JP5683250B2 - Wiring harness wiring structure - Google Patents

Description

  The present invention relates to a wiring structure for a wire harness mounted on a vehicle.

  When wiring a wire harness to a vehicle, it is desirable to route it with the shortest possible route. For example, as shown in FIG. 9, when a wire harness is routed in a vehicle door, the trunk portion of the wire harness is connected from the grommet 35, which is the introduction portion of the wire harness into the door, to the connector 36 for the door lock device. Since it is necessary to route, there is a demand to route the trunk portion of the wire harness along the route 40 that connects the grommet 35 to the connector 36 for the door lock device with a straight line.

  However, the door panel 30 usually has a service hole 31 for work as described in, for example, Patent Document 1 and the like. A service hole cover (generally made of a flexible material such as vinyl resin) 32 is installed to prevent the intrusion of the wire, and a clamp for fixing the wire harness is provided in an area where the service hole cover 32 exists. There is a problem that it is difficult to install.

  In other words, conventional wire harnesses generally have a structure in which a plurality of electric wires are bundled and wound with tape, or an exterior material such as a resin sheet or a tube is attached to the outside of the electric wire bundle and is necessary. Accordingly, the wire harness itself does not have enough rigidity to keep its shape stable. Therefore, it is necessary to support the wire harness by arranging the clamps at appropriate intervals so as not to bend or bend unnecessarily. However, when the service hole cover 32 is larger than the necessary installation interval of the clamps. Since it is difficult to install a clamp on the service hole cover 32, it is impossible to route the route 40 connected by the shortest straight line.

  Therefore, in reality, the wiring harness 41 is routed along the detour route secured on the upper side of the service hole cover 32 without being routed in such a straight route. is there. In the detour route, the clamps 43 can be arranged at necessary installation intervals, and the wire harness 41 can be stably supported.

JP-A-9-76757

  However, when the wire harness is routed by the detour route, the length of the electric wire is increased by the detour amount, which is uneconomical. Moreover, since an extra protective material such as a clamp is required, there is a problem that the assembling workability is poor and the cost is high.

  The present invention has been made in view of the above-described circumstances, and the purpose thereof is to enable the routing in the shortest route, thereby reducing the length of the electric wire and reducing the number of clamps and protective materials. An object of the present invention is to provide a wiring harness wiring structure capable of improving workability and reducing costs.

The above object of the present invention can be achieved by the following constitution.
(1) There is a region where it is difficult to install a clamp for fixing the wire harness in the middle of the wiring path of the wire harness mounted on the vehicle. A resin protective material by molding is provided on the outer periphery of the electric wire bundle to be configured, and clamps integrally coupled to the resin protective material are disposed at positions on both sides of the resin protective material across the difficult installation area. A wiring structure of a wire harness, wherein the wire harness is fixed to a vehicle body by the clamp.

(2) The wire harness is a vehicle door wire harness, a service hole for operation is formed in the door panel of the vehicle, and a service hole cover is provided on a surface of the door panel on the vehicle interior side so as to cover the service hole. An area in which the service hole cover is installed is an area where the installation of the clamp is difficult, and the trunk portion of the wire harness is straight from the introduction portion of the wire harness into the door to the connector for the door lock device. The resin protective material is provided in a state where there is a gap between the wire harness and the service hole cover in a range where the trunk portion of the wire harness exceeds the service hole cover. The wiring structure of the wire harness according to the above (1), characterized by:

  (3) The wiring structure for a wire harness according to the above (1) or (2), wherein the resin protective material is formed of a foam.

  (4) The wiring structure of the wire harness according to (3), wherein the foam is foam-molded by a bead method.

  According to the wiring structure of the wire harness having the configuration of the above (1), the resin protective material by molding is provided on the outer periphery of the bundle of wires constituting the wire harness over the range of the length across the difficult installation area of the clamp. Therefore, the range in which the protective member made of resin is provided can have rigidity sufficient to hold its own shape without bending or bending unnecessarily.

  Therefore, it is possible to support the wire harness stably by simply providing clamps on both sides across the difficult installation area without providing any support in the difficult installation area of the clamp, and the clamp is placed in the middle of the routing path. The wire harness can be routed by the shortest route despite the difficult installation area.

  Therefore, it is possible to reduce the wire length compared to the case of routing by detour route, and it is possible to reduce extra protective materials and clamps when routing by detour route. Can improve productivity and reduce costs.

  In addition, in the past, a variety of exterior materials (protective materials) such as corrugated tubes, vinyl sheets, or tapes have been manually attached to the wire bundle to protect the electrical wires, but in the present invention, the protective material made of resin Since the wire bundle can be protected only by performing the collective molding, the mounting workability of the exterior material can be improved.

  In addition, since the clamp is also integrated with the resin protective material at the time of molding, it is possible to simplify the operation of joining the clamp and the wire bundle.

  According to the wiring structure of the wire harness configured as described in (2) above, when the trunk portion of the door wire harness is routed from the introduction portion into the door to the connector of the door lock device, a service hole is provided on the way. Despite having a cover, it can be routed by a straight route, so the wire length can be shortened, and the number of useless clamps and protective materials can be reduced. Improvement and cost reduction can be achieved.

  In addition, since there is a gap between the service hole cover and the resin protective material in the range where the trunk part of the wire harness exceeds the service hole cover, it does not hinder the removal of the service hole cover. .

  According to the wiring structure of the wire harness configured as described in (3) above, since the outer side of the wire bundle is covered with a foam having cushioning properties, wear and noise due to interference with peripheral parts and interference between wires are also generated. It can be lost.

  In addition, for example, when the wire bundle is covered with a hard resin protective material, the fixing force between the resin material and the wire increases, so the difference in expansion coefficient between the wire and the resin material during curing after molding. Due to this, excessive stress is applied to the resin material and the electric wire, and in the worst case, the resin material may be damaged or the electric wire may be disconnected, but when the foam is molded outside the electric wire bundle Can generate a slip between the electric wire and the foam to keep the adhesion force low, so it can absorb the difference in expansion that occurs between the materials during curing, Occurrence of problems such as wire breakage can be prevented.

  According to the wire harness configured as described in (4) above, the foam is foamed by the bead method (a foaming method in which beads having a size of about the size of primary expanded rice grains are laid in a mold and heated to perform secondary foaming). Since it is molded, it becomes difficult for the foam to enter the complex and fine irregularities on the outer surface of the wire bundle, and the amount of fixing can be further reduced.

According to the present invention, it is possible to stabilize the wire harness only by providing clamps on both sides of the difficult installation area without providing any support in the difficult installation area of the clamp (such as an area where the service hole cover of the door panel exists). The wire harness can be routed by the shortest route even though there is a region where it is difficult to install the clamp in the middle of the route.
Therefore, it is possible to reduce the length of the wire compared to the case of routing by the detour route, and the number of extra protective materials and clamps when routing by the detour route can be reduced. Can improve productivity and reduce costs.

BRIEF DESCRIPTION OF THE DRAWINGS It is a block diagram which shows embodiment at the time of applying this invention to the wiring structure of the wire harness for doors of a vehicle, Fig.1 (a) is a side view, FIG.1 (b) is Ib-Ib of Fig.1 (a). 1C is an Ic-Ic arrow sectional view of FIG. 1B, and FIG. 1D is an Id-Id arrow sectional view of FIG. 1B. It is explanatory drawing of the manufacturing process of the wire harness used for the routing structure of embodiment. FIG. 3 is an explanatory diagram of the next process of FIG. 2. It is explanatory drawing of the next process of FIG. It is explanatory drawing of the next process of FIG. It is explanatory drawing of the next process of FIG. It is explanatory drawing of the next process of FIG. It is explanatory drawing of the next process of FIG. It is a side view which shows the wiring structure of the conventional wire harness for doors.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1A and 1B are configuration diagrams showing the wiring structure of the wire harness according to the embodiment. FIG. 1A is a side view, FIG. 1B is a cross-sectional view taken along the arrow Ib-Ib in FIG. FIG. 1C is a cross-sectional view taken along an arrow Ic-Ic in FIG. 1B, and FIG. 1D is a cross-sectional view taken along an Id-Id arrow in FIG.

  In this routing structure, a wire harness WH having a configuration as shown in FIGS. 1A and 1B is used. The wire harness WH is a door wire harness that is routed on the vehicle interior side of the door panel 30. The door wire harness WH is used for a door lock device from a grommet 35 that is an introduction portion of the wire harness WH into the door. It is necessary to route the trunk portion (branch lines are not shown) to the connector 36.

  When the main line portion of the wire harness WH is linearly routed by the shortest route, a service hole cover (clamp installation difficult region) in which the clamp 5 for fixing the wire harness WH cannot be installed in the middle of the routing route. ) 32 exists. The service hole cover 32 is formed on the door panel 30 to cover the service hole 31 for work from the vehicle interior side, and is made of a material having low rigidity such as a vinyl sheet, and is attached to the surface of the door panel 30 with butyl rubber 33 or the like. It is attached.

  Therefore, the clamp 5 cannot be disposed on the service hole cover 32. Therefore, in this wire harness WH, the resin protective material 1 by molding is provided on the outer periphery of the wire bundle W constituting the wire harness WH over the range of the length across the service hole cover 32. In addition, clamps 5 are disposed in a state of being integrally coupled to the resin protective material 1 at positions on both sides of the resin protective material 1 across the service hole cover 32. As shown in FIG. 1C, the wire harness WH is fixed to the door panel (vehicle body) 30 by the clamps 5.

  Further, the resin protective material 1 is provided with a step portion 1c between the both end portions 1b and the intermediate portion 1a so that the intermediate portion 1a is higher than both end portions 1b in the length direction. Thus, when the clamps 5 provided at both ends 1b are fixed to the door panel 30, a gap 6 is formed between the intermediate portion 1a of the resin protective material 1 and the service hole cover 32 as shown in FIG. It is secured.

  Further, the resin protective material 1 in this case is constituted by a foam 1 molded so as to cover the outer circumference of the wire bundle W over the entire circumference. In particular, the foam 1 is foam-molded by a bead method, and is made of, for example, a bead-method polystyrene foam. The beaded polystyrene foam is made by pre-foaming raw material beads made of polystyrene resin and a hydrocarbon-based foaming agent, and then filling the mold and heating. In addition to the bead method polystyrene foam, a bead method polyurethane foam, a bead method polypropylene foam, or the like can be used instead.

  As described above, since the resin protective material 1 by molding is provided on the outer periphery of the wire bundle W constituting the wire harness WH over the range of the length across the service hole cover 32 which is a difficult installation region of the clamp 5, In the range where the protective material 1 made of resin is provided, it is possible to have rigidity sufficient to hold its own shape, which does not loosen or bend unnecessarily. Accordingly, the wire harness WH can be stably supported only by providing the clamps 5 on both sides of the service hole cover 32 without providing any support to the service hole cover 32. Despite the presence of the service hole cover 32 (an area where the clamp is difficult to install), the wire harness WH can be routed by the shortest route.

  Therefore, it is possible to reduce the length of the electric wire as compared with the case where the cable is routed by the detour route as in the conventional case, and it is possible to reduce extra protective materials and clamps when the cable is routed by the detour route. Therefore, the mounting workability can be improved and the cost can be reduced.

  In addition, in the past, a variety of exterior materials (protective materials) such as corrugated tubes, vinyl sheets, or tapes were manually attached to the wire bundle to protect the wires, but in this embodiment, resin protection is used. Since the wire bundle W can be protected only by batch molding of the material 1, the mounting workability of the exterior material can be improved.

  In addition, since the clamp 5 is also integrated with the resin protective material 1 at the time of molding, the coupling work of the clamp 5 and the wire bundle W can be simplified.

  Further, since the gap 6 is secured between the service hole cover 32 and the resin protective material 1 in a range where the trunk portion of the wire harness WH exceeds the service hole cover 32, the removal of the service hole cover 32 is hindered. Never come.

  Further, in the wiring structure of this wire harness, the outer side of the wire bundle W is covered with a foam having a cushioning property (resin protective material 1), so that wear and noise due to interference with peripheral parts and interference between wires are prevented. Occurrence can be eliminated.

  In addition, for example, when the wire bundle is covered with a hard resin protective material, the fixing force between the resin material and the wire increases, so the difference in expansion coefficient between the wire and the resin material during curing after molding. Due to this, excessive stress is applied to the resin material and the electric wire, and in the worst case, the resin material may be damaged or the electric wire may be disconnected, but when the foam is molded outside the electric wire bundle Can generate a slip between the electric wire and the foam to keep the adhesion force low, so it can absorb the difference in expansion that occurs between the materials during curing, Occurrence of problems such as wire breakage can be prevented.

  In particular, if the foam is foam-molded by the bead method (a foaming method in which beads that are approximately the size of primary expanded rice grains are spread in a mold and heated to perform secondary foaming), the outside of the wire bundle It becomes difficult for the foam to enter the complex and fine irregularities on the surface, and the amount of fixing can be further reduced.

Next, the manufacturing method of the wire harness WH used for this wiring structure is demonstrated.
First, as shown in FIG. 2, the lower mold 11 is fixed on the wiring jig plate 10 provided with the wiring jig 12, and the clamp 5 is disposed inside the lower mold 11. And on this wiring jig board 10, as shown in FIG. 3, the wire bundle (subwire harness) W by which the connector C was attached to the terminal was routed, and resin protection of the wire bundle W was carried out. A portion to be covered with a material (hereinafter referred to as a foam) 1 is accommodated in the lower mold 11.

  After wiring the wire bundle W, as shown in FIG. 4, the upper die 13 is put on the lower die 11 and the upper die 13 and the lower die 11 are clamped. When the mold is clamped, as shown in FIG. 5, the molding material 20 is filled into a cavity (not shown) formed by the lower mold 11 and the upper mold 13. Here, the raw material beads subjected to primary foaming are filled.

  Once filled, steam 21 is introduced into the cavity and heated as shown in FIG. Once heated, the foam is cured and cooled as shown in FIG. When the cooling is completed, as shown in FIG. 8, the upper mold 13 is removed, and the molded foam 1 is removed from the lower mold 11. Thereby, the wire harness WH by which the required part of the wire bundle W was covered with the foam 1 is obtained.

  In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably. In addition, the material, shape, dimensions, number, arrangement location, and the like of each component in the above-described embodiment are arbitrary and are not limited as long as the present invention can be achieved.

WH Wire harness W Wire 1 Resin protective material (foam)
5 Clamp 6 Clearance 30 Door panel 31 Service hole 32 Service hole cover (Clamp installation difficult area)
35 Grommet (Wire harness introduction part)
36 Connector for door lock mechanism

Claims (4)

  There is a region where it is difficult to install a clamp for fixing the wire harness in the middle of the wiring path of the wire harness mounted on the vehicle, and the electric wire that constitutes the wire harness over a range of length across the difficult region A resin protective material by molding is provided on the outer periphery of the bundle, and clamps integrally coupled to the resin protective material are disposed on both sides of the resin protective material across the difficult installation region, and the clamp A wiring structure for a wire harness, wherein the wire harness is fixed to a vehicle body. The wire harness is a vehicle door wire harness, a working service hole is formed in the vehicle door panel, and a service hole cover is provided on a surface of the door panel on the vehicle interior side so as to cover the service hole, An area where the service hole cover is installed is an area where the clamp is difficult to install, and the trunk portion of the wire harness is linearly arranged from the introduction portion of the wire harness into the door to the connector for the door lock device. The resin protective material is provided in a state where a gap exists between the main part of the wire harness and the service hole cover so that the trunk part of the wire harness extends over the service hole cover. The wiring structure of the wire harness according to claim 1.   The wiring structure of the wire harness according to claim 1, wherein the resin protective material is made of a foam.   The wiring structure according to claim 3, wherein the foam is foam-molded by a bead method.

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