Wire harness

Abstract

A wire harness 1 comprises: a flat wiring material (100) formed in a U-shape having a first portion (110), a second portion (120), and an intermediate portion (130) connecting an end of the first portion and an end of the second portion; a first case (10) for retaining the first portion; a second case (20) for retaining the second portion; a rotation structure (60) for linking the first case and the second case so as to be rotatable relative to each other; and a space portion (23) provided in the second case. The first case and the second case can engage with each other with the shape of the flat wiring material formed as a linear shape. The linear-shaped flat wiring material has a first folded-back portion and a second folded-back portion. The space portion accommodates an extra length of the second portion created when the first case and the second case rotate relative to each other while forming the second folded-back portion (160).

Description

Wire harness

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

[0002] Conventionally, there are flat wiring materials such as flexible printed circuit boards. Patent Document 1 discloses a flexible printed circuit board that can easily realize long wiring. The flexible printed circuit board of Patent Document 1 includes a first strip-shaped member and a second strip-shaped member having a conductive portion and an insulating portion covering the conductive portion, and a first connecting member that connects a first end of the first strip-shaped member to a first end of the second strip-shaped member.

[0003] JP 2015-170699 A

[0004] It is desirable to be able to elongate a U-shaped flat wiring material into a straight shape. When a U-shaped flat wiring material is used, it is possible to reduce the manufacturing cost and installation cost of the flat wiring material. Here, when excess length is generated when the flat wiring material is deformed into a straight shape, it is desirable to be able to relieve the stress caused by the excess length.

[0005] An object of the present invention is to provide a wire harness in which a flat wiring material formed in a U-shape can be elongated into a straight shape and stress caused by the generation of excess length can be alleviated.

[0006] The wire harness of the present invention includes a flat wiring material formed in a U-shape having a linear first portion, a linear second portion, and an intermediate portion connecting an end of the first portion and an end of the second portion, a first case for holding the first portion, a second case for holding the second portion, a rotation structure for connecting the first case and the second case so as to be relatively rotatable, and a space provided in the second case, wherein the first case and the second case can be engaged with each other while the shape of the flat wiring material is linear, and in the linear-shaped flat wiring material, the second portion extends on an extension line of the first portion in a plan view, and the linear-shaped flat wiring material The wiring material has a first fold portion and a second fold portion, and in the first fold portion, the middle portion is folded along a fold line along the extension direction in which the first portion extends, and in the second fold portion, the second portion is folded along a fold line perpendicular to the extension direction so as to overlap a part of the second portion with the middle portion, and the rotation structure is configured to form the second fold portion in the second portion by rotating the first case and the second case relative to each other, and the space portion accommodates excess length that occurs in the second portion when the first case and the second case rotate relative to each other while forming the second fold portion.

[0007] In the wire harness according to the present invention, the rotation structure is configured to form a second folded portion in the second portion by rotating the first case and the second case relative to each other, and the space portion accommodates excess length generated in the second portion when the first case and the second case rotate relative to each other while forming the second folded portion. The wire harness according to the present invention has the effect of enabling a flat wiring material formed in a U-shape to be elongated into a straight shape and capable of alleviating stress caused by the generation of excess length.

[0008] FIG. 1 is a perspective view of a wire harness according to an embodiment. FIG. 2 is a perspective view of a flat wiring material according to an embodiment. FIG. 3 is a plan view of the flat wiring material according to an embodiment. FIG. 4 is a plan view of a case according to an embodiment. FIG. 5 is a perspective view of a case according to an embodiment. FIG. 6 is a plan view of a wire harness according to an embodiment. FIG. 7 is a plan view of a wire harness according to an embodiment. FIG. 8 is a plan view of a wire harness according to an embodiment. FIG. 9 is a cross-sectional view of a wire harness according to an embodiment. FIG. 10 is a perspective view of a flat wiring material according to an embodiment. FIG. 11 is a cross-sectional view of a wire harness according to an embodiment. FIG. 12 is a perspective view illustrating a second rotation step. FIG. 13 is a cross-sectional view of a wire harness according to an embodiment. FIG. 14 is a cross-sectional view of a wire harness according to an embodiment. FIG. 15 is a perspective view showing an example of a holding structure according to an embodiment. FIG. 16 is a cross-sectional view showing an example of a holding structure according to an embodiment. FIG. 17 is a cross-sectional view showing an example of a holding structure according to an embodiment.

[0009] Hereinafter, a wire harness according to an embodiment of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiment. Furthermore, components in the following embodiments include those that can be easily imagined by a person skilled in the art or those that are substantially the same.

[0010] [Embodiment] An embodiment will be described with reference to Fig. 1 to Fig. 17. The embodiment relates to a wire harness. Fig. 1 is a perspective view of the wire harness according to the embodiment, Fig. 2 is a perspective view of a flat wiring material according to the embodiment, Fig. 3 is a plan view of the flat wiring material according to the embodiment, Fig. 4 is a plan view of a case according to the embodiment, Fig. 5 is a perspective view of the case according to the embodiment, Figs. 6 to 8 are plan views of the wire harness according to the embodiment, Fig. 9 is a cross-sectional view of the wire harness according to the embodiment, and Fig. 10 is a perspective view of the flat wiring material according to the embodiment.

[0011] Fig. 11 is a cross-sectional view of the wire harness according to the embodiment, Fig. 12 is a perspective view illustrating the second rotation step, Figs. 13 and 14 are cross-sectional views of the wire harness according to the embodiment, Fig. 15 is a perspective view illustrating an example of a holding structure according to the embodiment, and Figs. 16 and 17 are cross-sectional views illustrating an example of a holding structure according to the embodiment. Fig. 9 shows a cross-section taken along line IX-IX in Fig. 8. Fig. 11 shows a cross-section taken along line XI-XI in Fig. 8. Fig. 13 shows a cross-section taken along line XIII-XIII in Fig. 1. Fig. 14 shows a cross-section taken along line XIV-XIV in Fig. 13.

[0012] As shown in Fig. 1, the wire harness 1 of the embodiment has a flat wiring material 100, a first case 10, and a second case 20. As will be described below, the first case 10 and the second case 20 of the present embodiment can deform the U-shaped flat wiring material 100 into a linear shape and hold it. The first case 10 and the second case 20 are configured to engage with each other while holding the linear flat wiring material 100. The flat wiring material 100 of Fig. 1 is held in a linear shape by the two cases 10 and 20.

[0013] Figure 2 shows a main part of the flat wiring material 100 held in a linear shape as in Figure 1. Figure 3 shows the U-shaped flat wiring material 100 before being deformed into a linear shape. The flat wiring material 100 is, for example, an FPC (flexible printed circuit board). The flat wiring material 100 of this embodiment is arranged in a battery module and detects the voltage and temperature of the battery cells of the battery module.

[0014] When the flat wiring material 100 is an FPC, the flat wiring material 100 has a base film, a conductive layer, and a coverlay. The conductive layer is sandwiched and protected between the base film and the coverlay. The conductive layer is, for example, a conductive metal foil and has a circuit pattern including a plurality of detection lines 140. The flat wiring material 100 is flexible and can be bent when being wired.

[0015] The flat wiring material 100 shown in Figure 3 has a substantially U-shape in plan view. The flat wiring material 100 has a first portion 110, a second portion 120, and an intermediate portion 130. The first portion 110 and the second portion 120 have substantially rectangular shapes in plan view. The flat wiring material 100 has a slit 100s formed between the first portion 110 and the second portion 120.

[0016] The intermediate portion 130 connects the end of the linear first portion 110 and the end of the linear second portion 120. The shape of the intermediate portion 130 in a plan view is approximately trapezoidal. The intermediate portion 130 has a tapered shape in which the width narrows as it moves away from the first portion 110 and the second portion 120 along the extension direction X. The extension direction X is the direction in which the first portion 110 extends, and is the longitudinal direction of the first portion 110. In the flat wiring material 100 in its initial shape before deformation, the first portion 110 and the second portion 120 extend in the same extension direction X and are aligned in the width direction Y. The width direction Y is a direction perpendicular to the extension direction X and is the width direction of the first portion 110 and the second portion 120.

[0017] The flat wiring material 100 of this embodiment is provided with branch portions 170 connected to the bus bar 200. The branch portions 170 extend in the width direction Y from the first portion 110 and the second portion 120. The tip portions of the branch portions 170 are connected to the bus bar 200 by solder or the like.

[0018] 4 and 5 show the first case 10 and the second case 20 of this embodiment. The first case 10 and the second case 20 are molded, for example, from an insulating synthetic resin. The first case 10 has a main body 11 and a cover 18. The main body 11 and the cover 18 are molded, for example, as a single unit. In the first case 10 of this embodiment, the main body 11 and the cover 18 are connected via a hinge portion 11e. The main body 11 has a support wall 11a that supports the first portion 110 of the flat wiring material 100. The support wall 11a is formed in a straight line along the extension direction X. The cover 18 has an opposing wall 18a that covers the support wall 11a. The first portion 110 of the flat wiring material 100 is accommodated and held between the support wall 11a and the opposing wall 18a.

[0019] A first shaft support portion 19A and a second shaft support portion 19B are provided at an end portion of the main body 11 in the extension direction X. The first shaft support portion 19A rotatably supports a first rotating shaft 25A of the second case 20. The second shaft support portion 19B rotatably supports a second rotating shaft 25B of the second case 20.

[0020] The second case 20 according to the embodiment has a main body 21 and a cover 24. The main body 21 and the cover 24 are, for example, molded integrally. In the second case 20 according to the embodiment, the main body 21 and the cover 24 are connected via a hinge portion 21e. The main body 21 has a support wall 21a that supports the second portion 120 of the flat wiring material 100. The support wall 21a is formed in a straight line along the extension direction X. The cover 24 has an opposing wall 24a that covers the support wall 21a. The second portion 120 of the flat wiring material 100 is accommodated and held between the support wall 21a and the opposing wall 24a.

[0021] A first rotation shaft 25A is provided at an end of the main body 21 in the extension direction X. A second rotation shaft 25B is provided at an end of the cover 24 in the extension direction X. The first rotation shaft 25A protrudes from a side surface of the main body 21 in the width direction Y. The second rotation shaft 25B extends in the width direction Y so as to cross the end of the cover 24. Both end portions of the second rotation shaft 25B are supported by second bearing portions 19B.

[0022] In the wire harness 1 according to the embodiment, the rotation structure 60 is configured by the two journal portions 19A, 19B of the first case 10 and the two rotation shafts 25A, 25B of the second case 20. The rotation structure 60 enables the two cases 10, 20 to rotate relative to each other as shown in FIG.

[0023] 5, the first case 10 has a first engagement portion 12, and the second case 20 has a second engagement portion 22. The first engagement portion 12 is disposed at an end of the main body 11 in the extension direction X. The second engagement portion 22 is disposed at an end of the main body 21 in the extension direction X. The two engagement portions 12, 22 engage with each other at the second relative position shown in FIG.

[0024] Fig. 6 shows the flat wiring material 100 assembled to the first case 10 and the second case 20. The first case 10 and the second case 20 shown in Figs. 4 and 6 are arranged side by side in the width direction Y. In this specification, with respect to the first case 10 and the second case 20, the relative position in which the two cases 10, 20 are arranged side by side in the width direction Y is referred to as a first relative position. As shown in Fig. 4, when the two cases 10, 20 are arranged in the first relative position, the support wall 11a of the first case 10 and the support wall 21a of the second case 20 are arranged side by side in the width direction.

[0025] The first portion 110 of the flat wiring material 100 is accommodated in the main body 11 of the first case 10 and is supported by the support wall 11a. The process of accommodating the first portion 110 in the first case 10 is performed, for example, by a worker. The second portion 120 of the flat wiring material 100 is accommodated in the main body 21 of the second case 20 and is supported by the support wall 21a. The process of accommodating the second portion 120 in the second case 20 is performed, for example, by a worker. The two accommodation processes are performed, for example, with the two cases 10 and 20 held by a jig plate.

[0026] Once the flat wiring material 100 is housed in the two cases 10, 20, a closing process is performed to close the covers 18, 24. In the closing process, the cover 18 of the first case 10 is assembled to the main body 11 while bending the hinge portion 11e. In the closing process, the cover 24 of the second case 20 is assembled to the main body 21 while bending the hinge portion 21e. The two closing processes are performed, for example, by a worker. Figure 7 shows the covers 18, 24 in a closed state. The opposing wall 18a of the cover 18 covers the first portion 110 of the flat wiring material 100. The opposing wall 24a of the cover 24 covers the second portion 120 of the flat wiring material 100.

[0027] A first rotation step is performed to rotate the second case 20 relative to the first case 10 from the state shown in FIG. 7 . In the first rotation step, the second case 20 is rotated relative to the first case 10 around a rotation axis Cx shown in FIG. 7 as the rotation center. The rotation axis Cx is, for example, a straight line extending in the extension direction X between the two covers 18, 24. This rotation may be performed using, for example, a jig plate. In this case, the jig plate may have a main body that supports the first case 10 and a support member that supports the second case 20. The support member is supported by the main body so as to be rotatable around the rotation axis Cx.

[0028] The second case 20 is rotated relative to the first case 10 around the rotation axis Cx as the center of rotation, and the second case 20 is overlapped on the first case 10. As a result, the second portion 120 of the flat wiring material 100 overlaps with the first portion 110 and faces the first portion 110.

[0029] 8 shows the state in which the second case 20 is stacked on the first case 10 after the first rotation process is completed. In this specification, with respect to the first case 10 and the second case 20, the relative position in which the two cases 10, 20 overlap in the height direction Z is referred to as the intermediate relative position. In the intermediate relative position, the second portion 120 of the flat wiring material 100 overlaps with the first portion 110 and faces the first portion 110. The height direction Z is a direction perpendicular to both the extension direction X and the width direction Y.

[0030] When the two cases 10, 20 rotate around the rotation axis Cx and are positioned at an intermediate relative position, the middle portion 130 of the flat wiring material 100 is bent along the rotation axis Cx. Figure 9 shows a cross section IX-IX of Figure 8, and Figure 10 shows the flat wiring material 100 in the state of Figure 8. As shown in Figures 9 and 10, a first folded portion 150 is formed in the middle portion 130 of the flat wiring material 100.

[0031] In the first folded portion 150, the intermediate portion 130 is folded along a folding line L1 along the extension direction X. The folding line L1 is, for example, a straight line extending in the extension direction X between the two covers 18, 24. The intermediate portion 130 has a first region 130a connected to the first portion 110 and a second region 130b connected to the second portion 120. The intermediate portion 130 is folded so that the first region 130a and the second region 130b face each other in the height direction Z.

[0032] As shown in Figure 9, the first case 10 has a protective cover 11g that protects the middle portion 130 of the flat wiring material 100. The protective cover 11g is connected to the support wall 11a via a hinge portion 11f. The protective cover 11g engages with the support wall 11a after the first rotation process is performed. The first case 10 accommodates the middle portion 130, which is folded back in a U-shape, between the support wall 11a and the protective cover 11g. The opposing wall 18a of the cover 18 is sandwiched inside the folded back middle portion 130. The hinge portion 11f covers the first folded back portion 150 and protects it.

[0033] 11 , when the two cases 10, 20 are positioned in an intermediate relative position, the second portion 120 extends along the support surface 24b. The support surface 24b is a surface of the opposing wall 24a of the cover 24, and faces the support wall 21a. The support surface 24b supports the second portion 120 and causes the second portion 120 to extend in the extension direction X.

[0034] 11 , the second portion 120 has an inclined portion 120b formed therein. The inclined portion 120b is formed in a portion adjacent to the protective cover 11g of the first case 10. The inclined portion 120b is inclined with respect to the height direction Z and extends from the opposing wall 18a of the first case 10 to the support surface 24b of the second case 20. In other words, the inclined portion 120b is formed in accordance with the difference in height between the two opposing walls 18a, 24a in the height direction Z.

[0035] As shown in FIG. 11 , the second case 20 has a retaining structure 70 that retains the second portion 120 of the flat wiring material 100. The illustrated retaining structure 70 is a columnar portion that protrudes from the support wall 21 a of the second case 20 toward the opposing wall 24 a. The retaining structure 70 may be configured to contact the support surface 24 b. The retaining structure 70 of this embodiment has a cylindrical shape. The retaining structure 70 is inserted into a through hole 120 c of the second portion 120. The retaining structure 70 can restrict relative movement of the second portion 120 with respect to the second case 20. The retaining structure 70 restricts, for example, relative movement of the second portion 120 with respect to the second case 20 along the extension direction X.

[0036] When the first case 10 and the second case 20 are positioned at an intermediate relative position, the two cases 10, 20 are connected by the rotation structure 60. As shown in Fig. 9, the first rotation shaft 25A of the second case 20 is rotatably supported by the first pivot support portion 19A of the first case 10. The first pivot support portion 19A has a piece portion 19c standing in the height direction Z and a locking portion 19d. The piece portion 19c has a slit 19e extending in the height direction Z. The end of the first rotation shaft 25A is inserted into the slit 19e and locked by the locking portion 19d.

[0037] The second rotating shaft 25B of the second case 20 is rotatably supported by the second shaft support portion 19B of the first case 10. The second shaft support portion 19B has a slit 19f formed in the side wall 11h. The side wall 11h is disposed on both sides of the support wall 11a in the width direction Y. An end of the second rotating shaft 25B is inserted into the slit 19f and rotatably supported by the side wall 11h. The two rotating shafts 25A, 25B are inserted into the two shaft support portions 19A, 19B, thereby rotatably connecting the first case 10 and the second case 20. This forms a bus bar module 400. The bus bar module 400 includes a plurality of bus bars 200 and the wire harness 1 of the embodiment.

[0038] 12 is a diagram illustrating the second rotation process. The second rotation process is performed, for example, in a factory where the busbar module 400 is assembled to a vehicle or the like. As shown in FIG. 12 , in the second rotation process, the second case 20 is rotated relative to the first case 10 from an intermediate relative position toward a second relative position, which will be described later. In the second rotation process, the second case 20 rotates relative to the first case 10 around the central axes of the two rotation shafts 25A, 25B.

[0039] FIG. 1 shows a state in which the two cases 10, 20 are positioned in a second relative position after the second rotation process is completed. In the second relative position, the first case 10 and the second case 20 are aligned linearly along the extension direction X. In this state, the first portion 110 and the second portion 120 of the flat wiring material 100 are aligned linearly. In other words, the second portion 120 is positioned on an extension of the first portion 110 in a plan view. Furthermore, the multiple bus bars 200 are aligned linearly along the extension direction X. The cover 18 of the first case 10 covers and protects the first portion 110 with the opposing wall 18a. The cover 24 of the second case 20 covers and protects the second portion 120 with the opposing wall 24a.

[0040] By performing the second rotation process, a second folded portion 160 is formed in the flat wiring material 100. As shown in Figures 2 and 13, the second folded portion 160 is a portion folded along a folding line L2 perpendicular to the extension direction X. In the second folded portion 160, the second portion 120 is folded along the folding line L2 so that a part of the second portion 120 overlaps with the intermediate portion 130. In this embodiment, the folding line L2 is a straight line along the width direction Y. When the second folded portion 160 is formed, the second region 130b of the intermediate portion 130 and the base end portion 120a of the second portion 120 face each other. The base end portion 120a is the end portion of the second portion 120 closer to the intermediate portion 130.

[0041] Figure 13 shows the XIII-XIII cross section of Figure 1. That is, the cross section of Figure 13 is a cross section when the two cases 10, 20 are positioned in a second relative position. As shown in Figure 13, the second case 20 has a space 23 that absorbs the excess length of the flat wiring material 100. The space 23 is configured to absorb the excess length generated in the second portion 120 of the flat wiring material 100. The second portion 120 shown in Figure 13 has a curved portion 120d. The curved portion 120d is a portion formed by the excess length generated in the second portion 120, and is curved in the height direction Z.

[0042] The space 23 is a space between the support wall 21a and the opposing wall 24a in the second case 20. That is, the space 23 capable of accommodating the curved portion 120d generated in the second portion 120 is provided between the support wall 21a and the opposing wall 24a. The space 23 is disposed between the holding structure 70 and the rotating structure 60. As shown in FIG. 13 , the space 23 is disposed between the holding structure 70 in the first case 10 and the second rotating shaft 25B. In the wire harness 1 of this embodiment, the space 23 that absorbs the curved portion 120d generated in the second rotating process is provided. As a result, unnecessary reaction force is less likely to be generated in the flat wiring material 100, as will be described below.

[0043] First, one reason why the curved portion 120d occurs will be explained. In FIG. 13 , the position of the support surface 24b at the intermediate relative position is indicated by a dashed line. The height difference ΔZ shown in FIG. 13 is the height difference of the support surface 24b that occurs between the intermediate relative position and the second relative position. This height difference ΔZ causes the curved portion 120d to occur in the second rotation step. As shown in FIG. 11 , at the intermediate relative position, the second portion 120 extends along the support surface 24b. From this state, in the second rotation step, the support surface 24b rotates relative to the first case 10 while supporting the second portion 120. At this time, the height difference ΔZ shown in FIG. 13 is one of the reasons why an excess length occurs in the second portion 120.

[0044] When excess length occurs in the second portion 120 during the second rotation process, if there is no space 23 to absorb the excess length, a reaction force is generated in the second portion 120. This reaction force is a force that releases the excess length, and is, for example, a force in the longitudinal direction of the second portion 120. It is undesirable that the reaction force causes the second portion 120 to move relative to the second case 20. For example, if the second portion 120 moves with respect to the bus bar 200 held by the second case 20, unnecessary stress may be generated at the boundary between the branch portion 170 and the second portion 120.

[0045] In contrast, the wire harness 1 of this embodiment is provided with a space 23 that absorbs the excess length of the second portion 120. This suppresses the generation of reaction force, making it difficult for unnecessary stress to occur in the flat wiring material 100. As shown in Fig. 13 , the curved portion 120d is formed closer to the first case 10 than the holding structure 70 in the extension direction X. Since the space 23 is located closer to the first case 10 than the holding structure 70, it can accommodate the curved portion 120d and absorb the excess length of the second portion 120.

[0046] Note that a portion of the excess length generated in the second portion 120 may be absorbed by a space 13 near the rotation structure 60. The space 13 is a space between the opposing wall 24a of the second case 20 and the opposing wall 18a of the first case 10. The space 13 is located between the protective cover 11g of the first case 10 and the second rotation shaft 25B of the second case 20. The opposing wall 24a is provided with a protrusion 24c that forms the space 13. The protrusion 24c is adjacent to the second rotation shaft 25B and protrudes in the height direction Z so as to move away from the opposing wall 18a.

[0047] 14 , the holding structure 70 is disposed closer to the rotation structure 60 than the first branch portion 170A. The first branch portion 170A is the branch portion 170 disposed in the second portion 120 and is located closest to the rotation structure 60 in the extension direction X. In other words, the first branch portion 170A is the branch portion 170 that is located closest to the second folded portion 160 among the branches 170 connected to the second portion 120. The holding structure 70 can protect the branch portion 170 by restricting relative movement of the second portion 120 with respect to the second case 20.

[0048] The holding structure 70 of the second case 20 may be configured as described with reference to Figs. 15 to 17. The holding structure 70 shown in Fig. 15 has a columnar portion 26 provided on the main body 21 of the second case 20 and a protrusion 27 provided on the cover 24. The columnar portion 26 protrudes from the support wall 21a in the height direction Z. The columnar portion 26 has, for example, a cylindrical shape. The columnar portion 26 is inserted into the second portion 120 of the flat wiring material 100.

[0049] The protrusions 27 are arranged on the opposing walls 24a of the cover 24. The protrusions 27 protrude from the support surface 24b. The illustrated cover 24 has two protrusions 27. The two protrusions 27 are arranged on both sides of the columnar portion 26 in the extension direction X. The cover 24 has an engaging portion 24d. The main body 21 has an engaging portion 21b corresponding to the engaging portion 24d. The engaging portions 21b, 24d engage with each other, thereby fixing the cover 24 to the main body 21.

[0050] 16 shows a state in which the cover 24 is closed and the two cases 10, 20 are positioned in an intermediate relative position. When the cover 24 is closed, the tip of the columnar portion 26 is inserted between the two protrusions 27. The protrusions 27 support the second portion 120 to prevent the columnar portion 26 from slipping out of the second portion 120.

[0051] As shown in Fig. 16, the first case 10 may have a holding structure 80. The holding structure 80 of the first case 10 has a columnar portion 16 and a protrusion 17. The columnar portion 16 protrudes from the support wall 11a in the height direction Z. The columnar portion 16 has, for example, a cylindrical shape. The columnar portion 16 is inserted into the first portion 110 of the flat wiring material 100.

[0052] The protrusions 17 are disposed on the opposing wall 18a of the cover 18. When the cover 18 is closed as shown in FIG. 16 , the protrusions 17 protrude from the opposing wall 18a toward the support wall 11a. The illustrated cover 18 has two protrusions 17. The two protrusions 17 are disposed on both sides of the columnar portion 16 in the extension direction X. When the cover 18 is closed, the tip of the columnar portion 16 is inserted between the two protrusions 17. The protrusions 17 support the first portion 110 to prevent the columnar portion 16 from slipping out of the first portion 110.

[0053] The second part 120 does not have to have a through hole through which the columnar part 26 of the holding structure 70 is inserted. In this case, the holding structure 70 can hold the second part 120 by sandwiching it between the columnar part 26 and the two protrusions 27. Similarly, the holding structure 80 of the first case 10 may hold the first part 110 by sandwiching it between the columnar part 16 and the two protrusions 17.

[0054] As described above, the wire harness 1 of this embodiment includes the flat wiring material 100, the first case 10, the second case 20, the rotation structure 60, and the space 23 provided in the second case 20. The flat wiring material 100 is formed in a U-shape having a linear first portion 110, a linear second portion 120, and an intermediate portion 130 connecting an end of the first portion 110 and an end of the second portion 120. The first case 10 holds the first portion 110, and the second case 20 holds the second portion 120. The rotation structure 60 connects the first case 10 and the second case 20 so that they can rotate relative to each other.

[0055] The first case 10 and the second case 20 can be engaged with each other while the shape of the flat wiring material 100 is linear. In the linear flat wiring material 100, the second portion 120 extends on an extension line of the first portion 110 in a plan view. The linear flat wiring material 100 has a first folded portion 150 and a second folded portion 160. In the first folded portion 150, the middle portion 130 is folded back along a folding line L1 along the extension direction X in which the first portion 110 extends. In the second folded portion 160, the second portion 120 is folded back along a folding line L2 perpendicular to the extension direction X so that a part of the second portion 120 overlaps with the middle portion 130.

[0056] The rotation structure 60 is configured to form a second folded portion 160 in the second portion 120 by rotating the first case 10 and the second case 20 relative to each other. The space 23 accommodates excess length generated in the second portion 120 when the first case 10 and the second case 20 rotate relative to each other while forming the second folded portion 160. The wire harness 1 of this embodiment can elongate the flat wiring material 100 formed in a U-shape into a linear shape and can also relieve stress associated with the generation of excess length.

[0057] The second case 20 of this embodiment has a holding structure 70. The holding structure 70 is a structure that holds the second part 120 and restricts relative movement of the second part 120 with respect to the second case 20. The space 23 of the second case 20 is disposed between the holding structure 70 and the rotation structure 60. The space 23 disposed in this manner can appropriately accommodate any excess length that occurs.

[0058] The rotation structure 60 of this embodiment is configured to connect the first case 10 and the second case 20 in a state in which a first folded portion 150 is formed in the flat wiring material 100. In this case, the first case 10 and the second case 20 are connected by the rotation structure 60 while holding the flat wiring material 100 having the first folded portion 150. Thereafter, the first case 10 and the second case 20 rotate relative to each other, thereby forming a second folded portion 160 in the flat wiring material 100. Note that the two cases 10, 20 may be connected by the rotation structure 60 while forming the first folded portion 150 in the flat wiring material 100.

[0059] The contents disclosed in the above embodiments can be implemented in appropriate combinations.

[0060] 1: Wire harness 10: First case 11: Main body 11a: Support wall 11e: Hinge portion 11f: Hinge portion 11g: Protective cover 11h: Side wall 12: First engagement portion 13: Space portion 16: Pillar portion 17: Protrusion 18: Cover 18a: Opposing wall 19A: First pivot support portion 19B: Second pivot support portion 20: Second case 21: Main body 21a: Support wall 21e: Hinge portion 22: Second engagement portion 23: Space portion 24: Cover 24a: Opposing wall 24b: Support surface 24c: Protrusion 24d: Engagement portion 25A: First rotating shaft 25B: Second rotating shaft 26: Pillar portion 27: Protrusion 60: Rotation structure 70: Retaining structure 80: Retaining structure 100: Flat wiring material, 110: First portion, 120: Second portion, 120a: Base end portion, 120b: Inclined portion, 120c: Through hole, 120d: Curved portion, 130: Intermediate portion, 130a: First region, 130b: Second region, 140: Detection line, 150: First folded portion, 160: Second folded portion, 170: Branch portion, 200: Busbar, 400: Busbar module, L1, L2: Folded lines, X: Extension direction, Y: Width direction, Z: Height direction, ΔZ: Height difference

Claims

1. A flat wiring material formed in a U-shape having a linear first portion, a linear second portion, and an intermediate portion connecting the end of the first portion and the end of the second portion; a first case for holding the first portion; a second case for holding the second portion; a rotation structure for connecting the first case and the second case so that they can rotate relative to each other; and a space provided in the second case, wherein the first case and the second case are capable of engaging with each other while making the shape of the flat wiring material linear; in the linear shaped flat wiring material, the second portion extends on an extension line of the first portion in a plan view; the linear shaped flat wiring material has a first fold portion and a second fold portion; in the first fold portion, the intermediate portion is folded along a fold line along the extension direction in which the first portion extends; and in the second fold portion, the second portion is folded along a fold line perpendicular to the extension direction so that a part of the second portion overlaps the intermediate portion; the rotation structure is configured to form the second folded portion in the second portion by rotating the first case and the second case relative to each other, and the space portion accommodates an excess length that occurs in the second portion when the first case and the second case rotate relative to each other while forming the second folded portion.

2. A wire harness as set forth in claim 1, wherein the second case has a holding structure that holds the second part and restricts relative movement of the second part with respect to the second case, and the space is disposed between the holding structure and the rotation structure.

3. The wire harness according to claim 1, wherein the rotation structure is configured to connect the first case and the second case in a state where the first folded portion is formed in the flat wiring material.

Images