Wire harness

Abstract

To suppress fraying of yarns in a cut part, in a woven fabric.SOLUTION: A wire harness 10 includes an electric wire 20, and a woven fabric 30 covering the periphery of the electric wire 20. The woven fabric 30 is formed by weaving warps 31 and wefts 32 each having base yarns. At least one of the warps 31 and the wefts 32 is a composite yarn having the base yarns, and a resin part which is provided on the outer peripheral part of the base yarns and has a melting point lower than that of the base yarn. The end having a cut edge part 41 of the woven fabric 30 is defined as a weld part 42 in which the warps 31 and the wefts 32 are welded to each other through the resin part.SELECTED DRAWING: Figure 2

Description

[Technical Field]

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

[0002] Patent Document 1 discloses a net-like protective material for a wire harness. This net-like protective material is formed by pressurizing and heat welding the intersections of vertical and horizontal wires made of flame-retardant resin wire material, and the vertical and horizontal wires are overlapped at the intersections without being woven. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-148335 Summary of the Invention [Problem to be solved by the invention]

[0004] Woven fabrics are sometimes used as protective materials, and when such fabrics are cut to the required length, fraying of threads can occur at the cut portions.

[0005] Therefore, an object of the present invention is to suppress fraying of threads at cut portions in woven fabrics. [Means for solving the problem]

[0006] The wire harness of the present disclosure includes electric wires and a woven fabric covering the electric wires, the woven fabric being formed by weaving warp threads and weft threads each having a base yarn, at least one of the warp threads and the weft threads being a composite yarn having the base yarn and a resin portion having a lower melting point than the base yarn and provided on the outer periphery of the base yarn, and an end of the woven fabric having a cut edge portion is a welded portion where the warp threads and the weft threads are welded via the resin portion. [Effects of the Invention]

[0007] According to the present disclosure, fraying of threads at cut portions in woven fabric can be suppressed. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view showing a wire harness according to a first embodiment. [Figure 2] FIG. 2 is an exploded plan view showing the wire harness. [Figure 3] FIG. 3 is an explanatory diagram showing a composite yarn. [Figure 4] FIG. 4 is an enlarged view of area A1 in FIG. [Figure 5] FIG. 5 is a cross-sectional view taken along line VV in FIG. [Figure 6] FIG. 6 is an explanatory diagram showing how the woven fabric is formed. [Figure 7] FIG. 7 is an explanatory diagram showing how the woven fabric is formed. [Figure 8] FIG. 8 is an explanatory diagram showing how the woven fabric is formed. DETAILED DESCRIPTION OF THE INVENTION

[0009] [Description of the embodiments of the present disclosure] First, embodiments of the present disclosure will be listed and described.

[0010] The wire harness of the present disclosure is as follows.

[0011] (1) A wire harness comprising an electric wire and a woven fabric covering the electric wire, the woven fabric being formed by weaving warp threads and weft threads each having a base yarn, at least one of the warp threads and the weft threads being a composite yarn having the base yarn and a resin portion having a lower melting point than the base yarn and provided on the outer periphery of the base yarn, and an end of the woven fabric having a cut edge portion is a welded portion where the warp threads and the weft threads are welded via the resin portion.

[0012] According to the wire harness of (1), the end portion of the woven fabric having the cut edge portion is formed as a welded portion, so that fraying of the threads at the end portion due to cutting of the woven fabric is suppressed.

[0013] (2) In the wire harness of (1), the composite yarn may include a core yarn as the base yarn and a sheath yarn as the resin portion, and the sheath yarn may be spirally wound around the core yarn. This makes it easy to obtain a composite yarn having the base yarn and the resin portion. Furthermore, at the welded portion, the sheath yarn melts during welding and coats the core yarn, thereby suppressing fiber fuzzing at the cut edge.

[0014] (3) In the wire harness of (1) or (2), at least half of the area of ​​the woven fabric in a middle portion from the end portions may be a non-welded portion in which the warp yarns and the weft yarns are not welded, thereby making it easier to obtain the original properties of the woven fabric in the middle portion that is not a non-welded portion.

[0015] (4) In the wire harness of any one of (1) to (3), the woven fabric may be formed in an elongated sheet shape and wrapped around the electric wires so that the long sides are aligned in the extending direction of the electric wires and the short sides are aligned in the circumferential direction of the electric wires. This makes it easier to later attach the woven fabric to the electric wires compared to when the woven fabric is formed in a tubular shape in advance.

[0016] (5) In the wire harness of (4), the edge of the short side may be the cutting edge portion, which makes it easier to set the welding portion only in a portion along the extending direction of the electric wires.

[0017] (6) In the wire harness of (4) or (5), the long sides may be aligned along the direction in which the warp threads extend, the short sides may be aligned along the direction in which the weft threads extend, and the weft threads may be folded back at the long sides. This makes it difficult for the long sides of the woven fabric to fray even when they are used as non-welded portions.

[0018] (7) In the wire harness of any one of (1) to (6), the base yarn may be a yarn made of a high-strength fiber, which makes it easier to obtain a woven fabric with high protective performance.

[0019] [Details of the embodiments of the present disclosure] Specific examples of the wire harness of the present disclosure will be described below with reference to the drawings. Note that the present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0020] [Embodiment 1] The wire harness 10 according to the first embodiment will be described below. Fig. 1 is a perspective view showing the wire harness 10 according to the first embodiment. Fig. 2 is an exploded plan view showing the wire harness 10. Fig. 3 is an explanatory view showing a composite yarn 33. Fig. 4 is an enlarged view of an area A1 in Fig. 2. Fig. 5 is a cross-sectional view taken along line VV in Fig. 2.

[0021] The wire harness 10 includes an electric wire 20 and a woven fabric 30 that covers the electric wire 20. The wire harness 10 is mounted on a vehicle or the like to connect devices to each other. Such devices are not particularly limited, but may be, for example, a motor, an inverter, a high-voltage battery, etc. In this case, the wire harness 10 is also called a high-voltage harness, etc.

[0022] The electric wire 20 includes a core wire 21 and a covering layer 22. The electric wire 20 is a covered electric wire. The core wire 21 is made of a metal such as copper, a copper alloy, aluminum, or an aluminum alloy. The covering layer 22 is formed, for example, by extruding an insulating resin around the core wire 21. Such a resin is, for example, polyethylene or polyvinyl chloride. When the wire harness 10 is a high-voltage harness, the electric wire 20 is a high-voltage electric wire. The number of electric wires 20 may be one or more. A connection part such as a terminal or a connector 24 is provided at the end of the electric wire 20. Here, the ends of the multiple electric wires 20 are positioned by the housing of one connector 24. A connection terminal may be provided so that the ends of the multiple electric wires 20 can move freely relative to each other.

[0023] The woven fabric 30 is formed by weaving warp threads 31 and weft threads 32. The weave of the woven fabric 30 is not particularly limited and can be set as appropriate. FIG. 2 shows an example of a plain weave weave, but it may also be a twill weave, satin weave, or the like. Here, the woven fabric 30 is formed in the shape of an elongated sheet and wrapped around the electric wire 20. The long sides 40 of the woven fabric 30 are aligned along the extension direction of the electric wire 20. The short sides 41 of the woven fabric 30 are aligned along the circumferential direction of the electric wire 20. The woven fabric 30 is wrapped around the electric wire 20 so as to be so-called longitudinally attached. Here, the long sides 40 are aligned along the extension direction of the warp threads 31. The short sides 41 are aligned along the extension direction of the weft threads 32. The woven fabric 30 covers the electric wire 20 up to near the connector 24. The woven fabric 30 may be fixed to the electric wire 20 with adhesive tape or the like. In this case, adhesive tape or the like may be wrapped around the end of the woven fabric 30 and the electric wire 20 .

[0024] The woven fabric 30 includes an end portion having a cut edge 41. Here, the woven fabric 30 also includes an end portion without a cut edge 41. Here, the short sides 41 are the cut edges 41, and the long sides 40 are not the cut edges 41. In the woven fabric 30, the ends in the long direction are the ends with the cut edges 41, and the ends in the short direction are the ends without the cut edges 41. Hereinafter, the long direction may be referred to as the longitudinal direction, and the short direction may be referred to as the width direction.

[0025] The weft threads 32 are folded back at the long sides 40. Adjacent weft threads 32 are connected to each other at the widthwise end of the woven fabric 30. Connecting portions connecting the weft threads 32 are provided alternately at one end and the other end in the widthwise direction.

[0026] Each of the warp yarns 31 and the weft yarns 32 has a base yarn 34. At least one of the warp yarns 31 and the weft yarns 32 is a composite yarn 33. The composite yarn 33 has a base yarn 34 and a resin portion 35.

[0027] Here, the base yarn 34 is a yarn made of high-strength fiber. This gives the woven fabric high impact resistance. The high-strength fiber may be a fiber called super fiber or the like. Here, the high-strength fiber is para-aramid fiber. The high-strength fiber may also be meta-aramid fiber, ultra-high molecular weight polyethylene fiber, polyarylate fiber, ultra-high strength PVA fiber, PBO (polyparaphenylene benzobisoxazole) fiber, PPS (polyphenylene sulfide) fiber, polyimide fiber, glass fiber, carbon fiber, or the like.

[0028] The resin portion 35 is provided on the outer periphery of the base thread 34. The resin portion 35 has a lower melting point than the base thread 34. Here, the resin of the resin portion 35 is low-melting-point nylon or the like.

[0029] Here, the composite yarn 33 includes a core yarn 34 as the base yarn 34 and a sheath yarn 35 as the resin portion 35. The sheath yarn 35 is spirally wound around the core yarn 34. The core yarn 34 preferably extends as straight as possible, and preferably extends straighter than the sheath yarn 35. Each of the core yarn 34 and the sheath yarn 35 may be twisted yarn. The composite yarn 33 may be a covering yarn. The composite yarn 33 may be a single covering yarn in which the sheath yarn 35 is wound once. In this case, the sheath yarn 35 may be wound in an S twist or a Z twist. The composite yarn 33 may be a double covering yarn in which the sheath yarn 35 is wound twice. In this case, it is preferable that one of the inner sheath yarn 35 and the outer sheath yarn 35 is S twisted and the other is Z twisted. The composite yarn 33 may be a twisted yarn in which the base yarn 34 and the yarn forming the resin portion are twisted together in an S twist or a Z twist.

[0030] The woven fabric 30 includes a welded portion 42. Here, the woven fabric 30 further includes a non-welded portion 43. The welded portion 42 is a portion where the warp threads 31 and the weft threads 32 are welded via a resin portion 35. The non-welded portion 43 is a portion where the warp threads 31 and the weft threads 32 are not welded. The non-welded portion 43 is a portion that is not a welded portion 42.

[0031] In the welded portions 42, the warp yarns 31 and weft yarns 32 are fixed to each other at the intersections. In the non-welded portions 43, the warp yarns 31 and weft yarns 32 are constrained only by their intersections. In the non-welded portions 43, the warp yarns 31 and weft yarns 32 can move toward and away from each other within the range affected by the intersections. The relative movement of the warp yarns 31 and weft yarns 32 in the welded portions 42 is more difficult than the relative movement of the warp yarns 31 and weft yarns 32 in the non-welded portions 43.

[0032] The end of the woven fabric 30 having the cut edge 41 serves as the welded portion 42. Here, since the short side 41 serves as the welded portion 42, the welded portion 42 extends along the circumferential direction of the electric wire 20.

[0033] The extent of the welded portions 42 is not particularly limited and can be set as appropriate. The extent of the welded portions 42 at one end may be, for example, the extent of one or more weft threads 32, two or more weft threads 32, or three or more weft threads. The extent of the welded portions 42 at one end may be, for example, the extent of 10 or fewer weft threads 32, seven or fewer weft threads 32, or five or fewer weft threads 32. Here, the welded portions 42 at one end are approximately two to five weft threads 32. Here, the welded portions 42 are not provided in the woven fabric 30 other than the end portions. The welded portions 42 may be provided in the woven fabric 30 other than the end portions.

[0034] The extent of the non-welded portions 43 is not particularly limited and can be set as appropriate. For example, the extent of the non-welded portions 43 may be wider than the extent of the welded portions 42 in the longitudinal direction of the woven fabric 30. For example, more than half of the area of ​​the middle portion of the woven fabric 30 from the ends may be non-welded portions 43. The middle portion of the woven fabric 30 from the ends refers to the portion between the non-welded portions 43 on one end side and the non-welded portions 43 on the other end side, excluding the welded portions 42 on the ends. For example, the extent of the non-welded portions 43 in the middle portion of the woven fabric 30 from the ends may be 60% or more, 70% or more, 80% or more, 90% or more, or even 100%. When the extent of the non-welded portions 43 in the middle portion is 100%, the entire area between the welded portions 42 on one end side and the welded portions 42 on the other end side of the woven fabric 30 is non-welded portions 43. If the ratio is less than 100%, there will be a welded portion 42 sandwiched between non-welded portions 43 between a welded portion 42 on one end of woven fabric 30 and a welded portion 42 on the other end.

[0035] Furthermore, for example, more than half of the entire area of ​​the woven fabric 30 may be non-welded portions 43. The range of the non-welded portions 43 may be 60% or more, 70% or more, 80% or more, or 90% or more of the entire woven fabric 30. Since the woven fabric 30 has welded portions 42 at the end portions, the range of the non-welded portions 43 is less than 100% of the entire woven fabric 30.

[0036] In the welded portion 42, it is preferable that the warp yarns 31 and the weft yarns 32 are welded at positions where they overlap each other. In the welded portion 42, adjacent warp yarns 31 may be welded to each other. In the welded portion 42, adjacent weft yarns 32 may be welded to each other. In the welded portion 42, the woven pattern, which is the space between the yarns, may be completely filled with the resin portion 35. In the welded portion 42, the woven pattern, which is the space between the yarns, may remain.

[0037] In the welded portions 42, the resin portions 35 do not form the sheath yarn 35. In the welded portions 42, the resin portions 35 do not form a spiral thread. In the welded portions 42, the contacting portions of the sheath yarn 35 may be bonded to form a mass. For example, multiple sheath yarns 35 may be bonded to each other. Also, for example, adjacent spiral portions of each sheath yarn 35 may be bonded to each other. At the longitudinal end surface of the woven fabric 30, the end faces of multiple core yarns 34 may be embedded in the end face of the mass. At the longitudinal end surface of the woven fabric 30, the cut end face of a mass of one resin portion 35 may cover the end faces of the core yarns 34 of multiple warp yarns 31. In the non-welded portions 43, the resin portions 35 form the sheath yarn 35. In the non-welded portions 43, the sheath yarn 35 of the warp yarn 31 and the sheath yarn 35 of the weft yarn 32 are in contact with each other but are not welded. The resin portion 35 may be deformed from the cut edge portion 41 toward the unwelded portion 43 so as to gradually approach the body of the sheath thread 35 from a lump state.

[0038] The method for manufacturing the woven fabric will be described with reference to Figures 6 to 8. Figures 6 to 8 are explanatory diagrams showing how the woven fabric 30 is formed.

[0039] First, as shown in Fig. 6, a base material 30B is prepared by weaving warp yarns 31 and weft yarns 32. The warp yarns 31 and weft yarns 32 are composite yarns 33. The base material 30B does not have a welded portion 42. The base material 30B may be wound in a roll shape around a drum 80, for example. Here, the base material 30B is preferably wound so that the warp yarns 31 extend in the circumferential direction of the drum 80.

[0040] Next, as shown in FIG. 7, a portion of the substrate 30B fed from the drum 80 along its extension direction is heated by a heater 82 across the entire width. As a result, welded portions 42B are partially formed on the substrate 30B as shown in FIG. 8. When forming the welded portions 42, the portions that will become the welded portions 42B may or may not be pressed. The welded portions 42B are provided over an area twice the size of the welded portions 42. The welded portions 42B are provided sequentially along the extension direction of the substrate 30B at intervals corresponding to the length of the woven fabric 30.

[0041] Next, as shown in FIG. 8, the base material 30B is cut at the position of the welded portion 42B using a cutter 84 or the like. It is preferable that the cutting line passes through the center of the welded portion 42B. The welded portion 42B is cut and separated into two pieces to form the welded portion 42. By cutting the base material 30B at the two welded portions 42B, a woven fabric 30 having the required length and an end portion having the cut edge 41 as the welded portion 42 is produced. When cutting the base material 30B, cutting the welded portion 42 of the base material 30B prevents fraying of the threads after cutting.

[0042] After the base material 30B is cut to a required length, the end portion having the cut edge portion 41 may be heated to form the welded portion 42.

[0043] <Effects, etc.> According to the wire harness 10 configured as described above, the end of the woven fabric 30 having the cut edge portion 41 is made into a welded portion 42, thereby suppressing fraying of the threads at that end due to cutting of the woven fabric 30.

[0044] The composite yarn 33 includes a core yarn 34 and a sheath yarn 35, and the sheath yarn 35 is wound spirally around the core yarn 34. This makes it easy to obtain a composite yarn 33 having a base yarn 34 and a resin portion 35. Furthermore, at the welded portion 42, the sheath yarn 35 melts during welding and coats the periphery of the core yarn 34, thereby suppressing fuzzing of the fibers at the cut edge portion 41.

[0045] In addition, more than half of the area of ​​the woven fabric 30 in the middle portion from the ends is an unwelded portion 43 where the warp yarns 31 and weft yarns 32 are not welded. This makes it easier for the original properties of the woven fabric 30 to be obtained in the middle portion that is the unwelded portion 43.

[0046] The woven fabric 30 is formed in a long, thin sheet shape and is wound around the electric wire 20 so that the long sides 40 are aligned in the extending direction of the electric wire 20 and the short sides 41 are aligned in the circumferential direction of the electric wire 20. This makes it easier to later attach the woven fabric 30 to the electric wire 20 compared to when the woven fabric 30 is formed in a cylindrical shape in advance.

[0047] Further, the short side 41 is the cutting edge 41. This makes it easier to set the welding portion 42 only in a portion of the electric wire 20 along the extending direction.

[0048] Furthermore, the weft threads 32 are folded back at the long sides 40. This makes the long sides 40 of the woven fabric 30 less likely to fray even when they are made into non-welded portions 43.

[0049] Furthermore, since the base yarn 34 is made of high-strength fiber, it is easy to obtain a woven fabric 30 with high protective performance.

[0050] [Note] Up to now, the composite yarn 33 has been described as including a core yarn 34 as a base yarn 34 and a sheath yarn 35 as a resin portion 35, and the sheath yarn 35 is spirally wound around the core yarn 34, but this is not an essential configuration. The resin portion 35 may be formed by coating the outer periphery of the core yarn 34 with resin.

[0051] In addition, although it has been described above that the woven fabric 30 is formed in an elongated sheet shape and wound around the electric wire 20 so that the long sides 40 are aligned in the extending direction of the electric wire 20 and the short sides 41 are aligned in the circumferential direction of the electric wire 20, this is not a required configuration. The woven fabric 30 may be formed in a tubular shape. Furthermore, the woven fabric 30 formed in an elongated sheet shape may be spirally wound around the electric wire 20.

[0052] Furthermore, although the short side 41 has been described as being the cutting edge 41, this is not an essential configuration. The long side 40 may also be the cutting edge.

[0053] Although the weft yarns 32 have been described above as being folded back at the long sides 40, this is not a required configuration. For example, the weft yarns may not be folded back at the long sides 40 of the woven fabric 30, for example, by making the long sides 40 into cutting edges.

[0054] Although the base yarn 34 has been described as being made of high-strength fibers, this is not a necessary configuration. The base yarn 34 may be made of fibers other than high-strength fibers.

[0055] The wire harness 10 may further include a protective material other than the woven fabric 30. Such a protective material may be provided between the electric wires 20 and the woven fabric 30, or may be provided on the outer periphery of the woven fabric 30. The protective material may be, for example, a metal pipe.

[0056] The configurations described in the above embodiments and modifications can be combined as appropriate as long as they are not mutually contradictory. [Explanation of symbols]

[0057] 10 Wire harness 20 Electric wire 21 Core Wire 22 Covering layer 24 connectors 30 Woven fabric 30B base material 31 Warp 32 Weft 33 Composite yarn 34 Core thread (base thread) 35 Sheath thread (resin part) 40 Long side (widthwise edge) 41 Short side (longitudinal edge, cut edge) 42 Welded area 43 Non-welded area 80 drums 82 Heater 84 cutter

Claims

1. Electric wires and a woven fabric covering the electric wire; Equipped with The woven fabric is formed by weaving warp yarns and weft yarns each having a base yarn, At least one of the warp yarn and the weft yarn is a composite yarn having the base yarn and a resin portion provided on the outer periphery of the base yarn and having a melting point lower than that of the base yarn, an end portion of the woven fabric having a cut edge portion is a welded portion where the warp yarns and the weft yarns are welded via the resin portion, The wire harness, wherein the welded portion is a pressed portion.

2. The wire harness according to claim 1, the composite yarn includes a core yarn as the base yarn and a sheath yarn as the resin portion, The sheath yarn is wound spirally around the core yarn.

3. The wire harness according to claim 1 or 2, In the wire harness, at least half of the area of ​​the woven fabric in a middle portion from the end portions is a non-welded portion in which the warp threads and the weft threads are not welded.

4. The wire harness according to claim 1 or 2, The woven fabric is formed into an elongated sheet shape and is wound around the electric wires so that the long sides are aligned in the extending direction of the electric wires and the short sides are aligned in the circumferential direction of the electric wires.

5. The wire harness according to claim 4, The edge of the short side of the wire harness is the cut edge portion.

6. The wire harness according to claim 4, The long sides are aligned along the extension direction of the warp yarns, The short side is aligned along the extending direction of the weft yarn, The weft thread is folded back at the long side of the wire harness.

7. The wire harness according to claim 1 or 2, The base yarn is a yarn made of a high-strength fiber.

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