other are folded toward the other circumferential side of the protective member 52 (to the left side of the drawing). Furthermore, the adhesive layer 92 formed on the second end 94 is joined to the outer surface of the adhesive tape 90 at the tip of the first end 93.

[0075] (Jointing mode 2) 7A and 7B, adhesive layer 92 formed on first end portion 93 is overlaid on second end portion 94 and bonded to the outer surface of second end portion 94. In order to bond first end portion 93 and second end portion 94 with sufficient strength, it is preferable that first end portion 93 overlaps second end portion 94 by 10 mm or more.

[0076] The first end 93 and the second end 94 may be reversed. Specifically, the adhesive layer 92 formed on the second end 94 may be placed on the first end 93 and bonded to the outer surface of the first end 93.

[0077] 6A and 6B and the bonding modes shown in Figures 7A and 7B suppress protrusion of the first end 93 and the second end 94 compared to the bonding modes shown in Figures 4 and 5. In addition, the flexibility of the covered area including the adhesive tape 90 is improved.

[0078] The present invention is not limited to the above-described embodiment, and various modifications are possible without departing from the spirit and scope of the present invention. For example, the wire harness of the present invention can be connected to an electric brake device that does not have a parking brake function, or can be connected to devices or equipment other than an electric brake device.

[0079] The protective member 52 can be replaced with a protective member having a structure other than the bellows structure. The EPB cable 60 and the WSS cable 70 can be replaced with other cables (electric wires) having different structures, uses, etc. Furthermore, other cables (electric wires) having different structures, uses, etc. from the EPB cable 60 and the WSS cable 70 can also be added. [Explanation of symbols]

[0080] 1...electric brake device, 10...vehicle body, 11...wheel, 11a...wheel, 11b...tire, 12...controller, 13...connector, 20...suspension device, 21...upper arm, 22...lower arm, 23...shock absorber, 24...suspension spring, 25...knuckle, 26a...first mounting portion, 26b...second mounting portion, 26c...third mounting portion, 27...hub unit, 27a...flange, 28...disc rotor, 29a, 29b...brake pad, 30...housing, 31...electric motor, 32...reduction mechanism, 33...thrust generating mechanism, 33a, 33b...output member, 34...caliper, 34a...inner support portion, 34b...outer support portion, 34c... Coupling portion, 35...shaft, 36...wheel speed sensor, 40...parking brake mechanism, 41, 42...engaging member, 43...solenoid actuator, 43a...electromagnetic coil, 50...wire harness, 51...connector, 52...protective member, 53...gap, 60, 61, 62...electric wire (EPB cable), 63...center conductor, 64...insulator, 70...electric wire (WSS cable), 71, 72...core cable, 73...sheath (inner sheath), 74...center conductor, 75...insulator, 76...heat shrinkable tube, 80...sheath (outer sheath), 90...adhesive tape, 91...base material, 92...adhesive layer, 93...first end, 93a...overlapping portion, 93b...protruding portion, 94...second end, 95...gap

Claims

1. A method for producing a wire harness including a plurality of electric wires, a sheath that collectively covers the plurality of electric wires, and connectors provided at ends of the plurality of electric wires extending from the sheath, at least, a step of covering only the plurality of electric wires extending from the sheath between the sheath and the connector with a protective member; covering the end of the sheath, the end of the connector, and the plurality of electric wires with adhesive tape so as to wrap around both sides of the protective member in a circumferential direction; A method for producing a wire harness, comprising:

2. When the circumferential direction of the protective member is the width direction of the adhesive tape, a first end portion on one end side in the width direction of the adhesive tape and a second end portion on the other end side in the width direction of the adhesive tape are joined together; A method for producing the wire harness according to claim 1.

3. The adhesive tape has a sheet-like substrate and an adhesive layer formed on one surface of the substrate, The adhesive layer formed on the first end portion and the adhesive layer formed on the second end portion are bonded to each other. A method for producing the wire harness according to claim 2.

4. the first end portion and the second end portion are bent toward one side in a circumferential direction of the protection member, the adhesive layer formed on the first end portion extends over the second end portion and is bonded to the outer surface of the adhesive tape; A method for producing the wire harness according to claim 3.

5. The adhesive tape has a sheet-like substrate and an adhesive layer formed on one surface of the substrate, The adhesive layer formed on the first end portion is superimposed on the second end portion and bonded to an outer surface of the second end portion. A method for producing the wire harness according to claim 2.

6. When the axial direction of the protective member is the length direction of the adhesive tape, The length of the portion of the adhesive tape covering the sheath is 10 mm or more, The length of the portion of the adhesive tape covering the connector is 5 mm or more. A method for producing the wire harness according to any one of claims 1 to 5.

7. The plurality of electric wires include a power cable that supplies power to the electric brake device and a signal cable that transmits a signal output from a wheel speed sensor. A method for producing the wire harness according to any one of claims 1 to 6.

8. The protective member is a corrugated tube made of resin. A method for producing the wire harness according to any one of claims 1 to 6.

Images