JPH0487110A - flat wire harness - Google Patents

Abstract

PURPOSE:To facilitate automatic manufacture by forming specified separate wires, and connecting one end of separation wires to the parallel wires of sub- circuit while the other end thereof connected to others parallel wires of the sub-circuit. CONSTITUTION:One or more than two cut parts 1 are provided, to form separate wires a'n, a'n+1..., on the way of some of wires an, an+1... in multiple parallel wires a1, a2... an, an+1... of a main circuit A. One ends of the separate wires a'n, a'n+1 are connected 2 to paralle wires b1, b2,... of a sub-circuit B on one side, and the other side ends are connected to parallel wires c1, c2... of a sub- circuit C at the other side. Furthermore, sub-circuits Z, Z' and connectors 4 in terminal ends of each circuit B, C... Z, Z' are provided. The shape and structure are simplified and automation of manufacture is facilitated accordingly.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a flat wire harness used for electrical wiring of a vehicle.

(Prior Art) As shown in FIG. 13, the current wire harness has a trunk harness 32 in which a large number of electric wires 30 are bundled with a tape 31, and a plurality of technical harnesses 33a, 933b, 33c, . . .
It has a complex shape with branches. A terminal 34 is crimped to the end of each electric wire 30, and a connector housing 35 is attached to each branch harness.

FIG. 14 shows an example of a wiring diagram of a wire harness having a wire convergence shape as described above. In the diagram, 36 is the trunk harness, 37
a, 37b, 37c, 37d are technique harnesses, 38a, 3
8b, 38c, and 38d indicate connectors (housings).

The trunk harness 36 is composed of a plurality of common electric wires 39p and spanning electric wires 40q, 40r, . . . .

The common electric wire 39p connects each technical harness 37a to 37d (or the connector 38) from one end of the trunk harness 36 to the other end.
It refers to the electric wires that extend in common so as to span parts a to 38d), and in the example in the figure, three electric wires are shown (section P).

The spanning electric wire refers to an electric wire that connects two branch harnesses, such as two electric wires 40q spanning connectors 38a and 38c, and three electric wires 40r spanning connectors 38a and 38b, and in the figure, Q section and is indicated by the R part. Similarly, the S, T, and U sections are also connectors 38b.

38c and 38d are shown.

On the other hand, taking the branch harness 37b as an example, this harness 3
7b is a branch electric wire 41b which is branch-connected 43 from the common electric wire 39p by a joint terminal (not shown), and a connecting electric wire 40 r + 40 s between a plurality of branch harnesses,
It is composed of six lead-out electric wires 42b each extending from one end of 40u. Other branch harness 3
7a, 37c, and 37d, trunk harness 3
It is composed of at least one branch electric wire branch-connected from the common electric wire 39P of No. 6, and a plurality of lead-out electric wires 42a, 42c, . . . from the connecting electric wire between each branch harness.

In this way, the conventional wire harness with wire convergence shape is
The shape is extremely complex, making it difficult to automate production due to tape wrapping and thickening, and when assembling it into a vehicle, the complex shape and weight require the joint work of several workers. There was a demand for improvements in productivity and assembly workability.

Therefore, as shown in FIG. 15, an attempt has been made to use a flat cable in place of the wire-converging cable.

In the figure, Pyq-u indicates a flat cable having a length and number of core wires corresponding to P and QU in FIG. 14. but,
Since these flat cables ptq-u have different lengths and widths (number of core wires), it is necessary to prepare a large number of parts. For example, branch harness 3 in Figure 14
When assembling 7b, flat cable r.

In addition to the step of individually inserting one end of S and U into one connector (38b), it requires many steps such as branching and connecting another electric wire corresponding to the branch electric wire 41b to the flat cable p, Automated production and productivity improvements were not very effective.

[Problem to be solved by the invention]

An object of the present invention is to provide a flat wire harness that does not have the above-mentioned drawbacks, facilitates automatic production by generalizing the members constituting the wire harness, and is lightweight and thin so that it can be easily assembled into a vehicle. It is about providing.

[Means for Solving the Problems] To explain with reference to the drawings, the flat wire harness of the present invention, as shown in FIG. This is a flat wire harness in which a plurality of sub-circuit bodies B, C... are provided in a branched manner, and a plurality of parallel electric wires a+ g az "'an of a main circuit body A
, an++ ``'' One or more cuts 1 are provided in the middle of some of the electric wires ataM+1... to separate the separation line a'
, a'7.1..., and the separation line a' II
' *+1 ... one end of one sub-circuit body A circuit body B's parallel wires b+, bz..., the other end of the other sub-circuit body C...'s parallel electric wires cl, c2... It is characterized by interconnecting 2 to each other.

In the figure, Z and Z' indicate the sub-circuit bodies at both ends of the main circuit body A, and 4 indicates the connectors at the terminals of each circuit body B, C...z, z', and the connector 4 is press-connected as described later. Connectors are conveniently used.

At least two cuts 1 are provided in the parallel electric wires alya2... of the main circuit body A at a predetermined interval between the sub-circuit bodies B and C in the middle, but between the sub-circuit bodies Z and the sub-circuit body at the end. In the case of intermediate sub-circuit body B, one piece is sufficient.

The flat cable used to form each circuit body A, B, C... may be one in which a plurality of single wires, stranded wires, or their insulated wires are arranged flat in parallel.
Commercially available products can be suitably used.

Further, each sub-circuit body B, C... has at least one parallel electric wire b0 specified as described in claim 2.
9co... are parallel wires a,, aZ, of main circuit body A.
The branch connection 3 is made to one of the...

As described in claim 3, the flat cables constituting the main circuit body A and the sub circuit bodies B, C, etc. are formed separately for power lines and signal lines, and are stacked in two or more layers. be able to.

Further, the necessary connections between the main circuit body A and the sub circuit bodies B, C, . . . are easily made using press-contact terminals, as will be described later.

[Function] As is clear from FIG. 1, the flat wire harness according to the present invention has an extremely simple shape and structure, and its production can be easily automated.

By changing the position and number of cuts made in the parallel wires alya2... group of the main circuit body, various patterns (separation line) can be created from one type of flat cable.
t a' n. 1...) main circuit body can be made.

Therefore, flat cables are versatile and suitable for high-speed mass production because the length can be changed freely by cutting them by preparing several liters of wires with different wire diameters and widths (number of core wires). , the number of parts is small, and manufacturing costs can be reduced.

Moreover, since it is flat, it is easy to assemble into a vehicle.

Hereinafter, the structure and operation of the present invention will be explained in more detail with reference to drawings showing other embodiments.

〔Example〕

FIG. 2 shows a second embodiment of the present invention, in which the main circuit body A'
It has a two-layer structure consisting of a power line flat cable 5 and a signal line flat cable 6.

In the figure, D, E, F...H are intermediate sub-circuit bodies, Z"
, Z''' indicate sub-circuit bodies at both ends, and 7 indicates a protective case for each sub-circuit body.

FIG. 3 shows a perspective view of a part of the main circuit body A' in an expanded state.

Parallel wires of power line cable 5 and signal line cable 6 (
(not shown) is provided with one or two notches 1, as explained in FIG. These notches 1 are sub-circuit bodies.

It is provided corresponding to the connection position of E-H and Z", Z~. By changing the position and number of notches 1, 1
Main circuit bodies with various patterns are formed from the different types of cables 5 (6).

FIG. 4 shows an enlarged perspective view of the main parts of the power line cable 5 shown in FIG. 3. The cable 5 includes a plurality of parallel electric wires a8. a! ~al
+ is insulated and fixed in a flat shape with a synthetic resin insulator 5a, and the common electric wires a8 to a. By making two cuts 1°1 at a predetermined interval in the middle of the separation line a.
'8 to a'io are formed. a'+58'z also indicates a separation line formed in the same manner.

FIGS. 5a-5c are explanatory diagrams showing the connection structure between the main circuit body A' and the sub-circuit body E. FIGS.

In FIG. 5a, the sub-circuit body E includes the cable 5,
6, it is composed of two flat cables, a power line flat cable 5' and a signal line flat cable 6'. Pressure connectors 4 are attached to the ends of both cables 5' and 6', respectively.

As shown in FIG. 9, the pressure contact connector 4 has a terminal 16a having an electrical contact portion for a mating terminal at one end and a pressure contact portion at the other end, and is housed in a connector housing 16b. Since a configuration having the following configuration can be used, a detailed explanation will be omitted.

One of the cables 5', 6' is formed longer than the other, and the fifth
As shown in FIG.

These cables 5', 6' are connected to the cables 5, 6 of the main circuit body A', respectively, using insulation displacement terminals 9, with an insulating sheet 8 having a plurality of holes 8a provided at predetermined positions sandwiched therebetween.

Then, as shown in FIG. 5, the tips of the pressure contact terminals 9 exposed to the surface of the sub-circuit body E by pressure contact are molded and insulated by applying an adhesive 10 such as a hot melt adhesive. In this state, one cable 6' is folded toward the other cable 5', and the two pressure contact connectors 4, 4 are overlapped.

Next, as shown in FIG.
A protective case 7 is placed on top and bottom of 6' and fixed by screwing or locking means. The protective case 7 is for fixing and protecting the circuit, and may be fixed by molding with resin.

Next, the manufacturing process of the flat wire harness according to the present invention will be explained with reference to FIGS. 6 to 12.

FIG. 6 and FIG. 7 each show the manufacturing process of the flat cable.

Figure 6 shows the power flat cable 5 of main circuit body A'.
In this manufacturing process, a plurality of stranded wires 11 used for the common electric wires a1a2... are fed to an extrusion molding machine 12, a flat cable 5 having a desired number of core wires is manufactured,
cut it to a predetermined length, make a cut 1 at a predetermined position using the NC cutter 14, and then
, a/9°.

... to form. The same applies to the signal flat cable 6.

Figure 7 shows the manufacturing process of the flat cable 5'(6') for the sub-circuit bodies E, F..., and the main circuit body A'.
Since it has fewer core wires and is often thinner than the flat cable 5 (6), it is preferable to manufacture it in a separate system.

Figure 8 shows the main circuit body A' and the sub circuit body E.

This is a preparatory process for connection with F... That is, the two cables 5 and 6 are placed side by side on a pallet 15, and one pressure contact part 9a of the pressure contact terminal 9 is pressure contacted to a predetermined parallel wire or separated wire as shown in FIG. 5a. , cover with an insulating sheet 8.

Figure 9 shows the assembly process of the sub-circuit bodies E, F, etc., and shows the cable 5'(6') of the predetermined length obtained in Figure 7.
The pressure connector 4 having the pressure contact terminals 16a is attached to the end of the connector 4 by a known method.

Figure 10 shows the main circuit body A' and the sub circuit body.

In the connection step E..., for example, as shown in the figure, the other pressure contact portion 9b of the pressure contact terminal 9 is pressure-contacted to the sub-circuit body E.

Figure 11 shows the process of protecting the connection part, and shows the process for protecting the connection part of the cable 5'
, 6' are coated with a hot-melt adhesive 10 using a dispenser 17 to insulate and protect the tips of the pressure contact terminals 9 protruding from the surfaces of the cables 5', 6'.

FIG. 12 shows the folding and casing process of the circuit body. That is, as explained in FIG. In this state, the cable 5 and the cable 6 are further folded, and then the sub-circuit body E is clamped and fixed between the protective case 7 from above and below. Other sub circuits, F, G
..., Z" Z #.

In the above manner, a completed flat wire harness is obtained as shown in FIG. 2.

(Effects of the Invention) As explained above, according to the present invention, a conventional wire harness having a wire convergence shape in which a plurality of branch harnesses are provided to a main harness can be replaced with a main circuit body and a sub circuit body each consisting of a flat cable. The separation line can be formed into a desired pattern by changing the position and number of notches in the main circuit body, so the shape is simple, the number of parts is small, automatic production is easy, and the product is thin. The lighter weight also makes it easier to assemble into a vehicle.

[Brief explanation of the drawing]

Fig. 1 is a wiring diagram of a flat wire harness showing a first embodiment of the present invention, Fig. 2 is a perspective view of a flat wire harness showing a second embodiment of the invention, and Fig. 3 is a main circuit body A of the same. Figure 4 is an enlarged perspective view of the main parts of the power line flat cable 5 in Figure 3, and Figures 5a-c are the main circuit body A' and An explanatory diagram of the connection structure with each sub-circuit body and E... Figures 6 to 12 are explanatory diagrams of the manufacturing process of the flat wire harness shown in Figure 2. Figure 13 is an explanation of the conventional wire harness. 14 is an explanatory diagram of a conventional wire harness, and FIG. 15 is an explanatory diagram of a manufacturing method of a conventional wire harness using a flat cable. A, A'... Main circuit body, B, C, D-H...
・Sub-circuit body, z, z', z', z''...terminal sub-circuit body, al g az "'aB, ay++1
~...Parallel electric wire, a' y a 11-11
...Separation line, bo! bz~tc. CI, C2~...parallel electric wire, 1...notch,
2...Interconnection, 3...Branch connection, 4...Connector, 5,5'...Flat cable for power line, 6,6
'... Flat cable for signal line, 9... Pressure contact terminal. Figure Figure Figure 10 Figure 11

Claims (3)

[Claims] (1) A flat wire harness in which a plurality of sub-circuit bodies made of flat cables are provided in a branched manner at predetermined intervals in the middle of a main circuit body made of flat cables, and a part of the plurality of parallel electric wires of the main circuit body. 1 in the middle of the electric wire
Or, two or more cuts are formed to form a separation line, and one end of the separation line is interconnected to the parallel electric wire of one sub-circuit body, and the other end is interconnected to the parallel electric wire of the other sub-circuit body. Features a flat wire harness. (2) The flat wire harness according to claim 1, wherein at least one specified parallel electric wire of the sub-circuit body is branch-connected to one of the parallel electric wires of the main circuit body. (3) Claim 1 or 2, wherein the flat cables constituting the main circuit body and each sub-circuit body are formed separately into a power line flat cable and a signal line flat cable.
flat wire harness.