Wire harness and method for manufacturing wire harness

Abstract

To make it possible to reduce costs.SOLUTION: A harness component 30 is provided including an electric wire group 10 including a plurality of electric wires 11, and a pair of sheet-shaped insulating exterior members 20 sandwiching and housing a protection target region 10a of the electric wire group 10 therein. The harness component 30 includes joint portions 31 in contact with each other between the pair of exterior members 20, and a weld 32 having both ends, which are free ends, where the joint portion 31 are welded to each other along an axial direction of the protection target region 10a between the joint portions 31 in contact with each other.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a wire harness and a method for manufacturing the wire harness. [Background technology]

[0002] In a wire harness, the electric wires are protected by an exterior member. The exterior member may be, for example, a sheet wrapped around the electric wires or a cylindrical member such as a corrugated tube that houses the electric wires. The sheet is fixed to the electric wires using an adhesive member such as double-sided tape provided on the inside of the wrapping (see, for example, Patent Document 1 listed below). The cylindrical member is fixed by wrapping adhesive tape around both ends of the cylindrical member and the electric wires. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 7-105756 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional wire harnesses require adhesive members and adhesive tapes for fixing as components in addition to the exterior member. Furthermore, when a tubular member is used as the exterior member of a conventional wire harness, a process of winding the adhesive tape for fixing is also required. Therefore, the adhesive members and adhesive tapes for fixing are one of the factors that increase the cost of conventional wire harnesses.

[0005] Therefore, an object of the present invention is to provide a wire harness and a method for manufacturing the wire harness that can reduce costs. [Means for solving the problem]

[0006] A wire harness according to the present invention includes a harness component including an electric wire group having a plurality of electric wires and a pair of insulating sheet-like exterior members that sandwich and accommodate a portion of the electric wire group to be protected, and the harness component includes a joint portion that contacts the pair of exterior members, and a weld portion where the joint portions are welded to each other along the axial direction of the portion to be protected, and both ends of the joint portion are free ends. The harness components are integrated by welding the joints between the respective pairs of exterior members. It is characterized by the following.

[0007] The wire harness according to the present invention is a harness component including an electric wire group having a plurality of electric wires, and a sheet-like insulating exterior member that is folded back and accommodates portions of the electric wire group to be protected inside the folded back member. multiple The harness component includes a joint portion that contacts the folded end of the exterior member, and a welded portion where the joint portions are welded to each other along the axial direction of the portion to be protected, and both ends of the joint portion are free ends. The harness components are integrated by welding the joints between the exterior members. It is characterized by the following.

[0008] Further, a wire harness according to the present invention includes a plurality of harness components each including an electric wire group having a plurality of electric wires and a sheet-like insulating exterior member that houses a portion of the electric wire group to be protected therein, and the harness components include at least a first harness component that includes a first electric wire group as the electric wire group and a pair of first exterior members that sandwich the portion of the first electric wire group to be protected and house it therein, and a second harness component that includes a second electric wire group as the electric wire group and a second exterior member that is folded back and houses the portion of the second electric wire group to be protected therein. The first harness component has a joint that joins the pair of first exterior members and a welded portion with free ends at both ends where the joints are welded together along the axial direction of the portion to be protected of the first group of electric wires between the joining joints, and the second harness component has a joint that joins the pair of first exterior members at an end where the second exterior member is folded back and a welded portion with free ends at both ends where the joints are welded together along the axial direction of the portion to be protected of the second group of electric wires between the joining joints, and the multiple harness components are integrated by welding the joints together between the respective exterior members. Furthermore, a wire harness according to the present invention includes a harness component including an electric wire group having a plurality of electric wires, and a pair of insulating sheet-like exterior members that sandwich and accommodate a portion of the electric wire group to be protected, and the harness component has a joint portion where the pair of exterior members abut each other, and a weld portion with free ends at both ends where the joint portions are welded together along the axial direction of the portion to be protected between the abutting joint portions, and in the harness component, one end side and the other end side of the pair of exterior members that abut each other across the portion to be protected serve as the joint portion, and one of the pair of exterior members is formed in a flat sheet shape from a material harder than the other exterior member, and the one exterior member has a bent portion between the one end side and the other end side that forms an accommodation space for the portion to be protected between the one exterior member and the other exterior member.

[0009] A method for manufacturing a wire harness according to the present invention includes a first installation step of placing one sheet-like insulating exterior member on an installation surface of a first mold; a second installation step of placing a portion to be protected of a group of electric wires including a plurality of electric wires on the one exterior member; a third installation step of placing the other sheet-like insulating exterior member on the one exterior member and the portion to be protected and sandwiching the portion to be protected between the one exterior member and the other exterior member; a fourth installation step of sandwiching one end side and the other end side of the one exterior member and the other exterior member, as viewed from the portion to be protected, between the first mold and the second mold, respectively; and a welding step of welding the one end side and the other end side of the one exterior member and the other exterior member along the axial direction of the portion to be protected.

[0010] Furthermore, a method for manufacturing a wire harness according to the present invention is characterized by comprising: a first placing step of bending a sheet-like insulating exterior member into a V-shaped or U-shaped groove portion of a jig so that the bent member conforms to the shape of the groove portion and placing the bent member; a second placing step of placing a portion to be protected of a group of electric wires including a plurality of electric wires in the bent shape of the exterior member; a third placing step of sandwiching, between a first mold and a second mold, end portions of the exterior member folded back around the portion to be protected as an axis; and a welding step of welding the end portions of the exterior member together along the axial direction of the portion to be protected. [Effects of the Invention]

[0011] The wire harness according to the present invention and the wire harness produced by the manufacturing method according to the present invention do not require an adhesive member or adhesive tape for fixing an exterior member as in conventional wire harnesses, and therefore cost reduction can be achieved. Furthermore, this wire harness does not require the work step of winding the adhesive tape, which can also reduce cost. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a plan view showing a wire harness according to an embodiment. [Figure 2] FIG. 2 is a plan view showing a modified example of the wire harness of the embodiment. [Figure 3] FIG. 3 is an exploded perspective view showing the wire harness of the embodiment. [Figure 4] FIG. 4 is an exploded perspective view showing a modified example of the wire harness of the embodiment. [Figure 5] FIG. 5 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the embodiment. [Figure 6] FIG. 6 is a plan view illustrating how to handle the excess portion of the wire harness according to the embodiment. [Figure 7] FIG. 7 is a plan view illustrating how to handle an excess portion of a modified example of the wire harness of the embodiment. [Figure 8]FIG. 8 is a plan view illustrating an auxiliary welded portion of a modified example of the wire harness of the embodiment. [Figure 9] FIG. 9 is a plan view showing a wire harness according to an embodiment provided with a clamp. [Figure 10] FIG. 10 is a plan view showing a modified example of the wire harness of the embodiment provided with a clamp. [Figure 11] FIG. 11 is a perspective view illustrating the clamp. [Figure 12] FIG. 12 is a plan view showing a modified example of the wire harness of the embodiment. [Figure 13] FIG. 13 is a plan view showing a modified example of the wire harness of the embodiment. [Figure 14] FIG. 14 is a plan view showing a modified example of the wire harness of the embodiment. [Figure 15] FIG. 15 is a plan view illustrating a through hole used in a manufacturing process of a modified example of the wire harness of the embodiment. [Figure 16] FIG. 16 is a plan view illustrating a through hole used in a manufacturing process of a modified example of the wire harness of the embodiment. [Figure 17] FIG. 17 is a plan view illustrating another mode of use of the exterior member. [Figure 18] FIG. 18 is a perspective view showing a wire harness according to the first modification. [Figure 19] FIG. 19 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the first modification. [Figure 20] FIG. 20 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the first modification. [Figure 21] FIG. 21 is a plan view showing a wire harness according to the second modification. [Figure 22] FIG. 22 is a plan view showing a modified form of the wire harness of the second modification. [Figure 23] FIG. 23 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the second modification. [Figure 24]FIG. 24 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the second modification. [Figure 25] FIG. 25 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the second modification. [Figure 26] FIG. 26 is a plan view illustrating an auxiliary welded portion in a modified form of the wire harness of the second modified example. [Figure 27] FIG. 27 is a plan view showing a wire harness according to a second modification provided with a clamp. [Figure 28] FIG. 28 is a plan view showing a modified form of the wire harness according to the second modification provided with a clamp. [Figure 29] FIG. 29 is a plan view showing a wire harness according to the third modification. [Figure 30] FIG. 30 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the third modification. [Figure 31] FIG. 31 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the third modification. [Figure 32] FIG. 32 is an explanatory diagram illustrating a manufacturing process of the wire harness according to the third modification. [Figure 33] FIG. 33 is a plan view showing the wire harness of the fourth modification divided into harness components. [Figure 34] FIG. 34 is a plan view showing a wire harness according to the fourth modification. DETAILED DESCRIPTION OF THE INVENTION

[0013] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a wire harness and a method for manufacturing a wire harness according to the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to these embodiments.

[0014] [Embodiment] One embodiment of a wire harness according to the present invention will be described with reference to FIGS.

[0015] Reference numeral 1 in FIGS. 1 to 4 indicates a wire harness according to this embodiment.

[0016] The wire harness 1 includes a harness component 30 including a group of electric wires 10 including a plurality of electric wires 11 and a pair of insulating sheet-like exterior members 20 that sandwich and accommodate a region to be protected 10a of the group of electric wires 10 (FIGS. 1 to 4). The harness component 30 includes a joint 31 between the pair of exterior members 20 and a welded portion 32 with free ends at which the joints 31 are welded together along the axial direction of the region to be protected 10a between the joints 31 (FIGS. 1 to 4). In the harness component 30, the exterior members 20 are molded from an insulating raw material that enables welding in order to weld the exterior members 20 together. The exemplary exterior members 20 shown here are molded from raw materials such as vinyl chloride, polyvinyl chloride, polyamide, etc., and are welded using a known welding technique such as high-frequency welding or ultrasonic welding. The pair of exterior members 20 may be different members or the same member.

[0017] In the electric wire group 10, the plurality of electric wires 11 are bundled together (FIGS. 1 to 4). The electric wire group 10 has a trunk line 12 and branch electric wires 13 branched from a branch portion 12a of the trunk line 12 (FIGS. 2 and 4).

[0018] In the harness component 30 shown here, a portion of the main wire 12 is a portion to be protected 10a, and this portion of the main wire 12 is sandwiched between a pair of exterior members 20 (FIGS. 1 and 3), and at a location separate from this portion to be protected 10a, a portion of the main wire 12 including a branch portion 12a and a branch electric wire 13 are also designated as the portion to be protected 10a, and the periphery of the group of electric wires 10 including this branch portion 12a is sandwiched between the pair of exterior members 20 (FIGS. 2 and 4). In this harness component 30, one end side 21a and the other end side 21b of the pair of exterior members 20 that are adjacent to each other across the former portion to be protected 10a (part of the main wire 12) are each formed as a joint 31, and a welded portion 32 is provided between the one end side 21a and the other end side 21b of this joint 31 (FIG. 1). In this harness component 30, in the latter portion 10a to be protected, one end side 21a of the pair of exterior members 20 that abuts on each other across the trunk line 12, and intermediate portions 22a, 22b located between the trunk line 12 and the branch electric wire 13 on the other end side 21b of the pair of exterior members 20 that abuts on each other across the trunk line 12, are each formed as a joint portion 31, and a welding portion 32 is provided between the intermediate portions 22a and 22b as the joint portions 31 (FIG. 2). In this latter portion 10a to be protected, one branch electric wire 13 branches off from the branch portion 12a of the trunk line 12, and two abutting intermediate portions 22a, 22b are formed in the pair of exterior members 20.

[0019] The shape of the exterior member 20 is determined to match the shape of the area 10a to be protected. Here, a rectangular sheet-like exterior member 20 is used (FIGS. 1 to 4). Therefore, in the former area 10a to be protected (part of the main line 12), the axis of the exterior member 20 is aligned with one opposite side of the pair of exterior members 20, so that one end side 21a and the other end side 21b as the joint 31 each have a rectangular shape (FIG. 1). In this former area 10a to be protected, linear welded portions 32 extending in the axial direction of the area 10a to be protected are formed between the one end side 21a as the joint 31 and the other end side 21b as the joint 31. Each welded portion 32 is positioned close to the area 10a to be protected (part of the main line 12). In the latter region to be protected 10a (around the group of electric wires 10 including the branch portion 12a), the trunk 12 and the branch electric wires 13 are perpendicular to each other, and the axis of the trunk 12 is aligned along one opposite side of the pair of exterior members 20, so that one end side 21a as the joint 31 and two intermediate portions 22a, 22b as the joint 31 at the other end side 21b are each rectangular (FIG. 2). In this latter region to be protected 10a, a linear welded portion 32 extending in the axial direction of the trunk 12 is formed between the one end side 21a, and L-shaped welded portions 32 extending from the branch portion 12a in the axial direction of the trunk 12 and the axial direction of the branch electric wires 13 are formed between the intermediate portions 22a and 22b. The respective welded portions 32 are positioned close to the trunk 12 and the branch electric wires 13.

[0020] This wire harness 1 is assembled, for example, by the following manufacturing method: Here, the former part 10a to be protected (part of the main line 12) will be illustrated.

[0021] This manufacturing method includes a first installation step of placing one of the pair of exterior members 20 (hereinafter referred to as "one exterior member 20A") on an installation surface Ma1 of a first mold Ma (FIG. 5). For example, the first mold Ma is installed on a so-called jig plate or the like for assembling the wire harness 1.

[0022] This manufacturing method includes a second installation step of placing the portion to be protected 10a of the electric wire group 10 on one of the exterior members 20A on the first mold Ma (FIG. 5). In this second installation step, both ends of the portion to be protected 10a of the electric wire group 10 are supported by respective support members S on a jig plate. The support member S is provided with a support portion Sa that supports the electric wire group 10 in an inner space and passes the electric wire group 10 through the inner space. The support portion Sa has two support pins arranged opposite to each other with a gap between them and a bottom portion that connects one end of the two support pins. In the support portion Sa, the electric wire group 10 is inserted between the other end of the two support pins into the inner space formed by the two support pins and the bottom portion. Then, in the inner space of the support portion Sa, the electric wire group 10 is supported by being placed on the bottom, and the two support pins support the electric wire group 10 from both sides. For example, the support portion Sa is formed in a support shape such as a U-shape or a V-shape having the two support pins and a bottom portion. The support portion Sa is provided in at least one location in the support member S. In this example support member S, the U-shaped support portions Sa are provided in two locations.

[0023] This manufacturing method includes a third installation step in which the other of the pair of exterior members 20 (hereinafter referred to as the "other exterior member 20B") is placed on the one exterior member 20A and the area to be protected 10a, and the area to be protected 10a is sandwiched between the one exterior member 20A and the other exterior member 20B (Figure 5).

[0024] This manufacturing method includes a fourth installation step in which one end side 21a and the other end side 21b of the one exterior member 20A and the other exterior member 20B, as viewed from the area to be protected 10a, are clamped between a first mold Ma and a second mold Mb, respectively (Figure 5).

[0025] This manufacturing method includes a welding step of welding one end side 21a and the other end side 21b of the one exterior member 20A and the other exterior member 20B along the axial direction of the area to be protected 10a. Here, the first mold Ma and the second mold Mb also serve as electrodes, and heat is generated at predetermined locations on the one end side 21a and the other end side 21b to weld them together. As a result, linear welded portions 32 are formed on the one end side 21a and the other end side 21b, respectively, along the former area to be protected 10a (part of the main line 12).

[0026] According to this manufacturing method, the pair of exterior members 20 can be attached to the portion 10a to be protected of the group of electric wires 10 in the minimum necessary working space on the jig plate.

[0027] As described above, the wire harness 1 of the present embodiment sandwiches the region to be protected 10a of the group of electric wires 10 between a pair of exterior members 20 and welds the joints 31 where the pair of exterior members 20 meet, thereby insulating and protecting the region to be protected 10a with the pair of exterior members 20. Therefore, the wire harness 1 does not require an adhesive member or adhesive tape for securing the exterior members, as in conventional wire harnesses, thereby reducing costs. Furthermore, the wire harness 1 does not require the process of wrapping the adhesive tape, thereby reducing costs. For example, in conventional wire harnesses, a worker wraps the adhesive tape for securing the region to be protected 10a manually. Therefore, the wire harness 1 of the present embodiment has a greater cost reduction effect than conventional wire harnesses. Furthermore, the wire harness 1 of the present embodiment can reduce quality variations in the exterior members 20 attached to the region to be protected 10a compared to conventional wire harnesses.

[0028] Furthermore, since the wire harness 1 of this embodiment sandwiches the portion 10a of the wire group 10 to be protected between a pair of exterior members 20, it can accommodate various lengths and thicknesses of the wire group 10 simply by changing the size of the exterior members 20.

[0029] In the wire harness 1 of this embodiment, the welded portions 32 are formed between the joints 31 of the pair of exterior members 20, close to the main wire 12 and the branch wires 13, and therefore, there are excess portions 31a that are not welded between the joints 31 (FIGS. 6 and 7). Therefore, in the harness component 30, the excess portions 31a may be cut off after welding. Also, in the wire harness 1 of this embodiment, an exterior member 20 that is molded from the beginning so as not to have such excess portions may be used.

[0030] Furthermore, in the wire harness 1 of the present embodiment, when the portion to be protected 10a is the branch electric wire 13 and a part of the trunk 12 including the branch portion 12a, as described above, the L-shaped welded portions 32 are formed at the intermediate portions 22a, 22b of the pair of exterior members 20, extending from the branch portion 12a in the axial direction of the trunk 12 and the axial direction of the branch electric wire 13, respectively (FIG. 2). The welded portions 32 are positioned close to the trunk 12 and the branch electric wire 13 (FIG. 2). For example, in the harness component 30, if the pair of exterior members 20 are formed in a flexible sheet shape, the branch electric wire 13 may approach the trunk 12 as the joint 31 bends, and the shape of the trunk 12 and the branch electric wire 13 may not be kept constant. In particular, in this harness component 30, if the excess portions (portions not welded between the pair of exterior members 20) 31a are cut off from the respective middle portions 22a, 22b of the pair of exterior members 20 (FIG. 7), the branch electric wire 13 can be easily brought close to the trunk line 12.

[0031] Therefore, it is desirable that the harness component 30 has auxiliary welds 33 formed by welding the joints 31 between the pair of exterior members 20 from one free end to the other free end of the welded portions 32 between the adjacent joints 31, connecting the one free end to the other free end ( FIG. 8 ). For example, the auxiliary welds 33 are formed by welding the outer peripheries of the adjacent joints 31 (intermediate portions 22 a, 22 b) of the pair of exterior members 20 to connect the one free end to the other free end of the welded portions 32. This increases the rigidity of the joints 31 (intermediate portions 22 a, 22 b) between the one end side 21 a and the other end side 21 b of the pair of exterior members 20, reducing deflection, and thereby maintaining a constant shape between the trunk 12 and the branch electric wires 13.

[0032] Here, one free end of the welding portion 32 is connected to the other free end by a linear auxiliary welding portion 33 at each of the intermediate portions 22a, 22b of the pair of exterior members 20. This auxiliary welding portion 33 may be formed by welding the entire excess portion between the linear welding portion 32 and the auxiliary welding portion 33.

[0033] Here, the wire harness 1 of this embodiment is routed along a structure such as a vehicle body in a vehicle, and is assembled and fixed to this structure. The structure is the object to which the wire harness 1 is to be assembled, and the wire harness 1 includes clamps 40 for assembling and fixing predetermined locations of the electric wire group 10 to the object to be assembled (FIGS. 9 and 10). In the wire harness 1, the clamps 40 are fixed to predetermined locations of the electric wire group 10 by an exterior member 23. The predetermined locations of the electric wire group 10 may be, for example, the region 10a to be protected of the electric wire group 10, locations provided at predetermined intervals on the routing path of the electric wire group 10, or locations where the routing path changes, such as bending points of the electric wire group 10. The exterior member 23 is a weldable sheet-like member similar to the exterior member 20.

[0034] For example, the clamp 40 is fixed to the portion 10a to be protected of the group of electric wires 10 with the exterior member 23 (FIGS. 9 and 10). In the harness component 30 of FIG. 9, a part of the main line 12 is the portion to be protected 10a, and the clamp 40 is fixed to this portion to be protected 10a with the exterior member 23. In the harness component 30 of FIG. 10, a part of the main line 12 including the branch portion 12a and the branch electric wire 13 are the portion to be protected 10a, and the clamp 40 is fixed to this portion to be protected 10a with the exterior member 23.

[0035] The clamp 40 has a clamp body 41 for attaching a predetermined portion of the wire group 10 to an assembly object, and a fixing protrusion 42 protruding from the clamp body 41 (FIG. 11).

[0036] The clamp body 41 has a locking portion 41a that locks onto the object to be assembled (FIGS. 9 to 11). This locking portion 41a is formed, for example, in an anchor shape that can be inserted from one flat side into a through-hole in a flat portion of the object to be assembled and hooked onto the other flat side of the flat portion to be locked. The fixing protrusion 42 is a portion used to attach the clamp 40 to the exterior member 23. Here, the fixing protrusions 42 are provided in two locations.

[0037] In this wire harness 1, a pair of exterior members are attached to the region to be protected 10a in the same manner as in the previous examples. Here, the aforementioned exterior member 20 is used as one of the pair of exterior members, and the exterior member 23 is used as the other of the pair of exterior members (FIGS. 9 and 10). The exterior member 23 corresponds to the exterior member 20 provided with a through hole for inserting the clamp body 41. Therefore, the exterior member 23 has a through hole 23c for inserting the clamp body 41 from one wall surface 23a side to the other wall surface 23b side (FIG. 11). With the clamp body 41 inserted through the through hole 23c, the exterior member 23 clamps the fixing protrusion 42 between one wall surface 23a and the group of electric wires 10. Therefore, in this wire harness 1, the clamp body 41 is inserted through the through hole 23c of the other exterior member 23, and the respective joints 31 of the one exterior member 20 and the other exterior member 23 are welded together, thereby fixing the clamp 40 between the other exterior member 23 and the portion 10a to be protected of the group of electric wires 10.

[0038] In the harness component 30 shown in Fig. 10, the welded portion 32 of the intermediate portion 22a and the welded portion 32 of the intermediate portion 22b are positioned close to the branch electric wire 13, and the branch electric wire 13 is sandwiched between the two welded portions 32, and the two welded portions 32 suppress relative positional deviation of the pair of exterior members (one exterior member 20 and the other exterior member 23) in the axial direction of the main wire 12. Therefore, in this harness component 30, the two welded portions 32 can suppress relative positional deviation of the clamp 40 in the axial direction of the main wire 12. For example, the exterior member 23 shown in Fig. 10 has a through-hole 23c at the location where the branch portion 12a is located, thereby attaching the clamp 40 to the branch portion 12a.

[0039] Furthermore, in the wire harness 1 of the present embodiment, a portion of the straight-shaped main wire 12 is the portion to be protected 10a, and a T-shaped portion around the branch portion 12a consisting of a portion of the straight-shaped main wire 12 and one straight-shaped branch electric wire 13 is the portion to be protected 10a. Therefore, the wire harness 1 uses the exterior member 20 and the exterior member 23 formed in a rectangular sheet shape. However, the wire harness 1 may use a sheet-shaped exterior member having a shape other than rectangular to match the shape of the portion to be protected 10a. For example, in the wire harness 1, if a plurality of branch electric wires 13 (two in this example) branch from the branch portion 12a of the main wire 12 and the main wire 12 and the plurality of branch electric wires 13 form a radial shape such as a cross around the branch portion 12a, a pair of circular sheet-shaped exterior members 25 may be used at that location, with the branch portion 12a at the center ( FIG. 12 ). In this case, in the harness component 30, intermediate portions 27a, 27b located between the main line 12 and one of the branch electric wires 13 at one end side 26a where the main line 12 joins the pair of exterior members 25, and intermediate portions 27c, 27d located between the main line 12 and the other branch electric wire 13 at the other end side 26b where the main line 12 joins the pair of exterior members 25, respectively serve as joint portions 31, and L-shaped welding portions 32 with free ends at both ends are provided at each of these joint portions 31.

[0040] The aforementioned auxiliary welding portion 33 may be provided on the outer periphery of each of the intermediate portions 27a, 27b, 27c, and 27d (FIG. 13).

[0041] In the harness component 30, the outer shapes of the respective intermediate portions 27a, 27b, 27c, and 27d may be smaller than this. For example, in this case, an exterior member 28 is applied in which a circular portion forming the small-diameter intermediate portions 27a, 27b, 27c, and 27d and a cross-shaped portion corresponding to the trunk line 12 and the two branch electric wires 13 are combined into one (FIG. 14). In this case, auxiliary weld portions 33 are provided on the outer peripheries of the small-diameter intermediate portions 27a, 27b, 27c, and 27d. In this case, the auxiliary weld portions 33 connect the ends of the weld portion 32 along the trunk line 12 and the weld portion 32 along the branch electric wires 13.

[0042] In addition, in this wire harness 1, a through hole similar to the through hole 23c of the previous exterior member 23 may be provided in one of the pair of exterior members 25, and the clamp 40 may be fixed by this exterior member 25 with the through hole and the portion 10a to be protected of the group of wires 10 (not shown).

[0043] Here, in the manufacturing process of the wire harness 1 of this embodiment, the branch portion 12a is also supported by, for example, the aforementioned support member S. In this wire harness 1, the branch portion 12a is covered with exterior members 20, 23, and 25, and therefore through holes 29 are formed in the vicinity of the branch portion 12a at joints 31 of the exterior members 20, 23, and 25 (FIGS. 15 and 16), so that a support pin of the support member S can be inserted into the through holes 29 when the exterior members 20, 23, and 25 are assembled to the portion to be protected 10a. Here, the forms in the respective figures are shown as representative examples.

[0044] In addition, in this wire harness 1, for example, a pair of exterior members 20 may be provided before and after the branch portion 12a of the main line 12, and a desired number of electric wires 11 may be drawn out from the branch portion 12a, and a pair of exterior members 20 may also be provided on these electric wires 11, thereby creating branch electric wires 13 branched from the main line 12 (FIG. 17).

[0045] [Variation 1] The wire harness 2 of this modified example corresponds to the wire harness 1 of the above-described embodiment in which the pair of exterior members 20 provided on the protected portion 10a (part of the main wire 12) is replaced with a pair of exterior members 120 described below (FIG. 18). The wire harness 2 of this modified example is provided with a harness part 130 including an electric wire group 10 (for convenience of explanation, the same electric wire group 10 as in the embodiment is used) and the pair of exterior members 120.

[0046] The pair of exterior members 120 are formed from an insulating raw material that allows welding of the exterior members 120 to each other, similar to the exterior member 20 of the embodiment. Here, the pair of exterior members 120 are formed into rectangular sheet shapes.

[0047] In the pair of exterior members 120, one of the exterior members 120 (hereinafter referred to as "one exterior member 120A") is made of a harder material than the other exterior member 120 (hereinafter referred to as "the other exterior member 120B") and is formed in a flat sheet shape (FIG. 18). That is, one exterior member 120A is made of a softer material than the other exterior member 120B. This one exterior member 120A is formed in a flat sheet shape using such a soft material and is deformed by applying pressure or heat to it. By deforming the flat sheet-like one exterior member 120A, a bent portion 122 is formed between one end side 121a and the other end side 121b of the pair of exterior members 120, which are adjacent to each other across the area to be protected 10a, and the bent portion 122 forms a storage space for the area to be protected 10a between the flat sheet-like other exterior member 120B (FIG. 18). In the harness component 130, one end side 121a and the other end side 121b thereof each form a joint 131 where the pair of exterior members 120 come into contact with each other.

[0048] The manufacturing method of the wire harness 2 of this modified example is basically the same as the manufacturing method of the wire harness 1 of the above-described embodiment, but differs from the manufacturing method of the wire harness 1 of the embodiment in the following points.

[0049] First, in a first installation step of this modified example, a flat sheet-like exterior member 120A is placed on a first mold Ma having a flat installation surface Ma1 with a groove Ma2 (FIG. 19). Then, in the manufacturing method of this modified example, after this first installation step, a bent portion forming step is provided in which the one exterior member 120A is sandwiched between the first mold Ma and the third mold Mc, and the protrusion Mc2 of the third mold Mc is fitted into the groove Ma2 of the first mold Ma to form a bent portion 122 in the one exterior member 120A that is aligned with the groove Ma2 and the protrusion Mc2 (FIG. 19). Here, the groove Ma2 and the protrusion Mc2 are each formed in a linear shape.

[0050] Next, in a second installation step of this modified example, the area to be protected 10a is installed in the bent portion 122 formed in the bent portion forming step (FIG. 20). Then, in a third installation step of this modified example, the other exterior member 120B is placed on one exterior member 120A, and the area to be protected 10a in the bent portion 122 is sandwiched between the one exterior member 120A and the other exterior member 120B (FIG. 20). In a fourth installation step of this modified example, one end side 121a and the other end side 121b of the one exterior member 120A and the other exterior member 120B, which are adjacent to each other across the area to be protected 10a, are sandwiched between a first mold Ma and a second mold Mb, respectively (FIG. 20).

[0051] The manufacturing method of this modified example then proceeds to the welding process in the same manner as the manufacturing method of the embodiment, and linear welding portions 132 (Figure 18) are formed on one end side 121a and the other end side 121b along the area to be protected 10a (part of the main line 12).

[0052] The wire harness 2 of this modified example described above has the same effects as the wire harness 1 of the embodiment. For the wire harness 2 of this modified example, the first installation step to the welding step can be performed on a single jig plate, and the pair of flat sheet-like exterior members 120 (one exterior member 120A and the other exterior member 120B) can be transported to the work site. Therefore, compared to wire harnesses using cylindrical members such as corrugated tubes as exterior members, the wire harness 2 of this modified example can fit the pair of exterior members 120 into a transport container or the like without any gaps, thereby reducing the transportation costs for the pair of exterior members 120 and reducing the cost price.

[0053] Furthermore, when the wire harness 2 of this modified example is routed around other components, such as nearby components in a vehicle, deterioration in its own quality can be suppressed by arranging the other hard exterior member 120B on the other component side.

[0054] In this modification, since a portion of the trunk wire 12 is the region to be protected 10a, linear grooves Ma2 and protrusions Mc2 are provided in the first mold Ma and the third mold Mc. However, the wire harness 2 of this modification can be applied even when the region to be protected 10a is, for example, the periphery of the branch portion 12a in the group of electric wires 10. In this case, grooves Ma2 and protrusions Mc2 that match the shapes of the portion of the trunk wire 12 including the branch portion 12a and the branch electric wires 13 may be formed in the first mold Ma and the third mold Mc, or the portion of the trunk wire 12 including the branch portion 12a and the branch electric wires 13 may be divided into a plurality of areas, and a first mold Ma and a third mold Mc that have grooves Ma2 and protrusions Mc2 that match the shapes of each area may be provided for each area.

[0055] [Variation 2] The wire harness 3 of this modified example is provided with a harness component 230 including an electric wire group 10 (for convenience of explanation, the same electric wire group 10 as in the embodiment is used) and a sheet-like insulating exterior member 220 that is folded back and accommodates the portion to be protected 10a of the electric wire group 10 inside (FIGS. 21 and 22). The harness component 230 has joints 231 that meet at the ends of the folded back parts of the exterior member 220, and welded portions 232 with both ends being free ends, where the joints 231 are welded to each other between the joints 231 along the axial direction of the portion to be protected 10a (FIGS. 21 and 22).

[0056] In the harness component 230 shown here, similarly to the harness component 30 of the embodiment, a part of the main wire 12 is set as the portion to be protected 10a, and one exterior member 220 is attached to this portion of the main wire 12 (FIG. 21), and at a location separate from the portion to be protected 10a, a part of the main wire 12 including the branch portion 12a and the branch electric wire 13 are set as the portion to be protected 10a, and one exterior member 220 is attached around the group of electric wires 10 including the branch portion 12a (FIG. 22). In this harness component 230, the exterior member 220 is folded back around the former portion to be protected 10a (part of the main wire 12) as an axis, and end portions 221a and 221b that meet at the folded back end serve as a joint 231, and a welded portion 232 is provided between the end portions 221a and 221b that serve as the joint 231 (FIG. 21). In this harness part 230, in the latter portion 10a to be protected, the exterior member 220 is folded back around the trunk line 12 as an axis, and intermediate portions 222a, 222b located between the trunk line 12 and the branch electric wire 13 at the ends 221a, 221b that meet at the end of the fold back are used as joint portions 231, and welded portions 232 are provided between the intermediate portions 222a and 222b as joint portions 231 (FIG. 22). In this latter portion 10a to be protected, one branch electric wire 13 branches off from the branch portion 12a of the trunk line 12, and two mutually meeting intermediate portions 222a, 222b are formed in the exterior member 220.

[0057] The exterior member 220 is formed from a weldable insulating raw material similar to the exterior member 20 of the embodiment. Here, a rectangular sheet-like exterior member 220 is used. Therefore, in the former portion to be protected 10a (part of the main line 12), the end portions 221a, 221b serving as the joint 231 are rectangular (FIG. 21). In this former portion to be protected 10a, a linear weld portion 232 is formed between the end portions 221a, 221b serving as the joint 231, extending in the axial direction of the portion to be protected 10a. This weld portion 232 is positioned close to the portion to be protected 10a (part of the main line 12). In the latter region to be protected 10a (around the group of electric wires 10 including the branch portion 12a), the trunk 12 and the branch electric wires 13 are perpendicular to each other, so that two intermediate portions 222a, 222b serving as joints 231 at the ends 221a, 221b are each rectangular ( FIG. 22 ). In this latter region to be protected 10a, L-shaped welded portions 232 are formed between the intermediate portions 222a and 222b, extending from the branch portion 12a in the axial direction of the trunk 12 and the axial direction of the branch electric wires 13, respectively. Each of the welded portions 232 is positioned close to the trunk 12 and the branch electric wire 13.

[0058] The wire harness 3 is assembled, for example, by the following manufacturing method. Here, the former part 10a to be protected (part of the main line 12) will be illustrated.

[0059] This manufacturing method includes a first installation step of placing an exterior member 220 in a V-shaped or U-shaped groove T1 of a jig T (FIG. 23). In this first installation step, the exterior member 220 is bent into a V-shaped or U-shaped bent shape and placed in the groove T1 so as to fit the shape of the groove T1. For example, the jig T is installed on a so-called jig plate or the like for assembling the wire harness 3.

[0060] This manufacturing method includes a second installation step of installing the portion to be protected 10a of the electric wire group 10 inside the bent exterior member 220 (FIG. 24).

[0061] This manufacturing method includes a third setting step in which the ends 221a, 221b of the exterior member 220, which are folded back around the area to be protected 10a (part of the main wire 12), are sandwiched between a first mold Md and a second mold Me (FIG. 25). This manufacturing method then includes a welding step in which the ends 221a, 221b of the exterior member 220 are welded together along the axial direction of the area to be protected 10a (FIG. 25). Here, the first mold Md and the second mold Me serve as electrodes, and the ends 221a, 221b are welded together by heating predetermined locations. As a result, a linear welded portion 232 is formed at the ends 221a, 221b, which follows the area to be protected 10a (part of the main wire 12).

[0062] As described above, the wire harness 3 of this modified example houses the portion to be protected 10a of the group of electric wires 10 inside a single folded-over exterior member 220, and by welding the joint 231 that meets at the end of the folded-over portion, the portion to be protected 10a can be insulated and protected by this single exterior member 220. Therefore, the wire harness 3 does not require an adhesive member or adhesive tape for fixing the exterior member as in conventional wire harnesses, and only one exterior member 220 is required, thereby reducing costs. Furthermore, since the wire harness 3 does not require the process of wrapping the adhesive tape, costs can be reduced, similar to the wire harness 1 of the embodiment, and quality variations in the exterior member 220 attached to the portion to be protected 10a can be reduced compared to conventional wire harnesses.

[0063] Furthermore, the wire harness 3 of this modified example is configured by folding back a single exterior member 220 to encase the portion 10a of the wire group 10 to be protected, and therefore can accommodate various lengths and thicknesses of the wire group 10 simply by changing the size of the exterior member 220.

[0064] Incidentally, in the wire harness 3 of this modified example, the welded portions 232 are formed between the joints 231 in one exterior member 220, close to the main wire 12 and the branch wires 13, and thus, similar to the wire harness 1 of the embodiment, there is an excess portion that is not welded between the joints 231. Therefore, in the harness component 230 of this modified example, the excess portion may be cut off after welding, similar to the wire harness 1 of the embodiment. Furthermore, in the wire harness 3 of this modified example, an exterior member 220 that is molded from the beginning so that the excess portion does not exist may be used.

[0065] Furthermore, in the wire harness 3 of this modified example, similarly to the wire harness 1 of the embodiment, when a part of the trunk 12 including the branch portion 12a and the branch electric wire 13 are set as the protected portion 10a, if the intermediate portions 222a, 222b are cut away so that no excess portion (a portion not welded between the ends 221a, 221b of the exterior member 220) remains, the branch electric wire 13 may come close to the trunk 12, and the shape of the trunk 12 and the branch electric wire 13 may not be kept constant. Therefore, it is desirable that the harness part 230 has auxiliary weld portions 233 that are welded between the adjacent joints 231 of the exterior member 220 from one free end to the other free end of the weld portions 232 (FIG. 26). For example, the auxiliary welding portion 233 welds the outer peripheral edges of the adjacent joints 231 of the exterior member 220 together, connecting one free end of the welding portion 232 to the other free end. As a result, in the wire harness 3 of this modified example, similar to the wire harness 1 of the embodiment, the rigidity of the joints 231 (intermediate portions 222a, 222b) can be increased and deflection can be suppressed, so that the shape can be kept constant between the trunk line 12 and the branch electric wires 13.

[0066] Here, one free end of welding portion 232 is connected to the other free end by linear auxiliary welding portion 233 at each of intermediate portions 222a and 222b of exterior member 220. In addition, auxiliary welding portion 233 may be formed by welding the entire excess portion between linear welding portion 232 and auxiliary welding portion 233.

[0067] Here, the wire harness 3 of this modified example may be provided with a clamp 40 similar to the wire harness 1 of the embodiment (FIGS. 27 and 28). For example, the clamp 40 is fixed to the portion to be protected 10a of the electric wire group 10 by an exterior member 223 (FIGS. 27 and 28). This exterior member 223 is similar to the exterior member 23 of the embodiment and has a through hole (not shown) through which the clamp main body 41 is inserted from one wall surface side to the other wall surface side. In the wire harness 3 of this modified example, the clamp main body 41 is inserted through the through hole of one exterior member 223, and the adjacent joint portions 31 of the exterior member 223 are welded to each other, whereby the clamp 40 is fixed by the exterior member 223 and the portion to be protected 10a of the electric wire group 10.

[0068] In the harness part 230 of FIG. 27, a part of the main line 12 is a portion to be protected 10a, and the clamp 40 is fixed to this portion to be protected 10a by an exterior member 223.

[0069] In addition, in a harness component 230 shown in FIG. 28, a portion of the trunk line 12 including the branch portion 12a and the branch electric wire 13 are defined as the area to be protected 10a, and a clamp 40 is fixed to this area to be protected 10a by an exterior member 223. In this harness component 230, the welded portion 232 of the intermediate portion 222a and the welded portion 232 of the intermediate portion 222b are positioned close to the branch electric wire 13, and the branch electric wire 13 is sandwiched between the two welded portions 232, and these two welded portions 232 suppress relative positional deviation of the exterior member 223 in the axial direction of the trunk line 12. Therefore, in this harness component 230, the two welded portions 232 can suppress relative positional deviation of the clamp 40 in the axial direction of the trunk line 12. For example, the exterior member 223 shown in FIG. 28 has a through-hole at the location of the branch portion 12a, thereby attaching the clamp 40 to the branch portion 12a.

[0070] Furthermore, in the wire harness 3 of this modified example, similarly to the wire harness 1 of the embodiment, a sheet-like exterior member having a shape other than a rectangle may be used in accordance with the shape of the portion to be protected 10a.

[0071] Furthermore, in the wire harness 3 of this modified example, similar to the wire harness 1 of the embodiment, a through hole is formed near the branch portion 12a at the joint 231 of the exterior members 220, 223, so that when the exterior members 220, 223 are assembled to the area to be protected 10a, a support pin of the support member S can be inserted into the through hole.

[0072] [Variation 3] The wire harness 4 of this modified example corresponds to the wire harness 3 of the above-described modified example 2, except that a shielding member 51 is interposed between the portion to be protected 10a of the electric wire group 10 and the exterior member 220 to provide protection from noise (FIG. 29). Therefore, the harness part 330 of this modified example is the harness part 230 of modified example 2 to which the shielding member 51 is added. Note that this figure is simplified compared to the explanatory diagram of modified example 2 for ease of illustration.

[0073] The shielding member 51 used in the wire harness 4 is formed into a sheet shape. For example, here, a braid in which element wires are woven into a sheet shape, or a metal foil such as aluminum foil or copper foil is used for the shielding member 51. The shielding member 51 covers the portion to be protected 10a of the group of electric wires 10 all around inside the folded-back exterior member 220. Furthermore, the shielding member 51 has a shape that does not get into the area where the welded portion 332 is formed between the end portions 221a, 221b so as not to interfere with welding of the end portions 221a, 221b of the exterior member 220 as the joint portion 331 (FIG. 29).

[0074] Here, in this wire harness 4, one of the multiple electric wires 11 constituting the electric wire group 10 is a drain wire 11A in which the coating 11a is partially removed to expose the core wire 11b, and the exposed core wire 11b is brought into contact with the shielding member 51 (Figure 29).

[0075] This wire harness 4 is assembled, for example, by the following manufacturing method. The manufacturing method of the wire harness 4 of this modified example is basically the same as the manufacturing method of the wire harness 3 of modified example 2 described above, but differs from the manufacturing method of the wire harness 3 of modified example 2 in the following respects. In this example, a part of the trunk line 12 is set as the portion to be protected 10a.

[0076] The manufacturing method of this modified example includes a shield installation step (FIG. 30) following the first installation step (FIG. 23), in which sheet-like shielding member 51 is bent into a V- or U-shape and placed along the inner wall surface of bent exterior member 220. In the second installation step following the shield installation step, drain wire 11A is first installed within bent shielding member 51, with the exposed core of drain wire 11A in contact with the inner wall surface of shielding member 51 (FIG. 31). For example, in the second installation step, the portion of drain wire 11A corresponding to portion to be protected 10a is first inserted into bent shielding member 51, and then the remaining portions of wires 11 corresponding to portion to be protected 10a are inserted into bent shielding member 51 one by one, multiple by multiple, or all at once. The manufacturing method of this modified example then includes the third installation step and the welding step (FIG. 32).

[0077] The wire harness 4 of this modified example described above has the same effect as the wire harness 3 of modified example 2. A conventional wire harness may include one drain wire for each of a plurality of electric wire bundles. However, the wire harness 4 of this modified example can collect the electric wires 11 of the plurality of electric wire bundles of the conventional wire harness into one electric wire group 10 except for one drain wire 11A, which also reduces the cost.

[0078] Here, in the wire harness 4 of this modified example, if a drain wire 11A is required for each circuit, an exterior member 220 and a shielding member 51 may be provided for each bundle of one drain wire 11A and the remaining electric wires 11 grouped together for each circuit.

[0079] Furthermore, in the wire harness 4 of this modified example, the exterior member 220 and the shielding member 51 can be provided in a location other than the location determined as the protected portion 10a of the electric wire group 10. That is, in this wire harness 4, the exterior member 220 can also be used as a member for fixing the shielding member 51 to the electric wire group 10. Therefore, in the wire harness 4 of this modified example, the shielding member 51 can be added later to a location where a shielding function is required after assembly is completed. In this case, the primary function of the exterior member 220 is to fix the shielding member 51 to the electric wire group 10, but the exterior member 220 also secondarily protects the location of the electric wire group 10 where the shielding member 51 is provided. Therefore, that location of the electric wire group 10 ultimately becomes the protected portion 10a.

[0080] [Variation 4] The wire harness 5 of this modified example includes a plurality of harness components, each of which includes a group of electric wires having a plurality of electric wires and a sheet-like insulating exterior member that houses the portions of the group of electric wires to be protected. In this wire harness 5, the exterior members of the plurality of harness components are welded together to integrate the plurality of harness components into a single component. In other words, the wire harness 5 is formed by dividing the group of electric wires into a plurality of circuits, producing harness components for each circuit, and integrating the harness components for each circuit at locations where the exterior member is located. For example, the wire harness 5 of this modified example includes a plurality of harness components selected from at least two of the harness component 30 of the embodiment, the harness component 130 of Modification 1, the harness component 230 of Modification 2, and the harness component 330 of Modification 3.

[0081] The wire harness 5 of this modified example illustrated below includes a plurality of harness components 30 of the embodiment, and these harness components 30 are integrated together (FIGS. 33 and 34). In this wire harness 5, the joints 31 of the plurality of harness components 30 are welded together to integrate the plurality of harness components 30 into a single component. Therefore, in this wire harness 5, the excess portions 31a shown above are left at the joints 31 of the harness components 30, and these excess portions 31a are welded together. Note that although an exterior member 220 of the modified example is also included in the figures, for convenience it will be referred to as the harness component 30 of the embodiment.

[0082] In this wire harness 5, when all of the multiple harness components 30 include a pair of exterior members 20, the joints 31 between the respective pairs of exterior members 20 are welded and integrated together. When all of the multiple harness components 30 include a pair of exterior members 25, the joints 31 between the respective pairs of exterior members 25 are welded and integrated together. When one of the multiple harness components 30 includes a clamp 40 including a pair of exterior members 20 and 23, the joints 31 between this pair of exterior members (the exterior member 20, the exterior member 23) and the pair of exterior members 20 or the pair of exterior members 25 of another harness component 30 are welded and integrated together.

[0083] The wire harness 5 illustrated here includes two harness parts 30 (one harness part 30A and the other harness part 30B) in which the portion to be protected 10a of the electric wire group 10 is covered with a pair of exterior members 25 (FIGS. 33 and 34).

[0084] In one harness component 30A, the group of electric wires 10 has two branch electric wires 13 branched from a branch portion 12a of a main line 12, and a part of the main line 12 including the branch portion 12a and the branch electric wires 13 are the protected portion 10a covered by a pair of exterior members 25 (FIG. 33). Therefore, in this one harness component 30A, the pair of exterior members 25 are provided with four intermediate portions 27a, 27b, 27c, and 27d as joints 31.

[0085] The other harness component 30B has a portion of the main wire 12 as a protection target portion 10a that is covered by a pair of exterior members 25 (FIG. 33). Therefore, the other harness component 30B has a pair of exterior members 25 each having a first end side 26a and a second end side 26b that are joined to each other across the protection target portion 10a (part of the main wire 12) as a joint portion 31.

[0086] In this example wire harness 5, intermediate portions 27a and 27c of the pair of exterior members 25 of one harness part 30A are welded to one end side 26a of the pair of exterior members 25 of the other harness part 30B, and intermediate portions 27b and 27d of the pair of exterior members 25 of one harness part 30A are welded to the other end side 26b of the pair of exterior members 25 of the other harness part 30B. Thus, in this wire harness 5, four welded portions 34 are formed corresponding to the intermediate portions 27a, 27b, 27c, and 27d (FIG. 34).

[0087] In this example, in the wire harness 5, one branch electric wire 13 in one harness component 30A and the trunk 12 in the other harness component 30B are connected to a common mating connector. Therefore, in this wire harness 5, a connector 61 may be attached to an end of either one of the branch electric wire 13 in one harness component 30A or the trunk 12 in the other harness component 30B, and after welding the joints 31 of both harness components 30A together, the other end may be connected to the connector 61 (FIGS. 33 and 34). Here, the connector 61 is attached in advance to the end of the trunk 12 of the other harness component 30B, and after welding the joints 31 of both harness components 30A together, the end of one branch electric wire 13 in one harness component 30A is connected to the connector 61.

[0088] Even when the wire harness 5 of this modification includes a plurality of harness components 130 of the first modification, the excess portions of the joints 131 of the harness components 130 are welded together (not shown), just as when the wire harness 5 includes a plurality of harness components 30 of the embodiment. The harness component 130 of the first modification can be classified as the harness component 30 of the embodiment in which the hardness of each of the pair of exterior members 20 is changed. Therefore, hereinafter, the harness component 130 of the first modification will be treated as being similar to the harness component 30 of the embodiment.

[0089] Furthermore, even when the wire harness 5 of this modified example includes a plurality of harness components 230 of modified example 2, the excess portions of the joints 231 of the harness components 230 are welded together (not shown) in the same manner as when the wire harness 5 includes a plurality of harness components 30 of the embodiment. In this wire harness 5, if all of the plurality of harness components 230 include exterior members 220, the joints 231 of the respective exterior members 220 are welded together to form an integrated unit. Furthermore, if one of the plurality of harness components 230 includes a clamp 40 having an exterior member 223, the joints 31 of the exterior member 223 with the clamp 40 and the exterior member 220 of the other harness component 30 are welded together to form an integrated unit.

[0090] Even when the wire harness 5 of this modification includes a plurality of harness components 330 of modification 3, such as when a drain wire 11A is required for each circuit, the excess portions of the joints 331 of the harness components 330 are welded together (not shown), just as in the case where a plurality of harness components 230 of modification 2 are included. The harness component 330 of modification 3 can be classified as the harness component 230 of modification 2 to which a shielding member 51 has been added. Therefore, in the following, the harness component 330 of modification 3 will be treated as being of the same type as the harness component 230 of modification 2.

[0091] Furthermore, the wire harness 5 of this modified example includes at least one harness component 30 of the embodiment (harness component 130 of modified example 1) and at least one harness component 230 of modified example 2 (harness component 330 of modified example 3) as its harness components, and these multiple harness components can be integrated by welding the joints between their respective exterior members (not shown). Hereinafter, for convenience of explanation, the harness component 30 of the embodiment will be referred to as the "first harness component 30," and the harness component 230 of modified example 2 will be referred to as the "second harness component 230." In the first harness component 30, the electric wire group 10 will be referred to as the "first electric wire group 10," and the exterior members 20, 23, and 25 that enclose this first electric wire group 10 will be collectively referred to as the "first exterior members." In addition, in the second harness component 230, the group of electric wires 10 is referred to as the "second group of electric wires 10," and the exterior members 220, 223 that encase the second group of electric wires 10 are collectively referred to as the "second exterior member." For example, in this wire harness 5, when one first harness component 30 and one second harness component 230 are provided, the excess portions of the joints 31 between the first exterior member of the first harness component 30 and the second exterior member of the second harness component 230 are welded together to be integrated.

[0092] The wire harness 5 of this modified example described above achieves the same effects as the harness components that are the target of its combination. The wire harness 5 of this modified example is manufactured by manufacturing harness components for each circuit and integrating the harness components into a single component where the exterior member is located. This allows for easy assembly, which also reduces costs. The wire harness 5 of this modified example also has multiple harness components for each circuit, which can be selected and combined as needed, resulting in high yield and thus reducing costs. The wire harness 5 of this modified example also allows for multiple harness components to be selected and combined as needed, which can easily accommodate different specifications for different combinations, thereby also reducing costs. The wire harness 5 of this modified example also has harness components for each circuit that are pre-defined as standardized products, which can be selected and combined as needed from the multiple harness components, thereby reducing the number of newly manufactured components, which also reduces costs. Furthermore, in the wire harness 5 of this modified example, by increasing the positional accuracy of the exterior member relative to the protected portion 10a for each harness component, the positional accuracy of each component can be easily increased when these are integrated, which also reduces the cost.

[0093] Here, the wire harness 5 of this modified example does not require dedicated fixing parts for fixing the harness components to each other, which also contributes to cost reduction. Furthermore, even if the wire harness 5 of this modified example needs to add a circuit after assembly and there is no exterior member for assembling the harness components for the post-installation circuit to the pre-existing electric wire group 10, the exterior member can be simply provided at a desired location on the pre-existing electric wire group 10, and the exterior member of the harness components for the post-installation circuit can be welded to this exterior member. Therefore, the wire harness 5 of this modified example allows for easy post-installation of circuits without using dedicated fixing parts, which also contributes to cost reduction. [Explanation of symbols]

[0094] 1,2,3,4,5 Wire harness 10 wire group 10a Protected parts 11 Electric wire 11A drain wire 11a Covering 11b core wire 12 main line 12a Branch 13 Branch wire 20, 23, 25, 120, 220, 223 Exterior materials 20A, 120A One exterior member 20B, 120B Other exterior member 21a, 26a, 121a One end side 21b, 26b, 121b Other end side 23a One wall 23b The other wall 23c through hole 30,130,230,330 Harness parts 31,131,231,331 Joint 32,132,232,332 Welded part 33,233 Auxiliary welding part 40 Clamp 41 Clamp body 42 Fixing protrusion 51 Shielding material 122 Bend 221a,221b end Ma No. 1 Mold Ma1 installation surface Ma2 groove Mb 2nd mold Mc 3rd mold Mc2 protrusion T jig T1 groove

Claims

1. a plurality of harness components are provided, each of which includes an electric wire group having a plurality of electric wires and a pair of sheet-like insulating exterior members that sandwich and house portions of the electric wire group to be protected; The harness component has a joint portion that contacts the pair of exterior members and a weld portion where the joint portions are welded to each other along the axial direction of the portion to be protected, and both ends of the weld portion are free ends, The plurality of harness components are integrated by welding the joints between the respective pairs of exterior members.

2. A harness component is provided, the harness component comprising a wire group having a plurality of wires and a sheet-like insulating exterior member that is folded back and accommodates portions of the wire group to be protected inside the folded back member, The harness component has joints that meet at the folded ends of the exterior member, and a welded portion with free ends at both ends, where the joints are welded together along the axial direction of the portion to be protected between the joints, The plurality of harness components are integrated by welding the joints between the exterior members of the respective harness components.

3. A plurality of harness components are provided, each comprising an electric wire group having a plurality of electric wires and a sheet-like insulating exterior member that houses portions of the electric wire group to be protected therein, At least one first harness component is provided as the harness components, the first harness component including a first group of electric wires as the group of electric wires and including a pair of first exterior members as the exterior members that sandwich and accommodate the portion of the first group of electric wires to be protected therein, and at least one second harness component is provided as the harness components, the second harness component including a second group of electric wires as the group of electric wires and including a second exterior member as the exterior member that is folded back and accommodates the portion of the second group of electric wires to be protected therein, the first harness component has joints that contact each other between the pair of first exterior members, and a welded portion with both ends being free ends, where the joints are welded together between the contacting joints along the axial direction of the portion to be protected of the first group of electric wires, the second harness component has a joint portion that contacts the folded end of the second exterior member, and a welded portion having free ends at both ends, where the joint portions are welded to each other between the contacting joint portions along the axial direction of the portion to be protected of the second electric wire group, The plurality of harness components are integrated by welding the joints between the exterior members of the respective harness components.

4. A wire harness as described in claim 1, 2 or 3, characterized in that the group of electric wires has a main line and branch electric wires branched off from a branch portion of the main line, and that a part of the main line including the branch portion and the branch electric wires are the protected parts.

5. A wire harness as described in claim 4, characterized in that the harness parts have auxiliary welded portions between the adjoining joints, from the free end of one of the welded portions to the free end of the other, and connecting the free end of one of the welded portions with the free end of the other.

6. A wire harness as described in Claim 5, characterized in that the auxiliary welding portion welds the outer peripheral edges of the adjoining joint portions together to connect the free end of one of the welding portions to the free end of the other of the welding portions.

7. In the harness component, one end side and the other end side of the pair of exterior members that are in contact with each other across the portion to be protected are respectively the joint portions, One of the pair of exterior members is made of a material harder than the other exterior member, and the other exterior member is formed into a flat sheet shape, 2. The wire harness according to claim 1, wherein one of the exterior members has a bent portion between the one end side and the other end side, the bent portion forming an accommodation space for the portion to be protected between the other exterior member and the one of the exterior members.

8. A harness component is provided that includes an electric wire group having a plurality of electric wires, and a pair of sheet-like insulating exterior members that sandwich and house portions of the electric wire group to be protected, The harness component has a joint portion that contacts the pair of exterior members and a weld portion where the joint portions are welded to each other along the axial direction of the portion to be protected, and both ends of the weld portion are free ends, In the harness component, one end side and the other end side of the pair of exterior members that are in contact with each other across the portion to be protected are respectively defined as the joint portion, One of the pair of exterior members is made of a material harder than the other exterior member, and the other exterior member is formed into a flat sheet shape, The wire harness is characterized in that one of the exterior members has a bent portion between the one end side and the other end side, which forms an accommodation space for the part to be protected between the other exterior member and the one of the exterior members.

9. A clamp having a clamp body for assembling a predetermined portion of the group of electric wires to an assembly object, and a fixing protrusion protruding from the clamp body, 4. The wire harness according to claim 1, wherein the exterior member has a through hole through which the clamp body is inserted from one wall surface side to the other wall surface side, and the fixing protrusion is clamped between the one wall surface and the group of electric wires.

10. The group of electric wires has a trunk line and branch electric wires branched from a branch portion of the trunk line, and a part of the trunk line including the branch portion and the branch electric wires are the protected parts, The wire harness according to claim 9, wherein the exterior member has the through hole at a location where the branch portion is present.

11. A sheet-like shielding member is provided between the part to be protected and the exterior member, 4. The wire harness according to claim 1, 2 or 3, wherein one of the plurality of electric wires constituting the group of electric wires is a drain wire in which a portion of the covering is removed to expose a core wire, and the exposed core wire is brought into contact with the shielding member.

12. A first installation step of placing one sheet-like insulating exterior member on the installation surface of the first mold; a second installation step of placing a portion to be protected of a group of electric wires including a plurality of electric wires on one of the exterior members; a third installation step of placing a sheet-like insulating other exterior member on one of the exterior members and the portion to be protected, and sandwiching the portion to be protected between the one exterior member and the other exterior member; a fourth installation step of sandwiching one end side and the other end side of the one exterior member and the other exterior member, as viewed from the portion to be protected, between the first mold and the second mold, respectively; a welding process of welding the one end side and the other end side of the one exterior member and the other exterior member along an axial direction of the portion to be protected; A method for manufacturing a wire harness, comprising:

13. In the first installation step, one of the exterior members in the form of a flat sheet is placed on the first mold having a groove portion on the installation surface, a bent portion forming step is provided in which, after the first placing step, one of the exterior members is sandwiched between the first mold and a third mold, and a protruding portion of the third mold is fitted into the groove of the first mold to form a bent portion in one of the exterior members that is aligned with the groove and the protruding portion, In the second installation step, the part to be protected is installed in the bent portion formed in the bent portion formation step, In the third installation step, the other exterior member formed into a flat sheet shape using a material harder than the one exterior member is placed on the one exterior member, and the portion to be protected in the bent portion is sandwiched between the one exterior member and the other exterior member, 13. The method for manufacturing a wire harness according to claim 12, wherein in the fourth installation step, the one end side and the other end side of the one exterior member and the other exterior member that are in contact with each other across the portion to be protected are clamped between the first mold and the second mold, respectively.

14. A first installation step of bending a sheet-like insulating exterior member into a V-shaped or U-shaped bent shape and placing it in a V-shaped or U-shaped groove portion of a jig so that the bent shape conforms to the shape of the groove portion; a second installation step of installing a portion to be protected of a group of electric wires including a plurality of electric wires in the bent exterior member; a third installation step of sandwiching the ends of the exterior member, which are folded back around the portion to be protected as an axis, between a first mold and a second mold; a welding process of welding the ends of the exterior member together along the axial direction of the part to be protected; A method for manufacturing a wire harness, comprising:

15. After the first installation step, a shield installation step is provided in which a sheet-like shielding member is bent into a V-shaped or U-shaped bent shape and placed along the inner wall surface of the bent-shaped exterior member, 15. The method for manufacturing a wire harness according to claim 14, wherein in the second installation step, the portion to be protected is installed in the bent shielding member starting from the drain wire, and an exposed core wire of the drain wire is brought into contact with an inner wall surface of the shielding member.

Images