Wire harness

Abstract

This wire harness provides a simple structure that allows for the positioning of ferrules. [Solution] The wire harness 1 comprises a wire 2 having a braid 9 and a ferrule 14 used for ending the braid 9. The end of the braid 9 is fixed with a fixing member such as a metal tie band, with the ferrule 14 underneath. The ferrule 14 has an insertion portion 16 that is inserted between the braid 9 covered by the sheath 10 and the outer surface of the insulating coating 8 to position it relative to the wire 2 before being fixed with a fixing member such as a metal tie band.

Description

Technical Field

[0001] The present disclosure relates to a wire harness.

Background Art

[0002] Conventionally, as disclosed in Patent Document 1, a shielded electric wire is well known which includes a core portion having a conductor wire covered with insulation, a braided wire arranged on the outer periphery of the core portion, and a sheath covering the outer periphery of the braided wire. In this shielded electric wire, an inner ferrule is attached to the outer periphery of the braid folded back to the side opposite to the distal end of the electric wire. The distal end of the braided wire is further folded back so as to cover the outer periphery of the inner ferrule, and an outer ferrule is attached to the outer periphery of this folded portion. The inner ferrule and the outer ferrule are crimped in a state where the braided wire is sandwiched therebetween.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of Invention

Problems to be Solved by the Invention

[0004] Incidentally, when the inner ferrule is fitted to the outer periphery of the core portion of the electric wire, it is only arranged on the outer periphery of the braided wire. For this reason, for example, when crimping the outer ferrule, the inner ferrule may be displaced relative to the core portion of the electric wire, specifically the braided wire. As a measure against this displacement, for example, it is conceivable to crimp the inner ferrule to the core portion in advance. However, if this measure is adopted, a dedicated tool is required, and there is a concern that the workability of assembling the shielded electric wire will deteriorate.

[0005] An object of the present disclosure is to provide a wire harness that can position a ferrule with a simple structure.

Means for Solving the Problems

[0006] A wire harness that solves the above problem comprises an electric wire having a core wire, an insulating coating that houses the core wire, a braid covering the insulating coating, and a sheath covering the braid, and a cylindrical ferrule disposed between the end of the braid and the insulating coating, wherein the end of the braid is fixed by a fixing member with the ferrule underneath, and the ferrule has an insertion portion that is inserted between the outer surface of the braid covered by the sheath and the insulating coating before being fixed by the fixing member to position it relative to the electric wire. [Effects of the Invention]

[0007] This disclosure enables the positioning of a ferrule with a simple structure. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view showing the external appearance of a wire harness according to one embodiment. [Figure 2] Figure 2 is a cross-sectional view taken along line II-II shown in Figure 6. [Figure 3] Figure 3 is a cross-sectional view of the wire harness. [Figure 4] Figure 4 is a perspective view of the ferrule from the base end. [Figure 5] Figure 5 is a perspective view of the ferrule from the tip side at an oblique angle. [Figure 6] Figure 6 is a perspective view of a wire with a ferrule attached. [Figure 7] Figure 7 is a side view of the ferrule. [Figure 8] Figures 8(a) to 8(c) are step diagrams showing the process of engaging the ferrule with the braid. [Modes for carrying out the invention]

[0009] First, the embodiments of this disclosure will be listed and described. [1] The wire harness of the present disclosure comprises a wire having a core wire, an insulating coating housing the core wire, a braid covering the insulating coating, and a sheath covering the braid, and a cylindrical ferrule disposed between the end of the braid and the insulating coating, wherein the end of the braid is fixed by a fixing member with the ferrule underneath, and the ferrule has an insertion portion that is inserted between the outer surface of the braid covered by the sheath and the insulating coating before being fixed by the fixing member to position it relative to the wire.

[0010] In this configuration, the insertion portion formed on the ferrule is inserted into the gap between the insulation coating and the braid of the electric wire. The press-fitting load applied from the sheath covering the braid positions the ferrule relative to the electric wire. Therefore, when other components are assembled after the ferrule is attached to the electric wire, the ferrule is less likely to shift position. Consequently, the assembly workability of the wire harness is improved. Furthermore, the ferrule positioning structure is simply a matter of forming an insertion portion on the ferrule and inserting this insertion portion between the insulation coating and the braid. Thus, it is possible to position the ferrule with a simple structure.

[0011] [2] In the above [1], the insertion portion is formed in a cylindrical shape. With this configuration, it is possible to widen the range over which the press-fitting load from the sheath is applied in the insertion portion of the ferrule in the circumferential direction of the ferrule, thereby making it even less likely for the ferrule to shift position.

[0012] [3] In the above [1] or [2], the ferrule has a base end that is larger in diameter than the insertion portion and is formed continuously with the insertion portion, and a wall portion located at the boundary between the insertion portion and the base end portion, and is positioned relative to the electric wire with the wall portion positioned close to the end of the sheath. With this configuration, the axial position of the ferrule relative to the electric wire is such that the wall portion of the ferrule is closest to the end of the sheath. Therefore, when aligning the ferrule axially with respect to the electric wire, it is only necessary to move the ferrule linearly until the wall portion of the ferrule can no longer move at the end of the sheath, making it possible to easily position the ferrule. In addition, the ferrule positioned in this position is less likely to shift position because the insertion portion receives a press-fit load from the sheath.

[0013] [4] In the above [3], the wall portion is formed in a tapered shape that narrows from the base end towards the insertion portion. With this configuration, when inserting the insertion portion of the ferrule into the gap between the insulating coating and the braid, the tip of the braid is guided by the tapered wall portion and smoothly reaches the base end of the ferrule. This further contributes to improving the workability of assembling the wire harness.

[0014] [5] In the above [3] or [4], the corner of the wall portion located at the boundary with the base portion is formed in a curved shape. With this configuration, when inserting the insertion portion of the ferrule into the gap between the insulating coating and the braid, the tip of the braid is less likely to be damaged by the corner as it passes through the corner of the wall portion.

[0015] [6] In any of the above [3] to [5], the axial length of the insertion portion is set to a value within the range of 2 to 3 times the axial length of the base portion. With this configuration, it is possible to widen the range in the axial direction of the ferrule over which the press-fitting load from the sheath is applied in the insertion portion of the ferrule, thereby making it even less likely for the ferrule to shift position.

[0016] [Details of the embodiments of this disclosure] Hereinafter, specific examples of the present disclosure will be described with reference to the drawings. The present disclosure is not limited to these illustrative examples, but is defined by the scope of the claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of the claims. In each drawing, for convenience of description, part of the configuration may be shown exaggerated or simplified. In addition, the dimensional ratio of each part may also differ from the actual one.

[0017] (Wire harness 1) As shown in Figure 1, the wire harness 1 includes an electric wire 2 that electrically connects devices to each other, and a connector 3 attached to the tip of the electric wire 2. A pair of the electric wires 2 are provided, one being a positive line and the other being a negative line. At the tip of the electric wire 2, a protective member 4 covering the periphery of the electric wire 2 at a portion connected to the connector 3 is attached. The protective member 4 is, for example, a rubber boot.

[0018] The connector 3 is connected to a mating connector 5 provided on the mounting counterpart of the wire harness 1. When the wire harness 1 is used in a vehicle, the mounting counterpart of the wire harness 1 is, for example, the vehicle body. At least a part of the wire harness 1 is arranged outside the vehicle.

[0019] The wire harness 1 electrically connects, for example, two or more in-vehicle devices. Examples of the in-vehicle device include a high-voltage battery, an inverter, a motor, and an electrical connection box. Examples of the electrical connection box include a relay box, a fuse box, a junction box, and the like. In this example, the wire harness 1 electrically connects the inverter and the battery.

[0020] (Electric wire 2) As shown in Figure 2, the electric wire 2 includes a conductive core wire 7 and an insulation coating 8 that accommodates the core wire 7. The insulation coating 8 covers the entire outer peripheral surface of the core wire 7 in the circumferential direction. The insulation coating 8 is made of, for example, an insulating resin material. A terminal (not shown) that is electrically connected to the mating connector 5 is attached and fixed to the tip of the core wire 7 in the electric wire 2.

[0021] The electric wire 2 has a braid 9 covering the insulating coating 8 and a sheath 10 covering the outer surface of the braid 9. Thus, the electric wire 2 in this example is a shielded electric wire having a core wire 7, insulating coating 8, braid 9, and sheath 10 arranged radially outward from the center. The braid 9 is formed, for example, by weaving a plurality of metal strands into a tubular shape. The material used for the braid 9 is, for example, a metal material such as copper or aluminum. The sheath 10 is, for example, a resin covering material that protects the area around the braid 9.

[0022] (Connector 3) As shown in Figure 3, the connector 3 has connecting parts 12 for fitting the ends of the electric wires 2. One end of the electric wire 2 is connected to one of the pair of connecting parts 12, and the other end of the electric wire 2 is connected to the other of the pair of connecting parts 12. The connector 3 is fitted into the protective member 4 such that a portion of it, including the connecting parts 12, is housed inside the protective member 4.

[0023] (Ferrule 14) As shown in Figures 4 and 5, the wire harness 1 includes a ferrule 14 used for ending the braided section 9. The ferrule 14 is, for example, formed in a substantially cylindrical shape and made of metal such as copper. The ferrule 14 is attached to the wire 2 so that the core wire 7 and the insulating sheath 8 are inserted into the hole 15.

[0024] As shown in Figures 2 and 6, the ferrule 14 has an insertion portion 16 inserted between the insulating coating 8 and the braid 9, a base portion 17 exposed from the sheath 10, and a wall portion 18 located at the boundary between the insertion portion 16 and the base portion 17. Thus, the ferrule 14 in this example is formed with a shape that changes in diameter midway along the axial direction. The base portion 17 has a larger diameter than the insertion portion 16 and is formed continuously with the insertion portion 16. Both the insertion portion 16 and the base portion 17 are formed in a cylindrical shape and are arranged concentrically.

[0025] As shown in Figure 2, the base end 17 of the ferrule 14 is positioned between the end of the braid 9 and the insulating sheath 8. The ferrule 14 is positioned in the axial direction of the ferrule 14 (the X-axis direction in Figure 2) where the wall portion 18 is closest to the end of the sheath 10. In other words, by positioning the ferrule 14 close to the end of the sheath 10, it is positioned near the end of the sheath 10.

[0026] (End treatment of braid 9) As shown in Figure 3, the ends of the braid 9 are fixed to the ferrule 14 using a fixing member 20. The fixing member 20 is, for example, a metal tie band, which is a type of fastening member. The ends of the braid 9 are fixed to the base end 17 of the ferrule 14 via the fixing member 20 attached to the outer surface. In this example, the ends of the braid 9 are fixed to the base end 17 of the ferrule 14 by crimping the fixing member 20.

[0027] A bundled braid 21 is attached to the braided 9, which electrically connects the pair of braided 9 to the GND terminal of the mating connector 5. The bundled braid 21 has a shape in which multiple metal strands are woven together, and electrically connects both of the pair of braided 9 to the GND terminal of the mating connector 5. In this example, the bundled braid 21 is formed in a cylindrical shape with a length extending from the pair of braided 9 to the mating connector 5.

[0028] The metal tie band, acting as the fixing member 20, is secured to the ferrule 14 by passing its end through, for example, a hole (not shown) formed in the braided assembly 21 and fixing the end of the band to the fastening portion, thereby securing both the braided assembly 9 and the braided assembly 21 together. In other words, the metal tie band acting as the fixing member 20 secures both the braided assembly 9 and the braided assembly 21 to the ferrule 14. Any excess portion of the braided assembly 21 that remains after the fixing member 20 is attached is folded back to the opposite side and stored therein.

[0029] (Positioning of ferrule 14) As shown in Figures 2 and 6, the insertion portion 16 of the ferrule 14 is inserted between the braided 9 covered by the sheath 10 and the outer surface of the insulating coating 8 to position it relative to the electric wire 2 before it is fixed by the fixing member 20. In this example, the ferrule 14 is positioned relative to the electric wire 2 by the press-fitting load applied from the sheath 10, by inserting the insertion portion 16 into the small gap between the insulating coating 8 and the braided 9. As shown in Figure 2, the ferrule 14 is positioned relative to the electric wire 2 with the wall portion 18 positioned close to the end of the sheath 10.

[0030] As shown in Figure 7, the axial length L1 of the insertion portion 16 (in the X-axis direction in Figure 7) is set to a value within the range of 2 to 3 times the axial length L2 of the base portion 17 (in the X-axis direction in Figure 7). In this way, the axial length L1 of the insertion portion 16 of the ferrule 14 is formed to be longer than the axial length L2 of the base portion 17 of the ferrule 14 in order to widen the range of press-fitting load applied from the sheath 10 to the insertion portion 16.

[0031] (Wall part 18) As shown in Figure 7, the wall portion 18 is formed in a tapered shape that narrows from the base end portion 17 towards the insertion portion 16. The wall portion 18 is formed along the entire circumference centered on the axis of the ferrule 14. The corner portion 23 located at the boundary with the base end portion 17 of the wall portion 18 is formed in a curved shape. Furthermore, a guide portion 24 is formed at the tip of the insertion portion 16 to guide the tip of the braid 9 to ride up when the ferrule 14 is inserted. The guide portion 24 is formed by making the outer circumference of the tip of the insertion portion 16 curved.

[0032] [Effect of the Embodiment] Next, the operation of the wire harness 1 of this embodiment will be described. As shown in Figure 8(a), when positioning and fixing the ferrule 14 to the electric wire 2, first, the tip of the insertion portion 16 of the ferrule 14, which has a hole 15 on the outer surface of the insulating coating 8 of the electric wire 2, is inserted into the gap between the end of the braid 9 and the insulating coating 8. Then, the insertion into this gap is continued by pushing the ferrule 14 in a straight line direction along the axis of the electric wire 2 (in the direction of the arrow in the figure). In this example, since a curved guide portion 24 is formed at the tip of the insertion portion 16, the tip of the insertion portion 16 is smoothly inserted into the gap between the end of the braid 9 and the insulating coating 8.

[0033] As shown in Figure 8(b), when the tip of the insertion portion 16 reaches the inside of the end of the sheath 10, the end of the insertion portion 16 begins to be inserted between the double layer of the braid 9 and the sheath 10 and the insulating coating 8. At this time, the tip of the insertion portion 16 is inserted into the small gap between the braid 9, which is receiving a press-fit load from the sheath 10, and the insulating coating 8. Therefore, the insertion of the insertion portion 16 continues while a strong insertion load is applied to the ferrule 14. In this way, the insertion portion 16 of the ferrule 14 is inserted into the small gap between the braid 9, which is covered by the sheath 10, and the insulating coating 8.

[0034] As shown in Figure 8(c), when the tip of the braid 9 reaches the wall portion 18 during the insertion process of the ferrule 14, the tip of the braid 9 is guided by the tapered wall portion 18, causing it to expand in diameter and move closer to the outer surface of the base end portion 17 of the ferrule 14. The insertion of the ferrule 14 is then continued until the wall portion 18 of the ferrule 14 is restricted from moving by the end of the sheath 10, and the base end portion 17 of the ferrule 14 is positioned closest to the sheath 10 (the state in Figure 2). In this way, the ferrule 14 is aligned with respect to the electric wire 2.

[0035] (Prevents misalignment of ferrule 14) In this example, the insertion portion 16 of the ferrule 14 is inserted between the portion of the braid 9 covered by the sheath 10 and the outer surface of the insulating coating 8, so that the ferrule 14 is positioned relative to the electric wire 2 by the press-fitting load received from the sheath 10. Therefore, when fixing the end of the braid 9 by crimping the fixing member 20 with the ferrule 14 as a base, the ferrule 14 is less likely to shift position. Thus, it is possible to improve the assembly workability of the wire harness 1. In this way, the ferrule 14 can be positioned by a simple structure in which the insertion portion 16 of the ferrule 14 is inserted between the insulating coating 8 and the braid 9.

[0036] [Effects of the Embodiment] According to the wire harness 1 of the above embodiment, the following effects can be obtained. (1) The wire harness 1 comprises a wire 2 having a braid 9 and a ferrule 14 used for ending the braid 9. The end of the braid 9 is fixed by a fixing member 20 with the ferrule 14 underneath. The ferrule 14 has an insertion portion 16 that is inserted between the braid 9 covered by the sheath 10 and the outer surface of the insulating coating 8 to position it relative to the wire 2 before being fixed by the fixing member 20.

[0037] According to this configuration, by inserting the insertion portion 16 formed on the ferrule 14 into the gap between the insulating sheath 8 and the braid 9 of the electric wire 2, the ferrule 14 is positioned relative to the electric wire 2 by the press-fitting load applied from the sheath 10 covering the braid 9. Therefore, when other parts are assembled after the ferrule 14 is attached to the electric wire 2, the ferrule 14 is less likely to shift position. Consequently, the assembly workability of the wire harness 1 is improved. Furthermore, the positioning structure of the ferrule 14 is simply a structure in which the insertion portion 16 is formed on the ferrule 14 and this insertion portion 16 is inserted between the insulating sheath 8 and the braid 9. Thus, the ferrule 14 can be positioned with a simple structure.

[0038] (2) The insertion portion 16 is formed in a cylindrical shape. With this configuration, the range over which the press-fitting load from the sheath 10 is applied to the insertion portion 16 of the ferrule 14 can be widened in the circumferential direction of the ferrule 14, making it even less likely for the ferrule 14 to shift position.

[0039] (3) The ferrule 14 has a larger diameter than the insertion portion 16 and includes a base portion 17 formed continuously with the insertion portion 16, and a wall portion 18 located at the boundary between the insertion portion 16 and the base portion 17. The ferrule 14 is positioned relative to the electric wire 2 with the wall portion 18 positioned close to the end of the sheath 10. With this configuration, the axial position of the ferrule 14 relative to the electric wire 2 is such that the wall portion 18 of the ferrule 14 is closest to the end of the sheath 10. Therefore, when aligning the ferrule 14 axially with respect to the electric wire 2, it is only necessary to move the ferrule 14 linearly until the wall portion 18 of the ferrule 14 can no longer move at the end of the sheath 10, so the ferrule 14 can be easily positioned. In addition, the ferrule 14 positioned in this location is less likely to shift position because the insertion portion 16 receives a press-fit load from the sheath 10.

[0040] (4) The wall portion 18 is formed in a tapered shape that narrows from the base end portion 17 towards the insertion portion 16. With this configuration, when inserting the insertion portion 16 of the ferrule 14 into the gap between the insulating coating 8 and the braid 9, the tip of the braid 9 is guided by the tapered wall portion 18 and smoothly reaches the base end portion 17 of the ferrule 14. This further contributes to improving the workability of assembling the wire harness 1.

[0041] (5) The wall portion 18 has a curved corner portion 23 located at the boundary with the base portion 17. With this configuration, when inserting the insertion portion 16 of the ferrule 14 into the gap between the insulating coating 8 and the braid 9, the tip of the braid 9 is less likely to be damaged by the corner portion 23 as it passes through the corner portion 23 of the wall portion 18.

[0042] (6) The axial length L1 of the insertion portion 16 is set to a value within the range of 2 to 3 times the axial length L2 of the base portion 17. With this configuration, the range over which the press-fitting load from the sheath 10 is applied to the insertion portion 16 of the ferrule 14 can be widened in the axial direction of the ferrule 14, making it even less likely for the ferrule 14 to shift position.

[0043] [Other embodiments] This embodiment can be implemented with the following modifications. This embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0044] The shape of the base portion 17 may be changed to another shape, such as a mortar-shaped one. The diameter of the base portion 17 can be changed to a size other than that of the embodiment as appropriate. The insertion portion 16 may have a stepped shape in which the outer diameter changes midway along the axial direction, for example.

[0045] The outer circumferential surface of the insertion portion 16 may be formed in a tapered shape, for example, that narrows towards the tip. The length L1 of the insertion portion 16 may be the same as the length L2 of the base portion 17, or it may be shorter than the length L2 of the base portion 17.

[0046] The insertion portion 16 is not limited to a cylindrical shape; for example, it may have a shape in which multiple legs extend from the base portion 17. The wall portion 18 may have a recess into which the end of the sheath 10 engages together with the braid 9 when aligning with the electric wire 2.

[0047] The ferrule 14 is not limited to being positioned such that the wall portion 18 is located near the end of the sheath 10, but the wall portion 18 may be positioned away from the end of the sheath 10. The ferrule 14 may be a simple cylindrical member with the insertion portion 16 and the base portion 17 having the same diameter.

[0048] The fixing member 20 is not limited to metal tie bands or other fastening bands; any member capable of fixing the braid 9 is acceptable. Wire harness 1 may be used not only in vehicles, but also in products and devices other than vehicles.

[0049] This disclosure is described in accordance with the embodiments, but it is understood that this disclosure is not limited to such embodiments or structures. This disclosure also includes various modifications and variations within the scope of equivalence. In addition, various combinations and forms, as well as other combinations and forms that include only one, more, or less of those elements, fall within the scope and concept of this disclosure. [Explanation of symbols]

[0050] 1 Wire harness 2 electric wire 3 Connectors 4. Protective component 5. The other connector 7 core wires 8. Insulating coating 9 braid 10 sheaths 12 Connection part 14 ferrules 15 holes 16 Insertion part 17 Proximal end 18 Wall 20 Fixing member 21 Batch braiding 23 corners 24 Information Department L1 Length L2 Length

Claims

1. A wire having a core wire, an insulating covering that houses the core wire, a braid covering the insulating covering, and a sheath covering the braid, The braided end and the insulating coating are positioned between the ends of the braid and the insulating coating, The ends of the braided structure are wire harnesses fixed by fixing members with the ferrules as a base, The ferrule has an insertion portion that is inserted between the braided structure covered by the sheath and the outer surface of the insulating coating to position the wire before being fixed by the fixing member, the wire harness.

2. The wire harness according to claim 1, wherein the insertion portion is formed in a cylindrical shape.

3. The wire harness according to claim 1, wherein the ferrule has a larger diameter than the insertion portion and a base end formed continuously with the insertion portion, and a wall portion located at the boundary between the insertion portion and the base end, and is positioned relative to the electric wire with the wall portion positioned close to the end of the sheath.

4. The wire harness according to claim 3, wherein the wall portion is formed in a tapered shape that narrows from the base end to the insertion portion.

5. The wire harness according to claim 3, wherein the corner portion located at the boundary with the base end portion of the wall portion is formed in a curved shape.

6. The wire harness according to claim 3, wherein the axial length of the insertion portion is set to a value within the range of two to three times the axial length of the base portion.

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