Method for forming a sealing structure for a wire harness and injection member

Abstract

To provide a method, etc., for forming the sealing structure of a wire harness, capable of preventing air bubbles from being further formed in the inside of a sealing part.SOLUTION: A method for forming the sealing structure of a wire harness comprises: holding a wire harness including a connector including a plurality of terminal fittings and a plurality of electric wires connected to the respective wire connection of the plurality of terminal fittings so as to position the housing of the connector below the electric wires in the vertical direction; opening both ends so as to surround the plurality of wire connections and attaching a cylindrical mold having a through hole on a side surface on the vertical upper side of the housing; attaching a detention plug for blocking the through hole from the inside of the mold to a tip; inserting an injection needle for discharging a resin from a predetermined place on the side surface into the through hole; injecting the resin into the inside of the mold from the injection needle; drawing the injection needle from the through hole; and blocking the through hole from the inside of the mold by the detention plug when drawing the injection needle from the through hole.SELECTED DRAWING: Figure 28

Description

Technical Field

[0001] The present invention relates to a method for forming a sealing structure of a wire harness and the like.

Background Art

[0002] A wire harness is a component composed of a bundle of a plurality of electric wires and connectors. For example, wire harnesses are widely used in high-performance machines and automobiles. Generally, connectors are attached to both ends of the electric wires of the wire harness. The connectors are used for connecting wire harnesses to each other, connecting electrical components, and the like. In the following description, among the plurality of surfaces constituting the exterior of the connector, the surface on the side that fits with another connector is referred to as the front, and the surface on the side to which the electric wire is connected is referred to as the back.

[0003] A hollow portion for arranging terminal fittings is formed in the housing of the connector, and the terminal fittings are inserted into the hollow portion. Thereby, the terminal fittings are fixed to the housing. One side of the terminal fitting is an electric wire connection portion, and the other side is a terminal portion that fits with another connector. The end portions of the respective electric wires are connected to the electric wire connection portions of the terminal fittings by crimping or soldering. Therefore, the electric wire connection portions are aligned on the back of the connector. This arrangement is determined according to a standard specification in a general connector. For example, the pin arrangement of a general connector, D-SUB (D-Subminiature), is defined by a standard specification by the IEC (International Electrotechnical Commission, International Electrotechnical Commission). If the above-mentioned electric wire connection portion is exposed, there is a possibility that conduction failure due to oxidation of the terminal fitting or short circuit between the terminal fittings due to adhesion of dust may occur.

[0004] Therefore, methods for protecting the wire connection are being considered. For example, Patent Document 1 discloses a technique for providing a sealing part (molded part) at the connection between the connector and the wire. This technique uses a jig attached to the front of the connector and a mold attached to the back of the connector. The jig is hermetically attached to the front of the connector. This configuration forms an air reservoir chamber. The air reservoir chamber is in communication with the hollow part (terminal housing chamber) of the housing in which each metal terminal is housed. The mold includes an opening attached to the back of the connector, a cavity for housing the wire for a required length, a wire exit hole from which the wire is pulled out, a resin injection port, and an air vent hole formed on the side of the cavity. When injecting the mold resin into the cavity, the front of the connector is positioned vertically upward and the back of the connector is positioned vertically downward. That is, when injecting the mold resin, the jig is positioned vertically upward and the mold is positioned vertically downward. The mold resin is then injected into the cavity from the resin injection port of the mold. When the molding resin is injected into the cavity, the front side of the connector is sealed by a jig. As a result, a sealed space is formed in the terminal housing chamber. The air pressure in this sealed space prevents the molding resin from flowing out into the terminal housing chamber. In this way, a sealing portion (molded portion) that covers the connection between the connector and the electric wire can be formed. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2018-129125 [Overview of the project] [Problems that the invention aims to solve]

[0006] In the technology described in Patent Document 1, a jig is attached to the front of the connector so as to form a sealed space in the terminal housing chamber, and then molding resin is injected into the cavity. This fills the cavity with molding resin. As the molding resin filled in the cavity solidifies, a sealing portion (molded portion) is formed. At this time, the air contained in the molding resin moves vertically upward. The air that reaches the surface of the molding resin is then discharged through the air vent hole. However, in the above configuration, the terminal housing chamber is a sealed space. Therefore, the air pressure in the space above the molding resin increases when the molding resin is injected. As a result, the air contained in the molding resin is less likely to be released into the sealed space of the terminal housing chamber. Thus, there were cases where the air contained in the molding resin was not discharged through the air vent hole. That is, the air contained in the molding resin sometimes remained as bubbles in the molding resin. And when the molding resin solidified, bubbles sometimes formed in the sealing portion (molded portion).

[0007] In a normal temperature and atmospheric pressure environment, the presence of air bubbles within the sealing portion (molded portion) does not pose a particular problem. However, under high temperature or low pressure conditions, the air bubbles within the sealing portion expand. This expansion of air bubbles causes damage to the sealing portion (e.g., cracking).

[0008] This invention has been made in view of the above-mentioned problems, and aims to provide a method for forming a wire harness sealing structure in which air bubbles are less likely to form inside the sealing portion. [Means for solving the problem]

[0009] To solve the above problems, the present invention provides a method for forming a sealed structure for a wire harness, comprising a connector having a plurality of terminal fittings and a plurality of wires connected to each of the wire connection parts of the plurality of terminal fittings, and holding the wire harness such that the housing of the connector is positioned below the wires in the vertical direction. A cylindrical mold with open ends and through holes on its sides is attached vertically above the housing so as to surround the plurality of wire connection parts. An injection needle, which discharges resin from a predetermined location on its side, is inserted into the through hole, a retaining plug is attached to the tip of the mold for closing the through hole from the inside, resin is injected into the mold from the injection needle, the injection needle is withdrawn from the through hole, and the through hole is closed from the inside of the mold with the retaining plug when the injection needle is withdrawn from the through hole.

[0010] Furthermore, the injection member of the present invention comprises an injection needle having a discharge port for discharging the resin at a predetermined location on the side surface of a hollow tube, and a retaining plug attached to the tip of the injection needle having an outer diameter larger than the outer diameter of the injection needle, wherein the retaining plug holds a part of the retaining plug and is removed from the injection needle by moving the injection needle away from the retaining plug. [Effects of the Invention]

[0011] The effect of the present invention is to provide a method for forming a wire harness sealing structure in which air bubbles are less likely to form inside the sealing portion. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic diagram illustrating the method for forming a sealing structure for a wire harness according to the first embodiment. [Figure 2] This is a schematic top view showing an example of a wire harness used in the first embodiment. [Figure 3] This is a schematic side view showing an example of a wire harness used in the first embodiment. [Figure 4] This is a schematic rear view showing an example of a wire harness used in the first embodiment. [Figure 5] It is a side schematic view showing an example of a formwork used in the first embodiment. [Figure 6] It is a side schematic view explaining the outline of a method for forming a sealing structure of a wire harness in the first embodiment. [[ID=�]] [Figure 7] It is a schematic view showing a specific example of an injection member in the first embodiment. [Figure 8] It is an exploded view showing a specific example of an injection member in the first embodiment. [Figure 9] It is an exploded view showing another specific example of an injection member in the first embodiment. [Figure 10] It is a cross-sectional schematic view showing the first state of forming a sealing structure of a wire harness in the first embodiment. [Figure 11] It is a cross-sectional schematic view showing the second state of forming a sealing structure of a wire harness in the first embodiment. [Figure 12] It is a cross-sectional schematic view showing the third state of forming a sealing structure of a wire harness in the first embodiment. [Figure 13] [[ID=2🎈]]It is a cross-sectional schematic view showing the fourth state of forming a sealing structure of a wire harness in the first embodiment. [Figure 14] It is a flowchart showing a method for forming a sealing structure of a wire harness in the first embodiment. [Figure 15] It is a cross-sectional schematic view showing a modification example 1 of the formwork used in the first embodiment. [Figure 16] It is a cross-sectional schematic view showing a modification example 2 of the formwork used in the first embodiment. [Figure 17] It is a side schematic view showing a modification example 3 of the formwork used in the first embodiment. [Figure 18] It is a side schematic view showing the first state of resin injection in modification example 3 of the first embodiment. [Figure 19] It is a side schematic view showing the second state of resin injection in modification example 3 of the first embodiment. [Figure 20] It is a side schematic view showing the third state of resin injection in modification example 3 of the first embodiment. [Figure 21]It is a schematic cross-sectional view showing a first state of forming a sealing structure of a wire harness according to a second embodiment. [Figure 22] It is a schematic cross-sectional view showing a second state of forming a sealing structure of a wire harness according to a second embodiment. [Figure 23] It is a schematic cross-sectional view showing a third state of forming a sealing structure of a wire harness according to a second embodiment. [Figure 24] It is a schematic cross-sectional view showing a fourth state of forming a sealing structure of a wire harness according to a second embodiment. [Figure 25] It is an exploded view showing a specific example of an injection member according to a second embodiment. [Figure 26] It is an exploded view showing another specific example of an injection member according to a first embodiment. [Figure 27] It is a flowchart showing a method of forming a sealing structure of a wire harness according to a second embodiment. [Figure 28] It is a schematic view explaining a method of forming a sealing structure of a wire harness according to a third embodiment. [Figure 29] It is a flowchart showing a method of forming a sealing structure of a wire harness according to a third embodiment.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the embodiments described below have technically preferable limitations for carrying out the present invention, but do not limit the scope of the invention below. In addition, the same reference numerals are given to the same components in each drawing, and the description may be omitted.

[0014] (First Embodiment) Figure 1 is a schematic diagram illustrating a method for forming a sealing structure for a wire harness according to a first embodiment. In this embodiment, the method for forming a sealing structure for a wire harness forms a sealing structure on the wire harness 100. The wire harness 100 comprises a connector 90 and an electric wire 80. Here, the electric wire and the wire of the wire harness 100 have the same meaning. In this embodiment, the side of the connector 90 that is mated with other connectors is referred to as the front, and the opposite side is referred to as the back.

[0015] In the method for forming the sealing structure of the wire harness 100 according to this embodiment, a mold 10, an injection needle 20, and a retaining plug 30 are used.

[0016] The injection needle 20 is a hollow tubular component. The tip of the injection needle 20 is closed. A discharge port 21 for discharging resin is provided at a predetermined location on the side of the injection needle 20 near the tip.

[0017] A retaining plug 30 is attached to the tip of the injection needle 20. In this embodiment, the combination of the injection needle 20 and the retaining plug 30 is referred to as the injection member 50. The retaining plug 30 closes the through hole 11 from inside the mold 10 after the resin has been injected.

[0018] In Figure 1, the connector 90 is held such that, in the vertical direction, the housing 92 of the connector 90 is located below the electric wire 80. A formwork 10 is attached to the vertically upper side of the housing 92. The formwork 10 surrounds the electric wire connection part 91b, and the vertically upper side of the formwork 10 is open. A through hole 11 is provided on the side of the formwork 10. An injection needle 20 is inserted into the inside of the formwork 10 from the through hole 11. A retaining plug 30 is attached to the tip of the injection needle 20. A discharge port 21 for discharging resin is provided on the side near the tip of the injection needle 20. With this configuration, resin is injected into the inside of the formwork 10 from the discharge port 21. After the resin is injected, the injection needle 20 is withdrawn from the through hole 11. At this time, the retaining plug 30 catches on the edge of the through hole 11, and the retaining plug 30 closes the through hole 11.

[0019] Next, a specific example of the wire harness 100 sealed in this embodiment will be described. Figure 2 is a schematic top view showing an example of the wire harness 100 used in the first embodiment. Figure 3 is a schematic side view showing an example of the wire harness 100 used in the first embodiment. Figure 4 is a schematic rear view showing an example of the wire harness 100 used in the first embodiment. Figure 4 shows the rear view as seen when cut at AA' in Figure 2.

[0020] The connector 90 comprises a plurality of terminal fittings 91 and a housing 92. The housing 92 holds the plurality of terminal fittings 91. The housing 92 is an insulator. The terminal fittings 91 are arranged in the housing 92 at predetermined intervals. The terminal portions 91a of the terminal fittings 91 are lined up on the front side of the connector 90. The wire connection portions 91b of the terminal fittings 91 are lined up on the back side of the connector 90. The wire 80 is connected to the wire connection portions 91b. For connection, for example, crimping or soldering can be used.

[0021] In this specific example, a 25-pin D-SUB connector is assumed as connector 90. In a 25-pin D-SUB connector, 25 terminal fittings 91 are arranged in two rows. However, in Figure 2, one row is omitted to avoid making the diagram too complex.

[0022] As shown in Figures 2 and 3, each terminal fitting 91 is arranged in the housing 92 such that one end is a terminal portion 91a and the other end is a wire connection portion 91b. The housing 92 is held in place by the shell 93.

[0023] As shown in Figure 4, the wire connection portions 91b of the terminal fitting 91 are arranged on the back side of the connector 90. A wire 80 is connected to each of the wire connection portions 91b. The wire 80 is, for example, an insulated wire. The insulation is removed from the ends of the wire 80, and the wire 80 is connected to the wire connection portion 91b by crimping or soldering.

[0024] Next, a specific example of the formwork 10 will be described. Figure 5 is a schematic side view showing an example of the formwork 10 used in the first embodiment. The formwork 10 is a cylindrical member with openings at both ends. Through holes 11 are formed on the side of the formwork 10. The formwork 10 may be a single piece or a structure made up of two or more parts.

[0025] As shown in Figure 5, the connector 90 is held such that, in the vertical direction, the housing 92 of the connector 90 is located below the electric wire 80. A cylindrical formwork 10 is attached to the vertically upper side of the housing 92 so as to surround the multiple electric wire connection portions 91b. A through hole 11 is provided in the formwork 10 near the housing 92.

[0026] Figure 6 is a schematic side view illustrating the outline of the method for forming the sealing structure of the wire harness 100 according to the first embodiment. First, as shown in Figure 6, the connector 90 is held. At this time, in the vertical direction, the housing 92 of the connector 90 is located below the electric wire 80. A mold 10 is attached to the vertically upper side of the housing 92. The mold 10 surrounds the electric wire connection part 91b, and the vertically upper side of the mold 10 is open. A through hole 11 is provided on the side of the mold 10. An injection needle 20 is inserted from the through hole 11 into the inside of the mold 10. A retaining plug 30 is attached to the tip of the injection needle 20. A discharge port 21 for discharging resin is provided on the side near the tip of the injection needle 20. With this configuration, the injection needle 20 is inserted into the through hole 11. Next, resin is injected into the inside of the mold 10 from the discharge port 21. After the resin is injected, the injection needle 20 is withdrawn from the through hole 11. At this point, the retaining plug 30 catches on the edge of the through hole 11, and the retaining plug 30 closes the through hole 11.

[0027] Next, a specific example of the injection member 50 will be described. Figure 7 is a schematic diagram showing a specific example of the injection member of the first embodiment. The injection needle 20 is a hollow tubular member. The tip of the injection needle 20 is closed. In addition, a discharge port 21 is provided on the side near the tip of the injection needle 20. The position where the discharge port 21 is provided is not particularly limited, but for example, a projection 22 is provided at the tip of the injection needle 20 at a distance from the tip that is approximately the thickness of the material forming the injection needle 20. A retaining plug 30 is attached to this projection 22.

[0028] A base 23 is provided on the opposite side of the tip of the injection needle 20. The base 23 is attached to the syringe 40. Resin is supplied to the injection needle 20 from the syringe 40. The resin supplied to the injection needle 20 is discharged from the discharge port 21. The material of the injection needle 20 is, for example, stainless steel or a metal with plating.

[0029] Figure 8 is an exploded view showing a specific example of the injection member 50 of the first embodiment. The tip of the injection needle 20 is provided with a projection 22. The retaining plug 30 is provided with a mounting hole 31 that fits into the projection 22. The tip of the retaining plug 30 is, for example, conical. In the example of Figure 8, the shape of the retaining plug 30 is bulging in the middle, with the outer diameter in the middle being larger than both ends. Figure 8 is merely an example, and the shape of the retaining plug 30 is not limited to this example. The shape of the retaining plug 30 may be, for example, a polygonal pyramidal shape or a spheroidal shape. The retaining plug 30 is an elastic material such as rubber or soft plastic. The projection 22 is inserted into the mounting hole 31. The retaining plug 30 is held on the injection needle 20 by frictional force. Therefore, if a force is applied in a direction that separates the retaining plug 30 and the injection needle 20, the retaining plug 30 will detach from the injection needle 20.

[0030] Figure 9 is an exploded view showing another specific example of the injection member 50 of the first embodiment. In this example, the injection needle 20 has a projection 22 at its tip. A flange 22a is also provided at the tip of the projection 22. The retaining plug 30 is provided with a mounting hole 31a into which the flange 22a fits. In this configuration, the flange 22a engages with the mounting hole 31a, making it difficult for the retaining plug 30 to come off the projection 22.

[0031] Next, the injection of resin into the mold 10 will be described. Figure 10 is a schematic cross-sectional view showing the first state of the formation of the sealing structure of the wire harness in the first embodiment. Figure 10 shows the state before the injection member 50 is inserted into the mold 10. The figure is viewed from vertically above. The outer diameter of the retaining plug 30 is larger than the inner diameter of the through hole 11.

[0032] Figure 11 is a schematic cross-sectional view showing the second state of the sealing structure formation of the wire harness according to the first embodiment. The retaining plug 30 is inserted into the through hole 11. Since the retaining plug 30 is an elastic body, it can be deformed. The retaining plug 30 is inserted into the through hole 11 while deforming.

[0033] Figure 12 is a schematic cross-sectional view showing the third state of the formation of the sealing structure of the wire harness in the first embodiment. The discharge port 21 of the injection needle 20 is inside the mold 10. In the example of Figure 12, this positional relationship is formed when the base 23 abuts against the outer wall of the mold 10. Then, resin 200 is discharged from the discharge port 21 into the inside of the mold 10. This operation injects resin 200 around the wire connection part 91b and the wire 80 inside the mold 10. The injection is continued until the resin 200 inside the mold 10 reaches a predetermined height.

[0034] Figure 13 is a schematic cross-sectional view showing the fourth state of the sealing structure formation of the wire harness according to the first embodiment. Figure 13 shows the state after the injection of a predetermined amount of resin 200 has been completed and the injection needle 20 has been withdrawn from the through hole 11. The outer diameter of the retaining plug 30 is larger than the inner diameter of the through hole 11. Also, a projection 22 is inserted into the mounting hole 31. This insertion attaches the retaining plug 30 to the injection needle 20. Therefore, when the injection needle 20 is withdrawn from the through hole 11, the retaining plug 30 catches on the edge of the through hole 11. The retaining plug 30 is then left in the resin 200 with the through hole 11 blocked. By blocking the through hole 11 with the retaining plug 30, it is possible to prevent the resin 200 inside the mold 10 from flowing out to the outside.

[0035] Then, after the resin 200 has solidified, the mold 10 is removed, completing the formation of the sealing structure (not shown).

[0036] The method for forming the sealed structure of the wire harness 100 described above can be summarized in a flowchart. Figure 14 is a flowchart of the method for forming the sealed structure of the wire harness according to the first embodiment. First, the connector 90 is held so that the housing 92 of the connector 90 is located below the electric wire 80 in the vertical direction (S101). Next, a cylindrical mold 10 is attached to the vertically upper side of the housing 92 so as to surround the multiple electric wire connection parts 91b (S102). Next, an injection needle 20 with a retaining plug 30 attached to its tip is inserted into the through hole 11 (S103). Next, resin 200 is injected from the injection needle 20 into the inside of the mold 10 (S104). Next, the injection needle 20 is withdrawn from the through hole 11. At this time, the retaining plug 30 closes the through hole 11 from the inside of the mold 10 (S105). Next, the resin is solidified, the mold 10 is removed, and the formation of the sealing structure is completed (S106).

[0037] In the above method for forming the sealed structure of the wire harness 100, resin 200 is injected through a through hole 11 provided on the side of the mold 10. The wire connection portion 91b is mounted vertically above the housing 92. The through hole 11 is closer to the wire connection portion 91b than the opening on the top surface of the mold 10. Therefore, the resin 200 can easily flow around the wire connection portion 91b. Also, the vertically above the resin 200 is open. Therefore, air bubbles mixed into the resin 200 can easily be released. Therefore, air bubbles are less likely to be mixed into the resin 200. As a result, air bubbles are less likely to form inside the sealed portion. Thus, the method of Patent Document 1 provides a method for forming the sealed structure of a wire harness 100 in which air bubbles are less likely to form in the sealed portion.

[0038] (Variation 1) Next, a modified example of the formwork 10 will be described.

[0039] Figure 15 is a schematic cross-sectional view showing a modified formwork 1 used in the first embodiment. In the example in Figure 15, the inner diameter of the through-hole 11 in the outer wall of the formwork 10 is smaller than the inner diameter of the through-hole 11 in the inner wall of the formwork 10. In other words, the through-hole 11 has a tapered shape with a smaller diameter on the outer wall side. In addition, the retaining plug 30 has a bulging shape in the middle. This combination of through-hole 11 and retaining plug 30 makes it easier for the retaining plug 30 to lock into the through-hole 11. As a result, the closure of the through-hole 11 becomes more reliable.

[0040] (Modification 2) Figure 16 is a schematic cross-sectional view showing a modified formwork 2 used in the first embodiment. In the example of Figure 15, the inner diameter of the through-hole 11 in the outer wall of the formwork 10 is smaller than the inner diameter of the through-hole 11 in the inner wall of the formwork 10. The through-hole 11 has a stepped shape in which the inner diameter changes midway. In addition, the through-hole 11 in the inner wall of the formwork 10 is chamfered. Furthermore, the retaining plug 30 has a bulging shape in the middle. This combination of through-hole 11 and retaining plug 30 makes it easier for the retaining plug 30 to be locked into the through-hole 11. As a result, the closure of the through-hole 11 becomes more reliable.

[0041] (Variation 3) Figure 17 is a schematic side view showing a modified formwork 3 used in the first embodiment. The formwork 10 of modified formwork 3 is provided with multiple through holes 11. Each through hole 11 is at a different distance from the top surface of the housing 92. In other words, multiple through holes 11 are provided at different heights in the vertical direction. Then, the resin 200 is injected sequentially from the bottom through hole 11. In the example in Figure 17, there are three through holes 11.

[0042] Figure 18 is a schematic side view showing the first state of resin injection in Modification 3 of the first embodiment. Figure 18 shows the injection needle 20 inserted into the lowest of the three through holes 11 (closest to the housing 92). In this state, resin 200 is discharged from the discharge port 21 and injected into the mold 10. Resin 200 is injected until the upper surface of the resin 200 exceeds the retaining plug 30, and the injection needle 20 is withdrawn from the through hole 11. At this time, the retaining plug 30 detaches from the injection needle 20 and closes the through hole 11.

[0043] Figure 19 is a schematic side view showing the second state of resin injection in Modification 3 of the first embodiment. Figure 19 shows the injection needle 20 inserted into the second-to-last through hole 11 of the three. The bottommost through hole 11 is closed by a retaining plug 30. In this state, resin 200 is discharged from the discharge port 21 and injected into the mold 10. Resin 200 is injected until the top surface of the resin 200 exceeds the retaining plug 30, and the injection needle 20 is withdrawn from the through hole 11. At this time, the retaining plug 30 detaches from the injection needle 20 and closes the through hole 11.

[0044] Figure 20 is a schematic side view showing the third state of resin injection in Modification 3 of the first embodiment. Figure 20 shows the state in which the injection needle 20 is inserted into the third from the bottom, i.e., the uppermost through hole 11. The two lower through holes 11 are blocked by the retaining plug 30. Also, the resin 200 is filled up to this height. In this state, the resin 200 is discharged from the discharge port 21 and injected into the mold 10. Then the resin 200 is injected until the upper surface of the resin 200 exceeds the retaining plug 30, and the injection needle 20 is withdrawn from the through hole 11. At this time, the retaining plug 30 detaches from the injection needle 20 and blocks the through hole 11.

[0045] As described above, the resin 200 is injected into the mold 10 in stages using multiple through holes 11 of different heights provided in the mold 10. This method increases the probability of air bubbles escaping from the top surface of the resin 200 compared to injecting the entire amount of resin 200 at once. As a result, air bubbles are less likely to form inside the resin 200 that constitutes the sealing portion.

[0046] The method for forming a sealing structure for a wire harness according to the first embodiment has been described above.

[0047] The method for forming a sealing structure for a wire harness in this embodiment involves forming a sealing structure around the wire connection portion 91b of the wire harness 100. The wire harness 100 includes a connector 90 and wires 80. Multiple terminal fittings 91 are attached to the housing 92 of the connector 90. Multiple wires 80 are connected to each wire connection portion 91b of the multiple terminal fittings 91. In the method for forming a sealing structure for a wire harness in this embodiment, a mold 10, an injection needle 20, and a retaining plug 30 are used. The mold 10 is cylindrical with both ends open and through holes on its sides. The injection needle 20 discharges resin from a predetermined location on its side. A retaining plug 30 is attached to the tip of the injection needle 20. The retaining plug 30 closes the through hole 11 from inside the mold 10. In forming the sealing structure, first, the wire harness 100 is held so that the housing 92 of the connector 90 is positioned below the electric wire 80 in the vertical direction. Next, a mold 10 is attached to the vertically upper side of the housing 92 so as to surround the multiple electric wire connection parts 91b. Next, an injection needle 20 with a retaining plug 30 attached to its tip is inserted into the through hole 11. Next, resin 200 is injected into the mold 10 from the injection needle 20. Next, the injection needle 20 is withdrawn from the through hole 11. At this time, the retaining plug 30 closes the through hole 11 from the inside of the mold.

[0048] In the above method for forming the sealed structure of the wire harness 100, resin 200 is injected through a through hole 11 provided on the side of the mold 10. The wire connection part 91b is mounted vertically above the housing 92. The through hole 11 is closer to the wire connection part 91b than the opening on the top surface of the mold 10. Therefore, the resin 200 can easily flow around the wire connection part 91b. Also, the vertically above the resin 200 is open. Therefore, air bubbles mixed into the resin 200 can easily be released to the outside. As a result, air bubbles are less likely to be mixed into the resin 200. In other words, air bubbles are less likely to form inside the sealed part.

[0049] In another embodiment, in a method for forming a sealed structure for a wire harness, the retaining plug 30 is made of an elastic material. The retaining plug 30 also has an outer diameter larger than the inner diameter of the through hole 11. In this method for forming a sealed structure for a wire harness, when the injection needle 20 is inserted into the through hole 11, the retaining plug 30 is deformed to pass through the through hole 11. With this configuration, the retaining plug 30 easily passes through the through hole 11 during insertion. Also, the retaining plug 30 easily closes the through hole 11 when withdrawing.

[0050] In another embodiment, in the method for forming a sealing structure for a wire harness, the tip of the retaining plug 30 has a conical or pyramidal shape. This configuration makes it easier for the retaining plug 30 to pass through the through hole 11 during insertion.

[0051] In another embodiment, in a method for forming a sealing structure for a wire harness, a projection 22 is provided at the tip of the injection needle 20, and the retaining plug 30 has a mounting hole 31 that fits into the projection 22. With this configuration, the retaining plug 30 is held by the injection needle 20 when inserted, and the retaining plug 30 can be easily removed from the injection needle 20 when withdrawn.

[0052] In another embodiment, in a method for forming a sealing structure for a wire harness, a projection 22 is provided at the tip of the injection needle 20, and the retaining plug 30 has a mounting hole 31 that fits into the projection 22. Furthermore, a flange portion 22a is formed at the tip of the projection 22. With this configuration, the retaining plug 30 is less likely to come off the injection needle 20 during insertion.

[0053] In another embodiment, in the method for forming a sealing structure for a wire harness, the inner diameter of the through-hole 11 in the outer wall of the formwork 10 is smaller than the inner diameter of the through-hole 11 in the inner wall of the formwork 10. This configuration makes it easier for the retaining plug 30 to be locked into the through-hole 11. As a result, the sealing of the through-hole 11 becomes more reliable.

[0054] In another embodiment, in a method for forming a sealing structure for a wire harness, a mold 10 is provided with a plurality of through holes 11. Each of the through holes 11 is at a different distance from the upper surface of the housing 92. Here, the upper surface is the vertically upward surface. Then, the injection needle 20 is sequentially inserted into each of the plurality of through holes 11 in order of proximity to the vertically upward surface of the housing 92, and resin is injected. In this configuration, the resin 200 is injected into the mold 10 in stages using the plurality of through holes 11 at different heights provided in the mold 10. By doing so, the probability of air bubbles escaping from the upper surface of the resin 200 is higher than in a method of injecting the entire amount of resin 200 at once. As a result, it becomes less likely for air bubbles to form inside the resin 200 that constitutes the sealing part.

[0055] Furthermore, the injection member 50 of this embodiment includes an injection needle 20 and a retaining plug 30. The injection needle 20 is provided with a discharge port 21 for discharging resin 200 at a predetermined location on the side of the hollow tube. The retaining plug 30 is attached to the tip of the injection needle 20. The outer diameter of the retaining plug 30 is larger than the outer diameter of the injection needle 20. A part of the retaining plug 30 is held, and when a force is applied to the injection needle 20 in a direction away from the retaining plug 30, the retaining plug 30 is removed from the injection needle 20. When this injection member 50 is used, the attachment of the retaining plug 30 to the injection needle 20 is maintained when it is inserted into the through hole 11 provided in the mold 10. When the injection of resin 200 into the mold 10 is completed and the injection needle 20 is withdrawn, the retaining plug 30 is removed from the injection needle 20 while blocking the through hole 11.

[0056] (Second embodiment) In the first embodiment, the retaining plug 30 was an elastic body, and the retaining plug 30 deformed to pass through the through hole 11. In this embodiment, an example is described in which the retaining plug 30b is formed in a cylindrical shape with screw threads on the outside, and the through hole 11 is a screw hole corresponding to the screw threads.

[0057] Figure 21 is a schematic cross-sectional view showing the first state of the formation of the sealing structure of the wire harness in the second embodiment. The retaining plug 30b is formed in a cylindrical shape with screw threads on the outside and is attached to the tip of the injection needle 20. The configuration of the injection needle 20 is the same as in the first embodiment, so its description is omitted. Figure 21 shows the state before the injection needle 20 is inserted into the mold 10.

[0058] Figure 22 is a schematic cross-sectional view showing the second state of the formation of the sealing structure of the wire harness in the second embodiment. By screwing the retaining plug 30b into the through hole 11, the injection needle 20 advances toward the inside of the formwork 10.

[0059] Figure 23 is a schematic cross-sectional view showing the third state of the formation of the sealing structure of the wire harness according to the second embodiment. As the retaining plug 30b is screwed into the through hole 11, the injection needle 20 becomes insertable into the through hole 11 once the retaining plug 30b has passed through the through hole 11. Figure 23 shows the injection needle 20 inserted until the base 23 abuts against the mold 10. In this state, resin 200 is discharged from the discharge port 21 and injected into the mold 10.

[0060] Figure 24 is a schematic cross-sectional view showing the fourth state of the sealing structure formation of the wire harness according to the second embodiment. In Figure 24, the retaining plug 30b is rotated in the opposite direction to when it was inserted, and the retaining plug 30b is fitted into the through hole 11. Furthermore, the injection needle 20 has been withdrawn from the retaining plug 30b. Also, the resin 200 is filled around the wire connection part 91b and the wire 80. In this state, the wire connection part 91b is sealed, and the resin 200 is prevented from flowing out of the mold 10.

[0061] Figure 25 is an exploded view showing a specific example of the injection member of the second embodiment. The projection 22b at the tip of the injection needle 20 has an elliptical cross-section. The retaining plug 30b is also provided with an elliptical mounting hole 31b that fits into the projection 22b. With this combination, the rotation of the injection needle 20 and the retaining plug 30b is linked. Therefore, by rotating the injection needle 20, the retaining plug 30b can be screwed into the through hole 11 or moved in the opposite direction.

[0062] Figure 26 is an exploded view showing another specific example of the injection member of the first embodiment. In this example, the projection 22b at the tip of the injection needle 20b has a hexagonal cross-section. The retaining plug 30b is also provided with a hexagonal mounting hole 31b. The mounting hole 31b is fitted into the projection 22b. With this combination, the rotation of the injection needle 20 and the retaining plug 30b is linked. Therefore, by rotating the injection needle 20, the retaining plug 30b can be screwed into the through hole 11 or moved in the opposite direction.

[0063] Although examples of elliptical and hexagonal cross-sectional shapes of the projection 22b were described above, the shape is not limited to these. In other words, any shape can be used as long as the injection needle 20 does not rotate freely against the indwelling plug 30b.

[0064] Figure 27 is a flowchart illustrating a method for forming a sealed wire harness according to a second embodiment. First, the connector 90 is held so that the housing 92 of the connector 90 is positioned below the electric wire 80 in the vertical direction (S201). Next, a cylindrical mold 10 is attached to the vertically upper side of the housing 92 so as to surround the multiple electric wire connection parts 91b (S202). Next, the retaining plug 30b is screwed into the screw hole of the mold, and the discharge port is positioned inside the mold (S203). Next, resin 200 is injected into the inside of the mold 10 from the injection needle 20 (S204). Next, the retaining plug 30b is rotated in the opposite direction to the screwing in, and the retaining plug 30b is screwed into the through hole 11 (S205). This closes the through hole 11. Next, the injection needle 20 is withdrawn from the retaining plug 30b (S206). Next, the resin 200 is solidified and the mold 10 is removed (S207). In this way, the sealing structure for the wire harness is formed. By the above method, a sealing structure for the wire harness is formed that is less likely to form air bubbles inside the sealing part, similar to the first embodiment.

[0065] The method for forming the sealing structure of the wire harness according to the second embodiment has been described above.

[0066] In the wire harness sealing structure formation method of this embodiment, the retaining plug 30b is formed in a cylindrical shape with screw threads on the outside. The through hole 11 is a screw hole corresponding to the screw threads. In this configuration, the retaining plug 30b is inserted into the mold 10 by rotating the injection needle 20. After the resin 200 is injected, the retaining plug 30b is retained in the through hole 11, and the through hole 11 is closed. In this way, it becomes possible to inject resin 200 with few air bubbles and to close the through hole 11.

[0067] In another embodiment, in the wire harness sealing structure forming method of this embodiment, a projection 22b is provided at the tip of the injection needle 20. The cross-sectional shape of the projection 22b is polygonal or elliptical. This cross-section is a plane perpendicular to the extending direction of the injection needle 20. Furthermore, the retaining plug 30b has a mounting hole 31b into which the projection 22b fits. With this configuration, the rotation of the injection needle 20 and the rotation of the retaining plug 30b are linked, allowing the retaining plug 30b to be screwed into the through hole 11 and to move in the reverse direction.

[0068] (Third embodiment) Figure 28 is a schematic diagram illustrating a method for forming a sealing structure for a wire harness according to a third embodiment. In this embodiment, the method for forming a sealing structure for a wire harness involves forming a sealing structure on a wire harness 100. The wire harness 100 comprises a connector 90 and an electric wire 80. The connector 90 comprises a plurality of terminal fittings 91 and a housing 92. The housing 92 holds the plurality of terminal fittings 91. The electric wire 80 is connected to the electric wire connection portion 91b.

[0069] In the wire harness sealing structure formation method of this embodiment, a mold 10, an injection needle 20, and a retaining plug 30 are used.

[0070] The formwork 10 is a cylindrical member with openings at both ends. Through holes 11 are formed on the side of the formwork 10.

[0071] An outlet 21 for discharging resin is provided at a predetermined location on the side of the injection needle 20.

[0072] A retaining plug 30 is attached to the tip of the injection needle 20. The retaining plug 30 closes the through hole 11 from inside the formwork 10.

[0073] Next, the details of the method for forming the sealing structure of the wire harness 100 according to this embodiment will be described. Figure 29 is a flowchart showing the method for forming the sealing structure of the wire harness according to the third embodiment. First, the connector 90 is held so that the housing 92 of the connector 90 is located below the electric wire 80 in the vertical direction (S301). Next, a cylindrical mold 10 is attached to the vertically upper side of the housing 92 so as to surround the plurality of electric wire connection parts 91b (S302). Next, an injection needle 20 with a retaining plug 30 attached to its tip is inserted into the through hole 11 (S303). Next, resin 200 is injected from the injection needle 20 into the inside of the mold 10 (S304). Next, the injection needle 20 is withdrawn from the through hole 11. At this time, the retaining plug 30 closes the through hole 11 from the inside of the mold 10 (S305).

[0074] In the above method for forming the sealed structure of the wire harness 100, resin 200 is injected through a through hole 11 provided on the side of the mold 10. The wire connection portion 91b is mounted vertically above the housing 92. The through hole 11 is closer to the wire connection portion 91b than the opening on the top surface of the mold 10. Therefore, the resin 200 can easily flow around the wire connection portion 91b. Also, the vertically above the resin 200 is open. Therefore, air bubbles mixed into the resin 200 can easily be released to the outside. In other words, air bubbles are less likely to be mixed into the resin 200. As a result, air bubbles are less likely to form inside the sealed portion. Thus, the method of Patent Document 1 provides a method for forming the sealed structure of a wire harness 100 in which air bubbles are less likely to form in the sealed portion.

[0075] The method for forming a sealing structure for a wire harness according to the third embodiment has been described above.

[0076] The method for forming a sealing structure for a wire harness in this embodiment involves forming a sealing structure around the wire connection portion 91b of the wire harness 100. The wire harness 100 includes a connector 90 and wires 80. Multiple terminal fittings 91 are attached to the housing 92 of the connector 90. Multiple wires 80 are connected to each wire connection portion 91b of the multiple terminal fittings 91. In the method for forming a sealing structure for a wire harness in this embodiment, a mold 10, an injection needle 20, and a retaining plug 30 are used. The mold 10 is cylindrical with both ends open and through holes on its sides. The injection needle 20 discharges resin from a predetermined location on its side. A retaining plug 30 is attached to the tip of the injection needle 20. The retaining plug 30 closes the through hole 11 from inside the mold 10. In forming the sealing structure, first, the wire harness 100 is held so that the housing 92 of the connector 90 is positioned below the electric wire 80 in the vertical direction. Next, a mold 10 is attached to the vertically upper side of the housing 92 so as to surround the multiple electric wire connection parts 91b. Next, an injection needle 20 with a retaining plug 30 attached to its tip is inserted into the through hole 11. Next, resin 200 is injected into the mold 10 from the injection needle 20. Next, the injection needle 20 is withdrawn from the through hole 11. At this time, the retaining plug 30 closes the through hole 11 from the inside of the mold.

[0077] In the above method for forming the sealed structure of the wire harness 100, resin 200 is injected through a through hole 11 provided on the side of the mold 10. The wire connection part 91b is mounted vertically above the housing 92. The through hole 11 is closer to the wire connection part 91b than the opening on the top surface of the mold 10. Therefore, the resin 200 can easily flow around the wire connection part 91b. Also, the vertically above the resin 200 is open. Therefore, air bubbles mixed into the resin 200 can easily be released to the outside. In other words, it is difficult for air bubbles to be mixed into the resin 200. As a result, it is difficult for air bubbles to form inside the sealed part.

[0078] The first to third embodiments have been described above as exemplary examples of the present invention. However, the present invention is not limited to the above embodiments. That is, the present invention can be applied in various forms that can be understood by those skilled in the art, within the scope of the present invention.

[0079] Some or all of the above embodiments may also be described as follows, but are not limited to the following:

[0080] (Note 1) A wire harness having a connector with multiple terminal fittings and multiple wires connected to the wire connection portions of each of the multiple terminal fittings is held in a vertical direction such that the housing of the connector is located below the wires. A cylindrical formwork, with open ends and through holes on its sides, is attached to the vertically upper side of the housing so as to surround the multiple wire connection points. A retaining plug for closing the through hole is attached to the tip of the mold, and an injection needle for discharging resin from a predetermined location on the side is inserted into the through hole. The resin is injected into the mold from the injection needle. Withdraw the injection needle from the through hole, When withdrawing the injection needle from the through hole, the through hole is closed from the inside of the formwork with the retaining plug. A method for forming a sealing structure for a wire harness, characterized by the features described above.

[0081] (Note 2) The retaining plug is formed of an elastic body having an outer diameter larger than the inner diameter of the through hole, When inserting the injection needle into the through hole, the retaining plug is deformed to allow it to pass through the through hole. A method for forming a sealing structure for a wire harness as described in Appendix 1, characterized by the features described herein.

[0082] (Note 3) The tip of the aforementioned retaining plug is Having a conical or pyramidal shape, A method for forming a sealing structure for a wire harness as described in Appendix 2, characterized by the features described herein.

[0083] (Note 4) A projection is provided at the tip of the injection needle. The retaining plug has a mounting hole that fits into the projection. Characterized by A method for forming a sealing structure for a wire harness as described in any one of the appendices 1 to 3.

[0084] (Note 5) A flange is formed at the tip of the aforementioned projection. A method for forming a sealing structure for a wire harness as described in Appendix 4, characterized by the features described herein.

[0085] (Note 6) The inner diameter of the through-hole in the outer wall of the formwork is smaller than the inner diameter of the through-hole in the inner wall of the formwork. A method for forming a sealing structure for a wire harness, characterized by the features described in any one of the appendices 1 to 5.

[0086] (Note 7) The aforementioned formwork is formed by assembling two or more parts. A method for forming a sealing structure for a wire harness, characterized by the features described in any one of the appendices 1 to 6.

[0087] (Note 8) Multiple through holes, each at a different distance from the vertically upward surface of the housing, are provided in the formwork. The injection needle is sequentially inserted into each of the multiple through holes in order of proximity to the vertically upward surface of the housing, and the resin is injected. A method for forming a sealing structure as described in any one of the appendices 1 to 7, characterized by the features described in the appendices 1 to 7.

[0088] (Note 9) The aforementioned retaining plug It is a cylindrical shape with screw threads on the outside, The aforementioned through hole, The screw hole corresponds to the aforementioned screw thread. A method for forming a sealing structure for a wire harness as described in Appendix 1, characterized by the features described herein.

[0089] (Note 10) A projection is provided at the tip of the injection needle. The cross-sectional shape of the projection perpendicular to the extending direction of the injection needle is polygonal or elliptical. The retaining plug has a mounting hole that fits into the projection. The method for forming a sealing structure as described in Appendix 9, characterized by the features described herein.

[0090] (Note 11) The formwork is provided with a plurality of through holes at different distances from the housing. The injection needle is inserted sequentially from the through hole closest to the housing, and the resin is injected. A method for forming a sealing structure as described in Appendix 9 or 10, characterized by the features described herein.

[0091] (Note 12) An injection needle equipped with a discharge port for dispensing resin at a predetermined location on the side of a hollow tube, An indwelling plug attached to the tip of the injection needle, with an outer diameter larger than the outer diameter of the injection needle, Equipped with, The aforementioned retaining plug is A portion of the indwelling plug is held, and when force is applied to the injection needle in a direction away from the indwelling plug, it detaches from the injection needle. An injection member characterized by the following features. [Explanation of symbols]

[0092] 10 formwork 11 Through holes 20 injection needles 21 Discharge port 22 Protrusions 23 Base 30 Indwelling plug 31 mounting holes 40 syringes 50 Injection component 90 connectors 91 Terminal fittings 91a Terminal section 91b Wire connection section 92 Housing 93 Shell 100 Wire Harness 200 resin

Claims

1. A wire harness having a connector with multiple terminal fittings and multiple wires connected to the wire connection portions of each of the multiple terminal fittings is held in a vertical direction such that the housing of the connector is located below the wires. A cylindrical formwork, with open ends and through holes on its sides, is attached to the vertically upper side of the housing so as to surround the multiple wire connection points. A retaining plug for closing the through hole is attached to the tip of the mold, and an injection needle for discharging resin from a predetermined location on the side is inserted into the through hole. The resin is injected into the mold from the injection needle. Withdraw the injection needle from the through hole, When withdrawing the injection needle from the through hole, the through hole is closed from the inside of the formwork with the retaining plug. A method for forming a sealing structure for a wire harness, characterized by the features described above.

2. The retaining plug is formed of an elastic body having an outer diameter larger than the inner diameter of the through hole, When inserting the injection needle into the through hole, the retaining plug is deformed to allow it to pass through the through hole. The method for forming a sealing structure for a wire harness according to feature 1.

3. The tip of the aforementioned retaining plug has a conical or pyramidal shape. The method for forming a sealing structure for a wire harness according to feature 2.

4. A projection is provided at the tip of the injection needle. The retaining plug has a mounting hole that fits into the projection. Characterized by A method for forming a sealing structure for a wire harness according to any one of claims 1 to 3.

5. A flange is formed at the tip of the aforementioned projection. The method for forming a sealing structure for a wire harness according to feature 4.

6. The inner diameter of the through-hole in the outer wall of the formwork is smaller than the inner diameter of the through-hole in the inner wall of the formwork. A method for forming a sealing structure for a wire harness according to any one of claims 1 to 3.

7. Multiple through holes, each at a different distance from the vertically upward surface of the housing, are provided in the formwork. The injection needle is sequentially inserted into each of the multiple through holes in order of proximity to the vertically upward surface of the housing, and the resin is injected. A method for forming a sealing structure for a wire harness according to any one of claims 1 to 3.

8. The aforementioned retaining plug It is formed in a cylindrical shape with screw threads on the outside, The aforementioned through hole, The screw hole corresponds to the aforementioned screw thread. The method for forming a sealing structure for a wire harness according to feature 1.

9. A projection is provided at the tip of the injection needle. The cross-sectional shape of the projection perpendicular to the extending direction of the injection needle is polygonal or elliptical. The retaining plug has a mounting hole that fits into the tip of the injection needle. The method for forming a sealing structure for a wire harness according to feature 8.

10. An injection needle equipped with a discharge port for dispensing resin at a predetermined location on the side of a hollow tube, An indwelling plug attached to the tip of the injection needle, with an outer diameter larger than the outer diameter of the injection needle, Equipped with, The aforementioned retaining plug is When a portion of the indwelling plug is held, and a force is applied to the injection needle in a direction that separates it from the indwelling plug, it detaches from the injection needle. An injection member characterized by the following features.

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