Wire harness and method for manufacturing the same

Abstract

To provide a wire harness in which a plurality of insulated wires are bundled without being bulky with stable quality.SOLUTION: In a wire harness 1 in which a plurality of covered wires 10 each having a conductor 5 covered with an insulation coating 6 are bundled, the insulation coatings 6 of the bundled covered wires 10 are bonded to each other via an adhesive layer 7 in a part of the longitudinal direction Y, and an adhesive fixing portion 30 was formed, and the adhesive layer 7 was composed of an adhesive that adheres and hardens under the action of at least one of heating, pressure, water, and light irradiation.SELECTED DRAWING: Figure 1

Description

Technical Field

[0006] ,

[0001] This invention relates to, for example, a wire harness in which a plurality of coated electric wires each having a conductor coated with an insulating coating are bundled, and a method for manufacturing the same.

Background Art

[0002] Electrical equipment installed in automobiles and the like constitutes an electrical circuit by connecting to another electrical equipment or a power supply device via a wire harness formed by bundling coated electric wires. Such a wire harness is routed along a three-dimensional wiring path, and thus is formed in a three-dimensional shape along the wiring path.

[0003] Specifically, each of the coated electric wires having a conductor coated with an insulating coating is arranged along a three-dimensional wiring path. After all the coated electric wires are arranged, as disclosed in Patent Document 1, all the coated electric wires are gathered together, and a tape is wound around the outer periphery thereof to form the wire harness. Thereby, the wire harness having a shape corresponding to the three-dimensional wiring path can be formed.

[0004] However, since each of the coated electric wires has flexibility, the tape winding operation of gathering a plurality of the coated electric wires together and winding a tape around them is difficult, and the manufacturing efficiency is poor. In addition, the force for winding the tape varies depending on the operator, and there is a risk that the quality of the tape winding state varies.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] An object of the present invention is to provide a wire harness with high manufacturing efficiency and stable quality, and a method for manufacturing the same. [Means for solving the problem]

[0007] This invention relates to a wire harness in which a plurality of insulated wires, each having a conductor covered with an insulating coating, are bundled together, wherein in a portion of the longitudinal direction, an adhesive fixing portion is formed in which the insulating coatings of the bundled insulated wires are bonded together. The insulated wire is provided with an adhesive layer covering the outer surface of the insulated wire, and a coating layer covering the outer surface of the adhesive layer, the coating layer being composed of an adhesive that adheres and hardens when at least one of heating, pressurizing, adding water, and irradiating with light is applied, and the adhesive fixing portion is formed when the adhesive layers exposed from the coating layer, which has increased fluidity, are bonded together. It is characterized by the following. The adhesive fixing portion in which the aforementioned insulating coatings are bonded together includes a mode in which the insulating coatings are bonded together with an adhesive or the like, or a mode in which the surface of the insulating coatings is melted and bonded together.

[0008] The above adhesive layers include hot melt layers such as polyamide-based hot melt, polyester-based hot melt, or olefin-based hot melt; reactive hot melt layers such as reactive polyurethane-based hot melt; thermoplastic adhesive films; and polyvinyl alcohol layers that dissolve and bond when water is applied. The adhesive layer may be composed of, for example, an anaerobic curing adhesive or a two-component reaction curing adhesive, in addition to the adhesive described above. Furthermore, the light refers to active light such as radiation or ultraviolet light.

[0009] This invention makes it possible to efficiently manufacture wire harnesses with consistent quality. More specifically, multiple insulated wires, each with an insulating coating covering the conductor, are bundled together, and an adhesive fixing portion is formed in a part of the longitudinal direction of the wire bundle constituting the wire harness, where the insulating coatings of the bundled insulated wires are bonded to each other. Therefore, the bundled insulated wires can be fixed together with more stable quality than a fixing method using tape, where multiple flexible insulated wires are bundled together and then wrapped with tape.

[0010] Furthermore, since the bundled insulated wires are fixed together by adhesive, this method of fixing is more efficient than the tape-wrapping method used to bundle multiple flexible insulated wires by wrapping tape around their outer circumference.

[0011] Furthermore, the insulated wire is provided with a coating layer that covers the outer surface of the adhesive layer, and in the adhesive fixing portion, the adhesive layers exposed from the coating layer, which has increased fluidity, are bonded to each other. As a result, the adhesive layer is covered with the coating layer, and the insulating coatings of other parts are not reliably bonded to each other, while efficiently bonding only the insulating coatings that constitute the adhesive fixing portion.

[0012] In another aspect of this invention, the adhesive layer may be composed of an adhesive that adheres and hardens when at least one of the following is applied: heating, pressurizing, adding water, and irradiating with light. This invention makes it possible to efficiently bond only the insulating coatings constituting the adhesive fixing portion to each other, without bonding the insulating coatings of other portions, by applying at least one of heating, pressurization, water addition, and light irradiation to the portion constituting the adhesive fixing portion.

[0013] Furthermore, adhesives that bond through the action of heating, pressurizing, adding water, or irradiating with light, as described above, refer to thermosetting adhesives, pressure-sensitive adhesives, wet-curing adhesives, and photocuring adhesives, respectively.

[0014] In one embodiment of this invention, the adhesive fixing portions may be provided in multiple locations at predetermined intervals in the longitudinal direction. This invention allows for more efficient manufacturing compared to, for example, forming the adhesive fixing portion along the entire length of the wire harness. Examples of locations where multiple adhesive fixing portions are formed along the longitudinal direction of the wire harness include near both ends, before and after bends, and at branching points where the shape changes. Furthermore, as described above, by forming the adhesive fixing portion at these shape-changing points, the desired shape can be maintained without forming the adhesive fixing portion along the entire length.

[0015] In another aspect of this invention, a main line and branch lines branching off from the main line may be provided, and the adhesive fixing portion may be formed at the branching portion where the branch lines branch off from the main line. The adhesive fixing portion formed at the branching portion may be formed only on the main line of the branching portion, or it may be formed across both the main line and the branch line of the branching portion.

[0016] This invention makes it possible to maintain the branch shape by the adhesive fixing part at branching points where the diameter of the wire bundle changes, such as branching points where the main wire and branch wires diverge, or branching points where the main wire branches into branch wires. At branching points where the diameter of the wire bundle changes, the main wire and branch wires extend in different directions, creating a junction between the main wire and branch wires. This makes the tape wrapping process, which involves wrapping tape around the junction, more complex. However, since the adhesive fixing part can be constructed simply by bonding the insulating coatings together, it is possible to prevent a decrease in manufacturing efficiency even at branching points.

[0017] In another aspect of this invention, the adhesive fixing portion may have higher rigidity than other parts. This invention makes it easier to maintain the shape of the adhesive fixing portion because the insulating coatings of the adhesive fixing portion are bonded together in such a way that they have higher rigidity than other parts. Furthermore, if the adhesive fixing portion is formed at a branching point, it is possible to prevent the branching between the main line and the branch line from spreading unintentionally.

[0018] As an aspect of the present invention, the coated wire may be provided with an adhesive layer that covers the outer peripheral surface of the coated wire. According to the present invention, the insulating coatings can be more reliably adhered to each other without degrading the insulating performance of the insulating coatings.

[0019] The present invention also relates to a method for manufacturing a wire harness in which a plurality of coated wires each having a conductor covered with an insulating coating are bundled, and in a part of the longitudinal direction, the insulating coatings of the bundled coated wires are adhered to form an adhesive fixing portion. The insulated wire is provided with an adhesive layer covering the outer surface of the insulated wire, and a coating layer covering the outer surface of the adhesive layer, the coating layer being composed of an adhesive that adheres and hardens when at least one of heating, pressurizing, adding water, and irradiating with light is applied, and the adhesive fixing portion is bonded to each other when at least one of heating, pressurizing, adding water, and irradiating with light is applied to the coating layer, which has increased fluidity, causing the adhesive layers exposed from the coating layer to adhere to each other. It is characterized by this.

[0020] According to the present invention, a wire harness of stable quality can be efficiently manufactured. Specifically, a plurality of coated wires each having a conductor covered with an insulating coating are bundled, and in a part of the longitudinal direction of the wire bundle constituting the wire harness, an adhesive fixing portion in which the insulating coatings of the bundled coated wires are adhered is formed. Therefore, compared with the fixing method by tape winding in which a plurality of the coated wires each having flexibility are bundled together by winding a tape around the outer periphery, the bundled coated wires can be fixed with stable quality, and a wire harness can be efficiently manufactured.

[0021] Further, as described above, according to the present invention, the operation of fixing a plurality of coated wires in a bundled state by adhering the plurality of coated wires to each other can be performed with stable quality, and thus it can contribute to the automation of the operation.

[0022] As an aspect of the present invention, a part of the plurality of coated wires may be bundled to form a plurality of thin wire bundles in which the adhesive fixing portions are formed, and the plurality of thin wire bundles may be bundled to form the adhesive fixing portions.

[0023] According to the present invention, a wire harness of stable quality can be manufactured more efficiently. More specifically, a bundle of thin wires, which consists of fewer insulated wires than a standard wire bundle, is easier to handle than a standard wire bundle, and the adhesive fixing portion can be easily formed. Furthermore, by bundling the thin wire bundles together and fixing them with the adhesive fixing portion, a more efficient and high-quality wire harness can be constructed.

[0024] Furthermore, when a bundle of thin wires is formed using only the insulated wires that constitute branch lines in a main line, the branch lines after branching are bundled together as a bundle of thin wires. This makes it possible to construct a higher quality wire harness without mishandling the insulated wires. [Effects of the Invention]

[0025] This invention provides a wire harness with high manufacturing efficiency and stable quality, as well as a method for manufacturing the same. [Brief explanation of the drawing]

[0026] [Figure 1] External view of the area around the branching section of the wire harness in this embodiment. [Figure 2] (a) is a cross-sectional view of line AA in Figure 1, and (b) is an enlarged view of region Z1 in Figure 2(a). [Figure 3] (a) is a cross-sectional view of line BB in Figure 1, and (b) is an enlarged view of region Z2 in Figure 3(a). [Figure 4] (a) is a cross-sectional view along line CC in Figure 1, and (b) is a cross-sectional view along line DD in Figure 1. [Figure 5] (a) is a cross-sectional view of the first wire group just before pressurization, corresponding to Figure 4(a); (b) is a cross-sectional view of the same wire group during pressurization; (c) is a cross-sectional view of the second wire group just before pressurization, corresponding to Figure 4(b); (d) is a cross-sectional view of the same wire group during pressurization. [Figure 6] (a) is a cross-sectional view showing the harness bonding process, corresponding to Figure 5(a), and (b) is a cross-sectional view showing the harness bonding process, corresponding to Figure 5(b). [Figure 7] External view of the area around another branching point of the wire harness in this embodiment. [Figure 8](a) is a cross-sectional view of the wire harness of modified example 1, corresponding to Figure 2(a), and (b) is a cross-sectional view of the same example, corresponding to Figure 2(b). [Figure 9] (a) is a cross-sectional view showing the state of the second wire group before pressurization during the manufacturing process of the wire harness of Modification 1, (b) is a cross-sectional view showing the state after the coating layer has melted, and (c) is a cross-sectional view showing the state after the adhesive layers have been bonded together. [Figure 10] (a) is an external view showing the process of forming an adhesive fixing part on the first wire group during the manufacturing process of the wire harness of Modification 2, (b) is a cross-sectional view of the EE wire in Figure 1 of (a), (c) is an external view showing the process of forming an adhesive fixing part on the second wire group, and (d) is an external view showing the process of forming a harness adhesive fixing part on the wire group. [Modes for carrying out the invention]

[0027] An embodiment of this invention will be described below with reference to the drawings. In the drawings, arrow X indicates the width direction of the wire harness 1, arrow Y indicates the longitudinal direction of the wire harness 1, and arrow Z indicates the up and down direction of the wire harness 1. Furthermore, in the drawings, arrow Xa indicates one side in the width direction, arrow Xb indicates the other side in the width direction, arrow Ya indicates one side in the longitudinal direction, arrow Yb indicates the other side in the longitudinal direction, arrow Za indicates the up direction, and arrow Zb indicates the down direction.

[0028] The wire harness 1 of this embodiment is incorporated into a vehicle such as an automobile, and each end in the longitudinal direction Y is electrically connected to various electrical equipment and on-board equipment such as power supplies (batteries) mounted on the vehicle via connectors (not shown), and is routed along a predetermined routing path in the vehicle.

[0029] Furthermore, as shown in Figure 1, the wire harness 1 includes a main harness 2 as a trunk line and a sub-harness 3 as a branch line that branches off from the main harness 2 and has a smaller diameter than the main harness 2. Both the main harness 2 and the sub-harness 3 have multiple electric wires 10.

[0030] At the branching point 4 where the sub-harness 3 branches off from the main harness 2, the wire harness 1 forms a roughly Y shape as the sub-harness 3 branches off from the main harness 2 toward the other longitudinal direction Yb and upward direction Za. However, the branching portion 4 is not limited to a Y shape; it may also be formed in a T shape or a cross shape such as a cross shape or an X shape, or it may be formed in a shape that branches into three or more branches.

[0031] In other words, the wire harness 1 consists of a first wire group 20A and a second wire group 20B. The first wire group 20A consists of multiple (19 in this example) wires 10 that extend continuously along the longitudinal direction Y, including the branching section 4, to constitute the main harness 2. The second wire group 20B constitutes part of the main harness 2 on one longitudinal side Ya with respect to the branching section 4, and constitutes the sub-harness 3 on the other longitudinal side Yb, and consists of multiple (7 in this example) wires 10 that extend continuously along the longitudinal direction Y, including the branching section 4.

[0032] In other words, in the wire harness 1, at Ya on one longitudinal side relative to the branching point 4, the first wire group 20A and the second wire group 20B are routed together to form the main harness 2. Furthermore, at Yb on the other longitudinal side relative to the branching point 4 in the wire harness 1, the first wire group 20A and the second wire group 20B are branched into two, so that the first wire group 20A constitutes the main harness 2 while the second wire group 20B constitutes the sub-harness 3. Of the multiple wires 10 that make up the wire harness 1, the wire 10 that makes up the first wire group 20A will be designated as the first wire 10A, and the wire 10 that makes up the second wire group 20B will be designated as the second wire 10B.

[0033] As shown in Figures 2(a) and 2(b), the electric wire 10 comprises a conductor 5, an insulating coating 6 that covers the entire outer circumference of the conductor 5, and an adhesive layer 7 that covers the entire outer circumference of the insulating coating 6. The conductor 5 is formed by a core wire consisting of at least one strand. The strand is made of a conductive material such as aluminum, copper, or an alloy thereof. The insulating coating 6 is made of an insulating material such as resin.

[0034] The adhesive layer 7 is a pressure-sensitive adhesive layer in which a known pressure-sensitive adhesive is applied to the surface of the insulating coating 6 in a thinner layer than the insulating coating 6. The pressure-sensitive adhesive is made of, for example, polyurethane, acrylic, or non-crosslinked rubber adhesive, and its fluidity (viscosity) increases when pressure is applied, allowing it to exhibit high adhesive strength. Furthermore, the electric wire 10 is formed such that the conductor 5, insulating coating 6, and adhesive layer 7 are concentric with each other in a cross-section perpendicular to the direction of extension.

[0035] As shown in Figure 1, the wire harness 1 has multiple adhesive fixing sections 30, to which multiple electric wires 10 are bonded together, provided at predetermined intervals in the longitudinal direction Y. Specifically, in the parts of the wire harness 1 other than the adhesive fixing portion 30 in the longitudinal direction Y, as shown in Figures 2(a) and 2(b), each of the multiple electric wires 10 is routed together along the same direction, but adjacent electric wires 10 are routed without being adhered to each other.

[0036] On the other hand, in the adhesive fixing portion 30 formed at a predetermined location in the longitudinal direction Y of the wire harness 1, as shown in Figures 3(a)(b) and 4(a)(b), the insulating coatings 6 of adjacent wires 10 are bonded to each other via the adhesive layer 7 of each wire 10. As a result, the multiple wires 10 constituting the wire harness 1 are bundled together as a single unit at the adhesive fixing portion 30.

[0037] The adhesive fixing portion 30 is formed to have higher rigidity than the other parts of the wire harness 1 in the longitudinal direction Y, i.e., other parts. Specifically, the adhesive fixing portion 30 is formed to have higher bending rigidity than other parts, making it easier to maintain the shape of the adhesive fixing portion 30.

[0038] Furthermore, the adhesive fixing portion 30 has peel strength equal to or greater than that of a fixing portion fixed by wrapping it with, for example, a resin fixing tape. As a result, the adhesive fixing portion 30 can keep the multiple electric wires 10 bundled together so that the adhesive layers 7 bonded to each other on the multiple electric wires 10 do not unintentionally separate by tearing along the longitudinal direction Y.

[0039] In this embodiment, as shown in Figure 1, a highly rigid adhesive fixing portion 30 is provided at least at the branching portion 4 in the longitudinal direction Y of the wire harness 1. This prevents the Y-shaped branching portion 4 from losing its shape, and prevents the bifurcated portion 4a at the branching portion 4 where the main harness 2 and the sub-harness 3 branch off from spreading unintentionally due to shearing or the like.

[0040] Furthermore, as shown in Figure 1, the crotch portion 4a at the branching portion 4 is provided with a reinforcing portion 41 that reinforces the crotch portion 4a and its periphery.

[0041] Specifically, the crotch portion 4a in the branching portion 4 can serve as the starting point (delamination initiation point) when shear stress is applied to the branching portion 4 from the other side Yb in the longitudinal direction to the one side Ya, causing the branching portion 4 to delaminate towards the one side Ya in the longitudinal direction.

[0042] In contrast, the crotch portion 4a of the branching portion 4 is provided with a reinforcing portion 41 as described above. The reinforcing portion 41 is formed by an adhesive layer 7 (pressure-sensitive adhesive) that connects the opposing electric wires 10 on the main harness 2 side and the sub-harness 3 side, which are spaced apart from each other, as part of the adhesive fixing portion 30 provided in the branching portion 4.

[0043] Here, the adhesive fixing portion 30 provided on the first wire group 20A is referred to as the first adhesive fixing portion 30A, the adhesive fixing portion 30 provided on the second wire group 20B is referred to as the second adhesive fixing portion 30B, and the adhesive fixing portion 30 that adhesively fixes the first wire group 20A and the second wire group 20B is referred to as the harness adhesive fixing portion 30C.

[0044] Next, an example of a manufacturing method for the wire harness 1 of this embodiment will be described. The manufacturing method of the wire harness 1 of this embodiment involves performing, in this order: a first bonding step of bonding a plurality of first wires 10A constituting the first wire group 20A at the adhesive fixing part 30; a second bonding step of bonding a plurality of second wires 10B constituting the second wire group 20B at the adhesive fixing part 30; and a harness bonding step of bonding the first wire group 20A and the second wire group 20B at the adhesive fixing part 30.

[0045] In the first bonding process, as preparation, multiple first wires 10A constituting the first wire group 20A are created by cutting each wire 10 to a predetermined wire length, and these first wires 10A are laid out on the wire distribution board along a predetermined wiring path.

[0046] Furthermore, in the first bonding step, the multiple laid first electric wires 10A, i.e., the first group of electric wires 20A, are bonded together by applying pressure at predetermined locations in the longitudinal direction Y. As a result, as shown in Figure 1, a first group of electric wires 20A can be obtained in which first bonded fixing portions 30A are formed at predetermined locations in the longitudinal direction Y.

[0047] In the first bonding step of this embodiment, as shown in Figures 5(a) and 5(b), the first group of electric wires 20A is bonded by pressure using an electric wire pressurizing device 90. The wire pressurizing device 90 includes a pressurizing unit 91 for pressurizing the first wire group 20A. In this embodiment, the pressurizing unit 91 includes an X-direction pressurizing unit 91X and a Z-direction pressurizing unit 91Z, both of which are positioned in the longitudinal direction Y of the first wire group 20A at a location corresponding to the first adhesive fixing portion 30A.

[0048] The X-direction pressurizing unit 91X includes a pair of X-direction pressurizing types 91Xa and 91Xb located on each side of the first wire group 20A in the X direction relative to the first wire group 20A in the circumferential direction. The X-direction pressurizing unit 91X is configured such that when it approaches the first wire group 20A, the pair of X-direction pressurizing types 91Xa and 91Xb pressurize the first wire group 20A by sandwiching it from both sides in the X direction.

[0049] The Z-direction pressurizing unit 91Z includes a pair of Z-direction pressurizing types 91Za and 91Zb located on each side of the first wire group 20A in the Z-direction relative to the first wire group 20A in the circumferential direction. These types are capable of moving closer to or further away from the first wire group 20A. When the Z-direction pressurizing unit 91Z approaches the first wire group 20A, the pair of Z-direction pressurizing types 91Za and 91Zb pressurize the first wire group 20A by sandwiching it from both sides in the Z-direction.

[0050] In this embodiment, the pressurizing unit 91 is driven by a motor, but the drive source is not limited to a motor; other means such as air pressure or hydraulic pressure may be used. Furthermore, the pressurization of the first wire group 20A is not limited to an automatic pressurization configuration using a drive source such as a motor, as in the wire pressurizing device 90 described above, but may also be performed manually. In addition, in the case of manual pressurization, the first wire group 20A may be indirectly pressurized by a person operating a crimping tool, or the first wire group 20A may be directly pressurized by a person using their fingers.

[0051] In the first bonding step of this embodiment, the portion of the first wire group 20A corresponding to the first bonded fixing portion 30A in the longitudinal direction Y is pressed using the pressurizing types 91Xa, 91Xb, 91Za, and 91Zb provided in the pressurizing unit 91 described above.

[0052] Specifically, as shown by the white arrows in Figure 5(a), the X-direction pressurizing unit 91X moves so that the pair of X-direction pressurizing units 91Xa and 91Xb move from positions spaced apart on each side in the X direction relative to the first wire group 20A to positions closer to it, and the Z-direction pressurizing unit 91Z moves so that the pair of Z-direction pressurizing units 91Za and 91Zb move from positions spaced apart on each side in the Z direction relative to the first wire group 20A to positions closer to it. As a result, as shown in Figure 5(b), the pair of X-direction pressurizing units 91Xa and 91Xb pressurize the first wire group 20A by sandwiching it in the X direction, and the pair of Z-direction pressurizing units 91Za and 91Zb pressurize the first wire group 20A by sandwiching it in the Z direction.

[0053] The pair of X-direction pressurizing types 91Xa, 91Xb and the pair of Z-direction pressurizing types 91Za, 91Zb in this embodiment are formed to a size corresponding to the outer diameter of the first wire group 20A so that they are arranged around substantially the entire circumference of the first wire group 20A when pressurizing the first wire group 20A.

[0054] In this way, the pair of X-direction pressurizing devices 91Xa, 91Xb and the pair of Z-direction pressurizing devices 91Za, 91Zb are arranged around the entire circumference of the first wire group 20A, and by simultaneously pressurizing the first wire group 20A, pressure can be applied to each first wire 10A in the first wire group 20A in a substantially uniform manner.

[0055] Here, when the portion of the first wire group 20A corresponding to the first adhesive fixing portion 30A in the longitudinal direction Y is pressurized by the X-direction pressurizing unit 91X and the Z-direction pressurizing unit 91Z, pressure is applied (acts) on the adhesive layer 7 of each first wire 10A in the first wire group 20A. As shown in Figure 5(b), the insulating coatings 6 of adjacent first wires 10A in a cross-sectional view in the longitudinal direction Y are bonded together via the adhesive layer 7. As a result, the portion of the first wire group 20A corresponding to the first adhesive fixing portion 30A in the longitudinal direction Y forms a first adhesive fixing portion 30A having the cross-sectional shape shown in Figure 4(a).

[0056] Furthermore, in the longitudinal direction Y of the first group of electric wires 20A, the portion that does not correspond to the first adhesive fixing portion 30A is not subjected to pressure, and therefore, each first electric wire 10A is kept in a state where the adhesive layers 7 do not adhere to each other.

[0057] Furthermore, the pair of X-direction pressurizing units 91Xa, 91Xb and the pair of Z-direction pressurizing units 91Za, 91Zb all move away from the position where they were in contact with the first wire group 20A after the first wire group 20A has been pressurized. This releases the pressurization of the first wire group 20A by the X-direction pressurizing unit 91X and the Z-direction pressurizing unit 91Z. At this time, the adhesive layer 7 in each first wire 10A, whose fluidity had been increased by the pressurization, solidifies rapidly and hardens instantaneously.

[0058] As shown in Figures 5(c) and 5(d), in the second bonding step, the multiple laid second electric wires 10B are bonded together by applying pressure at predetermined locations in the longitudinal direction Y, similar to the first bonding step. This makes it possible to obtain a second group of electric wires 20B in which second bonded fixing portions 30B are formed at predetermined locations in the longitudinal direction Y (see Figure 5(d)).

[0059] As the second bonding process is carried out in the same manner as the first bonding process, its explanation is omitted. Furthermore, the wire pressurizing device 90 used in the second bonding process has the same configuration as the wire pressurizing device 90 used in the first bonding process, except that a pair of X-direction pressurizing types 91Xa, 91Xb and a pair of Z-direction pressurizing types 91Za, 91Zb are formed to correspond to the outer diameter of the second wire group 20B, so its explanation is omitted.

[0060] In the harness bonding process, as shown in Figure 6(a), the first wire group 20A and the second wire group 20B are pressurized by the pressurizing unit 91 provided in the wire pressurizing device 90. Specifically, as preparation, the first wire group 20A and the second wire group 20B are laid along a predetermined wiring path on the wire distribution panel so that they are arranged in parallel to each other along the longitudinal direction Y.

[0061] Furthermore, in the harness bonding process, for example, a pair of Z-direction pressurizing types 91Za and 91Zb are used to pressurize the areas where the first bonded fixing portion 30A and the second bonded fixing portion 30B coincide in the longitudinal direction Y of the first wire group 20A and the second wire group 20B, which are arranged in parallel (see Figures 6(a) and 6(b)). As a result, as shown in Figures 3(a) and 6(b), the first wire 10A and the second wire 10B are bonded together via the adhesive layer 7 at the opposing portions of the first wire group 20A and the second wire group 20B, and the harness bonded fixing portion 30C is formed. In other words, a wire harness 1 can be obtained in which the harness bonded fixing portion 30C, in which the first wire group 20A and the second wire group 20B are integrated, is formed at predetermined locations in the longitudinal direction Y.

[0062] Furthermore, as shown in Figure 1, the harness adhesive fixing portion 30C of this embodiment is provided at the branching portion 4, where the first adhesive fixing portion 30A and the second adhesive fixing portion 30B are formed in the longitudinal direction Y of the wire harness 1.

[0063] However, the harness adhesive fixing portion 30C is not limited to this configuration. For example, it may be provided in a location other than the branching portion 4 in the longitudinal direction Y of the wire harness 1, at a location where either the first adhesive fixing portion 30A or the second adhesive fixing portion 30B (30A or 30B) is provided, or at a location where neither adhesive fixing portion 30A nor 30B is provided. The first adhesive fixing portion 30A and the second adhesive fixing portion 30B may be formed at the same or different positions in the longitudinal direction Y of the wire harness 1.

[0064] As shown in Figure 1, the wire harness 1 of the above-described embodiment has multiple wires 10 bundled together, each wire being an insulated wire with an insulating coating 6 covering the conductor 5. An adhesive fixing portion 30 is formed in a part of the longitudinal direction Y of the wire harness 1, where the insulating coatings 6 of the bundled wires 10 are bonded together via an adhesive layer 7. Therefore, the bundled wires 10 can be fixed together with more stable quality than a fixing method using tape, where multiple flexible wires 10 are bundled together and fixed by wrapping tape around them.

[0065] Specifically, when performing tape wrapping on multiple bundled wires 10, it is difficult to maintain a consistent wrapping force on all wires 10. As a result, variations in tape wrapping quality are likely to occur, and this issue has traditionally been an obstacle to automating tape wrapping work.

[0066] In contrast, in this embodiment, multiple wires 10 can be easily bonded and fixed together simply by applying pressure to them using the wire pressurizing device 90 described above. Furthermore, since multiple wires 10 can be stably bonded together without variations in quality, it becomes possible to automate the process of fixing multiple wires 10 in a bundled state.

[0067] Furthermore, even if the first adhesive fixing portion 30A and the second adhesive fixing portion 30B are provided at the same location in the longitudinal direction Y of the wire harness 1, and a harness adhesive fixing portion 30C is provided at the same location, the location will not become bulky due to the wrapped tape, as would be the case if the location were fixed by wrapping tape. Therefore, as shown in Figure 1, the wire harness 1 can suppress the harness adhesive fixing portion 30C from becoming thicker in diameter compared to other parts in the longitudinal direction Y.

[0068] For example, the branching section 4 of the wire harness 1 is particularly prone to becoming thicker in diameter than other parts because it needs to be carefully taped to prevent shearing of the main harness 2 and the sub-harness 3. Furthermore, in a configuration with a branching section 4' where two or more sub-harnesses 3 branch off from the main harness 2, such as the wire harness 1' shown in Figure 7, each sub-harness 3 needs to be taped to prevent shearing of the main harness 2, so the branching section 4' may become significantly thicker in diameter than other parts of the wire harness 1 in the longitudinal direction Y.

[0069] In contrast, in this embodiment, the first adhesive fixing part 30A, the second adhesive fixing part 30B, and the harness adhesive fixing part 30C are all fixed by bonding the electric wires 10 to each other via the adhesive layer 7. Therefore, even if the number of branches of the sub-harness 3 from the branching part 4 increases, for example, to three branches as in the branching part 4' of the wire harness 1' shown in Figure 7, or if the branching shape of the branching part 4' becomes three-dimensional, the bulkiness of the branching part 4' can be suppressed as much as possible.

[0070] Furthermore, as shown in Figure 1, at the branching point 4 where the sub-harness 3 branches off from the main harness 2, a crotch portion 4a is created between the main harness 2 and the sub-harness 3 because the extension directions of the main harness 2 and the sub-harness 3 are different. For this reason, in the tape wrapping work where tape is wrapped around the branching point 4, it is necessary to wrap tape around the crotch portion 4a of the branching point 4 as well, which complicates the work. In contrast, the wire harness 1 of this embodiment can be constructed simply by bonding the insulating coatings 6 together via an adhesive layer 7 at the adhesive fixing part 30, thus preventing a decrease in manufacturing efficiency even at the branching point 4.

[0071] Furthermore, in a configuration such as the wire harness 1 of this embodiment, where multiple electric wires 10 are bonded together, a more desirable cross-sectional shape can be obtained than when fixing them by wrapping tape around them.

[0072] Specifically, in a configuration where multiple electric wires 10 are bonded together, when the group of electric wires 20 is pressurized, the fluidity of the adhesive layer 7 on each electric wire 10 increases, as described above. Therefore, as the group of electric wires 20 is pressurized, the arrangement of the multiple electric wires 10 constituting the group of electric wires 20 can be easily changed from the arrangement before pressurization. Consequently, the cross-sectional shape of the group of electric wires 20 can be changed to any shape, such as a square or a circle.

[0073] Furthermore, the wire harness 1 has higher rigidity than other parts in the longitudinal direction Y because the insulating coatings 6 of the adhesive fixing portion 30 are bonded together via the adhesive layer 7, making it easier to maintain the shape of the adhesive fixing portion 30. Also, as in the wire harness 1 of this embodiment, when the adhesive fixing portion 30 is formed at the branch portion 4, it is possible to prevent the crotch portion 4a of the branch portion 4 from unintentionally spreading.

[0074] Furthermore, as shown in Figures 3(a)(b) and 4(a)(b), since the wire 10 is provided with an adhesive layer 7 covering the outer surface of the insulating coating 6, the insulating performance of the insulating coating 6 is not reduced compared to, for example, when the insulating coatings 6 of at least one of adjacent wires 10 are melted to directly bond them to each other, and the wires 10 can be bonded to each other more reliably via the adhesive layer 7.

[0075] Furthermore, as shown in Figures 5(b), (d), and 6(b), the adhesive layer 7 is made of a pressure-sensitive adhesive that becomes adhesive when pressure is applied, increasing its fluidity, and then hardens rapidly. Therefore, in the longitudinal direction Y of the wire harness 1, the wire group 20 in the area where the wires 10 are to be bonded together can be efficiently bonded by applying pressure only to that area.

[0076] As shown in Figure 1, in this embodiment, the wire harness 1 has multiple adhesive fixing portions 30 provided at predetermined intervals along the longitudinal direction Y, which allows for more efficient fixing in a bundled state compared to, for example, a case where adhesive fixing portions 30 are formed along the entire length.

[0077] Furthermore, the manufacturing method of the wire harness 1 described above involves bundling the first wire 10A from among the multiple wires 10 (wire group 20) constituting the wire harness 1 to form a first wire group 20A with a first adhesive fixing part 30A, as shown in Figures 5(a) and (b), and bundling the second wire 10B from among the multiple wires 10 constituting the wire harness 1 to form a second wire group 20B with a second adhesive fixing part 30B, as shown in Figures 5(c) and (d), and then bundling these first wire group 20A and second wire 10B to form a harness adhesive fixing part 30C, as shown in Figures 6(a) and (b), thereby enabling the efficient manufacture of a wire harness 1 with stable quality.

[0078] More specifically, rather than bonding and fixing all the wires 10 (wire groups 20) constituting the wire harness 1 together at once, they are broadly divided into a first wire group 20A and a second wire group 20B. By bonding and fixing each of these wire groups 20A and 20B individually, the number of wires 10 handled at one time is reduced, making it possible to easily and stably form the bonded fixing portion 30 in each of the wire groups 20A and 20B.

[0079] Then, by integrating the first wire group 20A, which is formed by integrating multiple first wires 10A, and the second wire group 20B, which is formed by integrating multiple second wires 10B, in the harness bonding process, the harness bonding and fixing portion 30C can be easily formed. Therefore, wire harness 1 can be manufactured efficiently.

[0080] Furthermore, before bundling the first wire 10A and the second wire 10B, the first wire group 20A is formed by bundling only the first wire 10A that constitutes the sub-harness 3. This prevents the first wire 10A and the second wire 10B from being mixed together in the sub-harness 3, thus preventing mishandling. Therefore, a wire harness 1 of stable quality can be constructed.

[0081] This invention is not limited to the configuration of the embodiments described above, and many other embodiments can be obtained. For example, the present invention may employ a wire harness 1S as shown in Figures 8(a) and 8(b), which is a modified example of this embodiment 1. The following describes the wire harness 1S according to Modification 1. However, components identical to those in the wire harness 1 according to the above-described embodiment are denoted by the same reference numerals and their descriptions are omitted.

[0082] In the modified example 1, the multiple electric wires 10S constituting the wire harness 1S are provided with an adhesive layer 7S on the outer surface of the insulating coating 6, similar to the electric wire 10 in the embodiment described above. However, the adhesive layer 7S in modified example 1 is formed of a known adhesive that adheres by reacting with trace amounts of moisture in the air.

[0083] Furthermore, in the modified example 1, the electric wire 10S has a coating layer 8 as its outermost layer, which covers the outer surface of the adhesive layer 7S. The coating layer 8 is a covering layer that covers the outer surface of the adhesive layer 7. In this example, the coating layer 8 is formed of a known pressure-sensitive adhesive, similar to the adhesive layer 7 in the wire harness 1 of the embodiment described above.

[0084] The coating layer 8 is formed by coating (applying) a pressure-sensitive adhesive to the surface of the adhesive layer 7S. In this process, the pressure-sensitive adhesive is applied to the adhesive layer 7S while it is still tacky (fluid), i.e., in an uncured, bondable state. This prevents the adhesive layer 7S from being exposed to the outside, i.e., to air, and unintentionally curing, which can be prevented by the coating layer 8.

[0085] The adhesive layer 7S and the coating layer 8 are formed continuously along the longitudinal direction Y of the wire harness 1S, including not only the adhesive fixing portion 30 in the longitudinal direction Y, but also portions other than the adhesive fixing portion 30.

[0086] In the parts of the wire harness 1S other than the adhesive fixing portion 30 in the longitudinal direction Y, as shown in Figures 8(a) and 8(b), adjacent electric wires 10S are routed in a state where they are simply in contact with each other without being bonded. On the other hand, in the wire harness 1S, adjacent electric wires 10S are routed in a state where they are bonded to each other at the adhesive fixing portion 30 in the longitudinal direction Y (see, for example, Figure 9(c)).

[0087] The following describes a method for manufacturing the wire harness 1S according to Modification 1. The differences from the method for manufacturing the wire harness 1 of the above-described embodiment will be explained using Figures 9(a),(b), and(c) as an example, focusing on the procedure for forming the second adhesive fixing portion 30B on the second wire group 20B constituting the sub-harness 3.

[0088] When the portion corresponding to the second adhesive fixing portion 30B in the longitudinal direction Y of the second wire group 20B constituting the sub-harness 3 is pressurized using the pressurizing unit 91 (see Figures 5(c) and 5(d)), the fluidity of the coating layer 8 on each second wire 10SB of the second wire group 20B increases from the state shown in Figure 9(a), and the adhesive layer 7S is exposed to the outside. As a result, as shown in Figure 9(b), the adhesive layers 7S of adjacent second wires 10SB come into direct contact with each other. Furthermore, if the pressurization of the second wire group 20B is continued, as shown in Figure 9(c), the adhesive layers 7S of adjacent second wires 10SB adhere to each other, and the insulating coatings 6 of adjacent second wires 10SB are bonded to each other via the adhesive layer 7S.

[0089] Furthermore, by releasing the pressure on the second group of electric wires 20B, the coating layer 8, which had increased fluidity, and the exposed adhesive layer 7S on each of the second electric wires 10SB instantly harden (dry), thereby suppressing the tackiness of the surface of the adhesive fixing portion 30 thereafter.

[0090] Even if the wire harness 1S of the modified example 1 described above has a configuration in which the adhesive layer 7S on the electric wires 10S constituting the wire harness 1S is covered with a coating layer 8, the electric wires 10S can be bonded together via the adhesive layer 7S at a desired location in the longitudinal direction Y, and an adhesive fixing portion 30 can be efficiently formed at that desired location.

[0091] On the other hand, the electric wires 10S that make up the wire harness 1S are normally tacky, and the adhesive layer 7S is covered with the coating layer 8, so they do not unintentionally adhere to surrounding components, including adjacent electric wires 10S, via the adhesive layer 7S.

[0092] Therefore, in the wire harness 1S of Modified Example 1, for example, when laying the electric wire 10S along a predetermined routing path on an electric wire distribution board, the adhesive layer 7S of the electric wire 10S does not inadvertently adhere to the worker's fingers or the support device that holds the electric wire 10S. Thus, even though the adhesive layer 7S is provided along the longitudinal direction Y of the electric wire 10S, the ease of handling of the electric wire 10S is not compromised, and the laying work can be performed smoothly.

[0093] Furthermore, the wire harness of the present invention may be configured such that, as shown in the modified example 2 wire harness 1T in Figure 10(d), the wires 10T constituting the wire harness 1T do not have an adhesive layer 7 formed along their entire length in the longitudinal direction Y, and coated wires consisting of a conductor 5 and an insulating coating 6 are used, and multiple coated wires 10T are integrated at predetermined locations in the longitudinal direction Y by adhesive fixing parts 30.

[0094] In this modified example 2, the wire harness 1T is bonded to each wire 10T by applying adhesive 80 to the area corresponding to the adhesive fixing part 30 during the wiring work in which the group of wires 20 are laid along a predetermined wiring path on the wire distribution board.

[0095] More specifically, on the upper surface of the wire distribution panel, multiple support members 95 (see Figure 10(d)) are erected at predetermined intervals along the wiring route to support multiple electric wires 10T that constitute the wire harness 1T. The main body 96 of the support member 95 has a length at least equivalent to the adhesive fixing portion 30, and its orthogonal cross-section along the wiring route is formed in a substantially U-shape so that it can support the multiple electric wires 10T routed along the wiring route from below and from the side.

[0096] A nozzle 97 for dripping adhesive 80 onto the wire group 20 supported by the main body 96 of the support member 95 is provided above the main body 96 of the support member 95. The tip of the nozzle 97 is positioned downward, that is, toward the wire group 20 supported by the main body 96 of the support member 95. The nozzle 97 is also provided so as to be retractable to a position directly above the main body 96 of the support member 95 so as not to interfere when the wire group 20 is placed on the upper surface of the main body 96 of the support member 95.

[0097] When manufacturing the wire harness 1T of the modified example 2, the first bonding step, the second bonding step, and the harness bonding step are performed in the same order as the manufacturing method of wire harness 1 described above.

[0098] Specifically, as shown in Figures 10(a) and 10(b), in the first bonding step, during the laying of the first wire group 20A, the area corresponding to the adhesive fixing portion 30 in the longitudinal direction Y is supported by the support 95, and adhesive 80 is dripped onto it. The dripped adhesive 80 spreads to the outer surface of the first wire group 20A and to every corner of the gaps between the wires 10T, and hardens. As a result, the first adhesive fixing portion 30A can be formed on the first wire group 20A, which is made up only of wires 10T that do not have an adhesive layer 7.

[0099] Furthermore, the second bonding process and the harness bonding process, which are carried out afterward, are performed in the same manner as the first bonding process described above, as shown in Figures 10(c) and 10(d), respectively, so their explanation will be omitted.

[0100] As described above, the wire harness 1T of the modified example 2 is composed only of wires 10T as insulated wires without an adhesive layer 7, but multiple wires 10T can be integrated by the adhesive fixing portion 30 formed during the wire laying work of the wire group 20.

[0101] Furthermore, although the adhesive layer 7 in the above-described embodiment or the coating layer 8 in Modification 1 is formed of a pressure-sensitive adhesive, the present invention is not limited to this, and may be formed of an adhesive that adheres and hardens when at least one of the following is applied: heating, pressurizing, adding water, and irradiating with light.

[0102] Furthermore, although the adhesive layer 7S in Modification 1 or the adhesive 80 in Modification 2 is formed of an adhesive that adheres by the addition of water, the present invention is not limited to this, and may be formed of an adhesive that adheres and hardens when at least one of heating, pressurizing, and light irradiation is applied.

[0103] Furthermore, in the wire harness of the present invention, the sub-harness 3 branches off from the main harness 2 at the branching section 4. However, this branching configuration is not limited to the configuration in which the second wire group 20B branches off from the first wire group 20A, as in the embodiment described above. It may also be a branching configuration in which the ends of the wire groups constituting the sub-harness 3 are connected to the main harness 2 at the branching section 4.

[0104] The wire harness of the present invention may be configured such that a harness adhesive fixing portion 30C is formed so that a plurality of second wires B are bonded together and fixed to a first wire group 20A on which a first adhesive fixing portion 30A is formed; a harness adhesive fixing portion 30C is formed so that a plurality of first wires A are bonded together and fixed to a second wire group 20B on which a second adhesive fixing portion 30B is formed; or a harness adhesive fixing portion 30C is formed so that a plurality of second wires B and a plurality of first wires A are bonded together and fixed to each other.

[0105] In the correspondence between the configuration of this invention and the embodiments described above, the wire harness corresponds to wire harnesses 1, 1', 1S, and 1T, and so on. The main line corresponds to Main Harness 2, The branch wire corresponds to sub-harness 3. The branching section corresponds to branching section 4,4', The conductor corresponds to conductor 5, The insulating coating corresponds to insulating coating 6. The adhesive layer corresponds to adhesive layer 7, 7S. The coating layer corresponds to coating layer 8, The insulated wires are compatible with wires 10, 10T, and 10S. The thin wire bundle corresponds to the first wire group 20A or the second wire group 20B. The adhesive fixing part corresponds to the adhesive fixing part 30 (30A, 30B, 30C), The longitudinal direction corresponds to the longitudinal direction Y. [Explanation of Symbols]

[0106] 1,1',1S,1T…Wire harness 2…Main harness 3…Sub-harness 4,4'...Branching point 5...Conductor 6…Insulating coating 7,7S…adhesive layer 8…Coating layer 10,10T,10S…Electric wire 20A…1st wire group 20B…Second wire group 30(30A,30B,30C)...Adhesive fixing part Y...longitudinal direction

Claims

1. A wire harness in which multiple insulated wires, each with an insulating coating covering the conductor, are bundled together, In a portion of the longitudinal direction, an adhesive fixing portion is formed in which the insulating coatings of the bundled insulated wires are bonded together. The insulated wire is provided with an adhesive layer covering the outer surface of the insulated wire, and a coating layer covering the outer surface of the adhesive layer. The aforementioned coating layer is It is composed of an adhesive that adheres and hardens when at least one of the following is applied: heating, pressurizing, adding water, and irradiating with light. The adhesive fixing portion is The adhesive layers exposed from the coating layer, whose fluidity has increased, are bonded together. Wire harness.

2. The adhesive layer is It is composed of an adhesive that adheres and hardens when at least one of the following is applied: heating, pressurization, water addition, and light irradiation. The wire harness according to claim 1.

3. Multiple adhesive fixing portions are provided in the longitudinal direction at predetermined intervals. The wire harness according to claim 1 or claim 2.

4. A main line and branch lines that diverge from the main line are provided. The adhesive fixing portion is formed at the branching point where the branch line branches off from the main line. A wire harness according to any one of claims 1 to 3.

5. The aforementioned adhesive fixing portion has higher rigidity than other parts. A wire harness according to any one of claims 1 to 4.

6. A method for manufacturing a wire harness in which multiple insulated wires, each insulated with an insulating coating over a conductor, are bundled together, In a portion of the longitudinal direction, the insulating coatings of the bundled insulated wires are bonded together to form an adhesive fixing portion. The insulated wire is provided with an adhesive layer covering the outer surface of the insulated wire, and a coating layer covering the outer surface of the adhesive layer. The aforementioned coating layer is It is composed of an adhesive that adheres and hardens when at least one of the following is applied: heating, pressurizing, adding water, and irradiating with light. The adhesive fixing portion is At least one of heating, pressurizing, adding water, and irradiating with light acts on the coating layer, causing the adhesive layers exposed from the coating layer, whose fluidity has increased, to adhere to each other. A method for manufacturing wire harnesses.

7. A portion of the multiple insulated wires is bundled together to form multiple bundles of thin wires, each with an adhesive fixing portion. Multiple bundles of the thin wires are bundled together to form the adhesive fixing portion. A method for manufacturing a wire harness according to claim 6.

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