WO2018235788A1 - Wire harness and method of manufacturing wire harness - Google Patents

Abstract

The purpose of the present invention is to provide a technique which is more suitable for fixation of an electric wire and a sheet material by means of welding such as ultrasonic welding and laser welding. A wiring harness according to the present invention is provided with a sheet material, an electric wire and a holding part. The electric wire comprises a core wire and an insulating cover that directly covers the circumference of the core wire; and the electric wire is arranged along the sheet material. At least a part of the holding part is interposed between the electric wire and the sheet material, and mediates the bonding of the sheet material and the electric wire by means of welding.

Description

Wire harness and method of manufacturing wire harness

The present invention relates to a technology for attaching an exterior member to a wire in a wire harness for a vehicle.

In attaching a sheet-like exterior member to a wire, Patent Document 1 positions the exterior member with respect to the wire by applying tape winding around each end of the exterior member and the wire extending from the end. It discloses technology.

JP, 2015-72798, A

Here, the applicant of the present application proposes a method of directly fixing the insulation coating of the electric wire and the sheet material by welding means such as ultrasonic welding or laser welding as a new fixing method of the electric wire and the exterior member.

However, in the case where the material of the wire and the material of the sheet are not compatible or the welding area is small, there is a possibility that sufficient fixing strength can not be obtained.

Then, an object of this invention is to provide the technique more suitable for fixation of the electric wire and sheet material by welding means, such as ultrasonic welding or laser welding.

In order to solve the above problems, a wire harness according to a first aspect includes a sheet material, a core wire, and an insulation coating directly covering the periphery of the core wire, and at least an electric wire disposed along the sheet material A holding portion is provided, a part of which is interposed between the electric wire and the sheet material, and which mediates bonding of the sheet material and the electric wire by welding.

The wire harness which concerns on a 2nd aspect is a wire harness which concerns on a 1st aspect, Comprising: The said holding | maintenance part contains the sheet | seat material side holding | maintenance part provided in the said sheet | seat material.

The wire harness which concerns on a 3rd aspect is a wire harness which concerns on a 2nd aspect, Comprising: At least one part of the said electric wire is embedded in the said sheet material side holding part.

A wire harness according to a fourth aspect is the wire harness according to the third aspect, wherein the sheet material side holding portion is made of the same sheet material as the resin which is the base of the sheet material, and the sheet material side holding portion is made of the sheet material It is also softly formed.

The wire harness which concerns on a 5th aspect is a wire harness which concerns on a 4th aspect, Comprising: Resin used as the base of the said insulation coating is the same as resin used as the base of the said sheet material side holding part.

A wire harness according to a sixth aspect is the wire harness according to any one of the first to fifth aspects, wherein the holding portion is provided on the electric wire to fix the electric wire to the sheet material. Wire side holding part.

The wire harness which concerns on a 7th aspect is a wire harness which concerns on a 6th aspect, Comprising: The said electric wire side holding | maintenance part is continuously provided along the longitudinal direction of the said electric wire.

The wire harness which concerns on a 8th aspect is a wire harness which concerns on a 6th aspect, Comprising: The said electric wire side holding | maintenance part is intermittently provided along the longitudinal direction of the said electric wire.

A wire harness according to a ninth aspect is the wire harness according to any one of the sixth to eighth aspects, wherein the electric wire side holding portion is provided over the entire circumference of the electric wire.

A wire harness according to a tenth aspect is the wire harness according to any one of the sixth to eighth aspects, wherein the electric wire side holding portion is provided only in a partial region along the circumferential direction of the electric wire. It is done.

A wire harness according to an eleventh aspect is the wire harness according to any one of the sixth to tenth aspects, wherein the insulating coating and the sheet material are formed of different materials, and the wire side holding portion is It is formed of a material that is easier to weld to the sheet material than the insulating coating.

A wire harness according to a twelfth aspect is the wire harness according to any one of the first to eleventh aspects, wherein the holding portion is a joint between the sheet material and the electric wire by ultrasonic welding or laser welding. To

The method for manufacturing a wire harness according to the thirteenth aspect includes (a) providing a holding portion on at least one of a sheet material and an electric wire, and (b) holding the holding portion between the sheet material and the electric wire. And solvating, and interposing the sheet material and the electric wire through the holding portion.

A method of manufacturing a wire harness according to a fourteenth aspect is the method of manufacturing a wire harness according to the thirteenth aspect, wherein the step (a) includes the step of (a1) providing the holding portion on the sheet material. .

A method of manufacturing a wire harness according to a fifteenth aspect is the method of manufacturing a wire harness according to the thirteenth or fourteenth aspect, wherein the step (a) includes (a2) the holding portion around the electric wire. The step (a2) and the step (b) are performed during the same wire feeding step including the step of providing.

According to each aspect, ultrasonic welding is performed by, for example, forming the holding portion interposed between the electric wire and the sheet material with a material having good bonding with the ultrasonic welding or laser welding counterpart of the electric wire and the sheet material. Alternatively, the bonding between the electric wire and the sheet material using laser welding can be strengthened.

According to the second aspect, ultrasonic welding or laser welding of the sheet material and the electric wire can be performed using the sheet material side holding portion provided in advance in the sheet material.

According to the third aspect, the welding area between the electric wire and the sheet material side holding portion can be increased. Thereby, the bonding strength can be improved.

According to the fourth aspect, the wire is easily connected to the sheet material by pressing the bonding portion between the electric wire and the sheet material at the time of ultrasonic welding or laser welding to weld the sheet material side holding portion in a bent state or the like. It is possible to form a structure embedded in the holding portion.

According to the fifth aspect, it becomes easy to weld the electric wire and the sheet material side holding portion. Thereby, the bonding strength can be improved.

Moreover, when fixing an electric wire and a sheet | seat material by welding, an insulation coating may melt | dissolve at the time of welding, and the thickness of insulation coating may become thin. Even in this case, according to the sixth aspect, since the wire-side holding portion provided on the outer periphery of the insulating coating is welded to the sheet material, the insulating coating is difficult to melt. For this reason, it is easy to ensure sufficient insulation after welding.

According to the seventh aspect, welding can be performed with the sheet material at any position along the longitudinal direction of the electric wire in the electric wire side holding portion.

According to the eighth aspect, material saving, weight reduction and the like can be achieved.

According to the ninth aspect, even when the wire-side holding portion and the insulating coating are not joined, the wire can be reliably held.

According to the tenth aspect, material saving, weight reduction and the like can be achieved.

According to the eleventh aspect, it becomes easy to obtain sufficient holding power between the electric wire and the exterior member after welding.

According to the fifteenth aspect, lead time can be shortened.

It is a perspective view showing the wire harness concerning a 1st embodiment. It is a bottom view showing the wire harness concerning a 1st embodiment. FIG. 3 is a cross-sectional view taken along the line III-III in FIG. It is an explanatory view showing the manufacturing method of the wire harness concerning a 1st embodiment. It is a perspective view showing the wire harness concerning a 2nd embodiment. FIG. 6 is a cross-sectional view taken along the line VI-VI of FIG. 5; It is explanatory drawing which shows the manufacturing method of the wire harness which concerns on 2nd Embodiment. It is a perspective view showing the wire harness concerning a 3rd embodiment. FIG. 9 is a cross-sectional view taken along line IX-IX of FIG. 8; It is a perspective view which shows the wire harness which concerns on 4th Embodiment. 11 is a cross-sectional view taken along the line XI-XI of FIG. It is sectional drawing which shows the wire harness which concerns on 5th Embodiment. It is explanatory drawing which shows a mode that the wire harness which concerns on 5th Embodiment is manufactured.

First Embodiment
Hereinafter, the wire harness according to the first embodiment will be described. FIG. 1 is a perspective view showing a wire harness 10 according to the first embodiment. FIG. 2 is a bottom view showing the wire harness 10 according to the first embodiment. FIG. 3 is a cross-sectional view taken along the line III-III of FIG. In addition, the part enclosed with a virtual line in FIG. 3 has shown the welding location of the sheet material 12 and the holding part 30. As shown in FIG.

The wire harness 10 is used as a wire for electrically connecting various electric devices mounted on a vehicle or the like. The wire harness 10 is routed around, for example, an instrument panel, a roof, a door or the like in a vehicle. Specifically, the wire harness 10 includes the sheet material 12, the electric wire 20, and the holding unit 30.

The sheet material 12 is a member packaged by the electric wire 20. The sheet material 12 is a member having at least one of the functions such as sound proofing (silence, sound absorption, sound insulation, etc.), protection (abrasion resistance, tension resistance, penetration resistance, etc.), heat radiation, shield, waterproof etc. It is. As the function of the sheet material 12, an appropriate function is selected according to the nature of the electric wire 20 and the environment of the place where the electric wire 20 is disposed. Here, as shown in FIG. 1, the sheet material 12 is formed in a rectangular shape. However, the shape of the sheet material 12 is not limited to the one described above, and can be appropriately changed according to the arrangement of the electric wire 20 and the like.

The sheet material 12 is formed of a resin such as PET (polyethylene terephthalate), PE (polyethylene), PP (polypropylene) or the like. In this case, the resin material may be a foamed resin. Further, it is also conceivable that the resin material is modified for the purpose of improving the bonding property. For example, polyolefin resins such as PE and PP are known to be improved in bonding property by being modified with maleic acid.

The sheet material 12 may have a uniform cross section formed by extrusion molding or the like, or may be a non-woven fabric. The sheet material 12 may also include a metal material such as an aluminum foil. In this case, it is preferable that the portion of the sheet material 12 in contact with the electric wire 20 be made of resin, for example, by coating the resin layer on the surface of the metal material.

The electric wire 20 is disposed so as to overlap the sheet material 12 in at least a partial area along the longitudinal direction. In the example shown in FIG. 1, the electric wire 20 is disposed only on the one main surface 12 a side of the sheet material 12, but may move to the other main surface 12 b on the way. At least one wire 20 may be included. Here, a plurality of (20 in the example shown in FIG. 1) electric wires 20 are included. The insulated wire 20 including the core wire 22 and the insulation coating 24 directly covering the core wire 22 is adopted as the wire 20. The core wire 22 is formed of a conductive material such as copper or aluminum. The core wire 22 may be a single wire or a stranded wire. It is conceivable that the insulating coating 24 is formed by extruding a resin such as polyvinyl chloride (PVC), PE, PP or the like on the outer periphery of the core wire 22. In this case, the resin material may be crosslinked to improve heat resistance. Further, the insulating coating 24 may be formed by baking a varnish or the like applied to the outer periphery of the core wire 22.

The holding portion 30 is an example of a wire-side holding portion which is provided on the wire 20 and fixes the wire 20 to the sheet material 12. The holding portion 30 is provided on the outer periphery of the electric wire 20. The holding portion 30 at least includes an intervening portion 32 interposed between the electric wire 20 and the sheet material 12. Then, at least a part of the intervening portion 32 in the holding portion 30 is ultrasonically welded or laser welded to the sheet material 12. Thus, the holding portion 30 is fixed to the sheet material 12, and the electric wire 20 is fixed to the sheet material 12.

Here, the holding portion 30 is provided over the entire circumference of the electric wire 20. At this time, the thickness of the holding portion 30 along the circumferential direction may be constant or partially different. When the thickness of the holding portion 30 along the circumferential direction is partially different, for example, it is conceivable that the thickness of the intervening portion 32 is thicker than the thickness of the other portions. Thereby, when welding the interposition part 32 and the sheet | seat material 12, the insulation coating 24 becomes difficult to melt | dissolve.

Here, the holding portion 30 is continuously provided along the longitudinal direction of the electric wire 20. At this time, the thickness of the holding portion 30 along the longitudinal direction may be constant or may partially differ.

Such a holding portion 30 can be formed, for example, by extruding a resin or the like around the electric wire 20. However, the holding portion 30 may be formed by applying a resin around the electric wire 20 as in the case of the holding portion 130 according to the second embodiment described later.

The holding portion 30 may or may not be bonded to the outer circumferential surface of the insulating coating 24. Even when the holding portion 30 is not joined to the outer peripheral surface of the insulating coating 24, the holding portion 30 is provided around the entire circumference of the electric wire 20, and thus is difficult to be detached from the electric wire 20. In addition, since the holding portion 30 is continuously provided along the longitudinal direction of the electric wire 20, the holding portion 30 is not easily detached from the electric wire 20 also in this point, and is further unlikely to be displaced in the longitudinal direction.

At this time, whether or not the holding portion 30 and the outer peripheral surface of the insulating coating 24 are joined is considered to be determined according to, for example, the manufacturing method, the material, and the like. Further, the bonding strength in the case where the holding portion 30 and the outer peripheral surface of the insulating coating 24 are bonded is also considered to be determined according to the manufacturing method, the material, and the like.

For example, in terms of the manufacturing method, the outer circumferential surface of the insulating coating 24 is roughened, so that when the holding portion 30 is extrusion-molded, it is filled between minute irregularities on the outer circumferential surface of the insulating coating 24. It is considered that the bonding strength between the holding portion 30 and the outer peripheral surface of the insulating coating 24 can be easily enhanced by the effect. Also, for example, the joint force between the holding portion 30 and the outer circumferential surface of the insulating coating 24 can be obtained by further extruding the holding portion 30 in the state of having heat immediately after the insulating coating 24 is extruded or the like. Is considered to be easier to

Also, for example, in terms of materials, the material of the insulating coating 24 and the holding section 30 is a combination of materials that can be easily chemically bonded, whereby the holding section 30 and the outer peripheral surface of the insulating coating 24 can be easily joined. For example, if the material of the insulating coating 24 and the holding portion 30 is the same material, it is considered that chemical bonding is facilitated.

When different materials are used as the insulating coating 24 and the holder 30, the following combinations can be considered as a combination of materials that are easily chemically bonded. In addition, in the following combination, it describes in order of (The material of the insulation coating 24, the material of the holding | maintenance part 30).

That is, (PVC, EEA (polyethylene-ethyl acrylate copolymer)), (PP, maleic acid modified PP) and the like.

Here, ultrasonic welding is employed as a welding means for the holding portion 30 and the sheet material 12. FIG. 4 is an explanatory view showing how ultrasonic welding is performed. As shown in FIG. 4, ultrasonic welding generally involves two members (here, the electric wire 20 and the sheet material 12 with the holding portion 30) to be welded between the horn 82 and the anvil 84 in the ultrasonic welding machine 80. )). The two members disposed between the horn 82 and the anvil 84 are in a state in which surfaces to be welded are in contact with each other.

The horn 82 abuts on one of the two members and applies ultrasonic vibration to the one member. As a transmission mode of the ultrasonic vibration from the horn 82, there are longitudinal vibration, lateral vibration and the like, but it can be appropriately selected according to the shape, physical properties and the like of the member to be welded.

The anvil 84 supports the other of the two members. In the example shown in FIG. 4, the wire 20 supporting surface of the anvil 84 is formed in a flat surface shape, but may be formed in a curved surface shape.

When ultrasonic vibration is applied from the horn 82 to one of the members in a state in which the two members to be welded are sandwiched between the horn 82 and the anvil 84, friction or compression occurs due to the applied ultrasonic vibration. Etc. to generate heat energy. As a result, a part of the contact surface is melted by the heat energy, and both are bonded. In addition, only one of the two members may be melted, or both may be melted. This is considered to be determined according to the physical properties and the like of the materials constituting the two members.

Here, when ultrasonic welding is performed, generally, there may be a case where a mark (hereinafter referred to as a horn mark 14) pressed against the horn 82 may remain on the member. Therefore, also in the wire harness 10, the horn mark 14 may remain. It is conceivable that, for example, the horn mark 14 has a shape corresponding to the uneven shape formed on the horn 82.

The area welded to the sheet material 12 in the longitudinal direction of the electric wire 20 may be continuous without interruption along the longitudinal direction of the electric wire 20, or a section which is partially interrupted along the longitudinal direction of the electric wire 20 May be included. In the example shown in FIG. 2, ultrasonic welding is intermittently performed so as to include a section that is partially interrupted along the longitudinal direction of the electric wire 20. At this time, the range of one welded portion, the interval between adjacent welded portions, and the like may be appropriately set according to the bonding strength and the like. Moreover, in the example shown in FIG. 2, although ultrasonic welding is intermittently carried out by fixed pitch along the longitudinal direction of the electric wire 20, the part from which a pitch differs may exist.

Moreover, as shown in FIG. 3, the area | region welded with the sheet material 12 in the circumferential direction of the electric wire 20 among the holding | maintenance parts 30 is an area | region smaller than 1/4 round here. However, an area larger than this may be welded to the sheet material 12.

In ultrasonic welding of the holding portion 30 and the sheet material 12, at least one of the holding portion 30 and the sheet material 12 includes a thermoplastic resin on the contact surface. Preferably, both of the two members comprise thermoplastic resin at the abutment surface. It is particularly preferable that the material of the holding portion 30 be the same as the material of the sheet material 12. Moreover, when the material of the insulation coating 24 and the material of the sheet material 12 are different, as a combination of the preferable material of the holding part 30 and the sheet material 12, the following combination can be considered. In addition, in the following combination, it has described in order of (The material of the holding part 30, the material of the sheet material 12).

That is, combinations of (EEA, PE), (maleic acid modified PP, PET) and the like are conceivable.

Therefore, in consideration of the combination of materials that are easily chemically bonded as the materials of the insulating coating 24 and the holding unit 30 described above, when the insulating coating 24 and the holding unit 30 are joined, the insulating coating 24, the holding unit 30, and As a combination of preferable materials of the sheet material 12, the following combinations can be considered. In addition, in the following combination, it describes in order of (The material of the insulation coating 24, the material of the holding | maintenance part 30, and the material of the sheet material 12).

That is, combinations of (PVC, EEA, PE), (PP, maleic acid modified PP, PET) and the like are conceivable.

Here, when the material of the insulation coating 24 and the material of the sheet material 12 are different, it is preferable that the material of the holding portion 30 be a material that is easier to weld to the material of the sheet material 12 than the material of the insulation coating 24 . Thereby, compared with the case where the insulation coating 24 and the sheet material 12 are welded, the joint strength at the time of welding the holding part 30 and the sheet material 12 can be improved. For example, when the material of the insulation coating 24 and the material of the sheet material 12 are different, if the material of the holding section 30 is the same as the material of the sheet material 12, the material of the holding section 30 is more than the material of the insulation coating 24 Also, it becomes easy to weld to the material of the sheet material 12.

In addition, when the holding part 30 and the sheet material 12 are different materials, it is a material which is easy to weld, for example, whether the said resin is crystalline or non-crystalline, has polarity, melting point of resins Alternatively, it is considered that the proximity of the glass transition point, compatibility, and the like are related. For example, when welding the holding portion 30 and the sheet material 12 with the condition other than the material under the same condition, welding can be performed if higher bonding strength can be obtained in the welded portion than when welding the insulating coating 24 and the sheet material 12 It can be regarded as easy material.

The electric wire 20 may be a power supply line or a signal line in relation to the application. Moreover, regarding thickness, it may be thick or thin. Moreover, regarding a cross-sectional shape, a round electric wire may be sufficient and a square electric wire may be sufficient. Here, in general, it is preferable that the contact surfaces of the two members at the start of ultrasonic welding have a convex shape in order to reduce the contact area. In this point of view, in the case of the round electric wire, any position in the circumferential direction has a convex shape, and the holding portion 30 provided on the outer periphery is also easily formed in a convex shape, so a shape suitable for ultrasonic welding It can be said that

The end of the wire 20 is incorporated into the connector 26 here. Then, in a state in which the wire harness 10 is disposed at an installation target location in a vehicle or the like, the connector 26 is connected to the connectors 26 on the various electric devices mounted on the vehicle or the like. Thus, the wire harness 10 is used as a wire for electrically connecting various electric devices mounted on a vehicle or the like. The connector 26 may be of a type having a pressure contact terminal pressed against the electric wire 20 or may be of a type that accommodates a crimp terminal crimped to the end of the electric wire 20.

In the example shown in FIG. 1, the end of the electric wire 20 is incorporated in the connector 26 in the state of extending outward of the sheet material 12, but this is not essential. The end of the electric wire 20 may be incorporated into the connector 26 with the end portion of the electric wire 20 positioned on the sheet material 12. In this case, a part of the connector 26 may be located on the sheet material 12. Furthermore, in this case, a part of the connector 26 may be joined and fixed to the sheet material 12.

Here, in the example shown in FIG. 2, all the three electric wires 20 are fixed to the sheet material 12 by welding via the holding portion 30. However, when the electric wire 20 is contained in multiple numbers by the wire harness 10, the electric wire 20 which is not fixed by welding with the sheet material 12 may be contained. Moreover, in the example shown in FIG. 2, all the three electric wires 20 are similarly fixed by welding. However, when a plurality of electric wires 20 fixed to the sheet material 12 by welding are included in the wire harness 10, at least a part of welding modes such as welding means and welding area may be different.

Further, in the example shown in FIG. 1, all three electric wires 20 are connected to the same connector 26. However, when the wire harness 10 contains multiple electric wires 20, the electric wires 20 connected to different connectors 26 may be included.

Moreover, in the example shown in FIG. 1, the electric wire 20 is arrange | positioned in linear form. However, the electric wire 20 may be bent and disposed. And when the electric wire 20 is contained in multiple numbers by the wire harness 10, the electric wire 20 arrange | positioned linearly may be present together with the electric wire 20 arrange | positioned by bending. In this case, branches may be formed on the plurality of electric wires 20 on the sheet material 12.

Further, in the example shown in FIG. 1, the electric wire 20 is disposed at a position closer to the center in the width direction than the sheet material 12. However, the path along which the electric wire 20 is disposed with respect to the sheet material 12 is not limited to the one described above. For example, the electric wire 20 may be disposed at a position close to the end in the width direction with respect to the sheet material 12. Also, for example, the electric wire 20 may extend obliquely to the sheet material 12.

Further, in the example shown in FIG. 1, the sheet material 12 is flat, but the sheet material 12 may be rounded around the electric wire 20. At this time, it may be a part including a flat part and a rounded part. Moreover, when the wire harness 10 is arrange | positioned along a rod-shaped member, at least one part of the sheet material 12 may be wound around a rod-shaped member.

In addition, the fixing member for fixing the wire harness 10 to attachment object, such as a vehicle body panel or a rod-shaped member, may be provided in the sheet | seat material 12. FIG. At this time, the fixing member may also be joined to the sheet material 12.

According to the above aspect, since the holding portion 30 provided on the outer periphery of the insulating coating 24 is welded to the sheet material 12, the insulating coating 24 is difficult to melt. For this reason, it is easy to ensure sufficient insulation after welding.

Further, since the holding portion 30 is provided over the entire circumference of the electric wire 20, even when the holding portion 30 and the insulating coating 24 are not joined, the holding portion 30 is not easily detached from the electric wire 20. Further, for example, when the thickness of the holding portion 30 is constant along the circumferential direction, any position along the circumferential direction of the electric wire 20 with the holding portion 30 can be welded to the sheet material 12.

Further, since the holding portion 30 is continuously provided along the longitudinal direction of the electric wire 20, welding can be performed with the sheet material 12 at any position along the longitudinal direction of the electric wire 20 in the holding portion 30. In addition, even when the holding portion 30 and the insulating coating 24 are not joined, the holding portion 30 does not easily come off the electric wire 20.

In addition, since the holding portion 30 is formed of a material that is easier to weld to the sheet material 12 than the insulating coating 24, a sufficient holding force can be easily obtained between the electric wire 20 and the exterior member after welding.

Second Embodiment
A wire harness according to a second embodiment will be described. FIG. 5 is a perspective view showing a wire harness 110 according to the second embodiment. 6 is a cross-sectional view taken along the line VI-VI of FIG. In FIG. 6, a portion surrounded by an imaginary line in the same manner as in FIG. 3 indicates a welded portion between the sheet material 12 and the holding portion 130. Further, in the description of the present embodiment, the same components as those described above are denoted by the same reference numerals, and the description thereof is omitted.

The wire harness 110 which concerns on this embodiment differs in the shape of the holding part 130 from the shape of the holding part 30 of the wire harness 10 which concerns on 1st Embodiment.

Specifically, the holding portion 130 is provided only in a partial region while including the intervening portion 132 along the circumferential direction of the electric wire 20. In the example shown in FIG. 6, the holding portion 130 is provided in a region extending along a half circumference along the circumferential direction of the electric wire 20, but may be provided in a wider region or in a narrow region. May be The holding portion 130 may be provided so that the electric wire 20 does not contact the sheet material 12 at least at the time of welding.

The holding portion 130 is continuously provided along the longitudinal direction of the electric wire 20, similarly to the holding portion 30 of the wire harness 10 according to the first embodiment.

The holding portion 130 is formed, for example, by coating a resin around the electric wire 20. Under the present circumstances, since the holding | maintenance part 130 is provided only in the one part area | region along the circumferential direction of the electric wire 20 here, there exists a possibility that the holding | maintenance part 130 and the insulation coating 24 may remove | deviate. In order to prevent this, it is preferable that the bonding strength between the holding portion 130 and the insulating coating 24 be enhanced by the method described above.

When manufacturing the wire harness 110 concerning this embodiment, as shown in FIG. 7, the process of providing the holding part 130 in the outer periphery of the electric wire 20 in the same electric wire delivery process, welding the holding part 130 and the sheet material 12 And the step of That is, both the resin supply unit 70 and the welding device 80 are provided for one wire delivery line drawn out from the wire storage portion 60 for storing the wires 20 in one manufacturing device. The resin supply unit 70 is a portion that supplies the resin to be the holding unit 130 around the electric wire 20. The resin supply unit 70 supplies the resin around the electric wire 20 by, for example, application or the like. The welding device 80 is, for example, the ultrasonic welding device 80 and is provided downstream of the resin supply unit 70. As described above, by performing the step of providing the holding portion 130 on the outer periphery of the electric wire 20 and the step of welding the holding portion 130 and the sheet material 12 in the same electric wire feeding step, the holding portion on the outer periphery of the electric wire 20 The lead time is shortened and the device is simplified as compared with the case where the wire 20 taken up when welding the holding part 130 and the sheet material 12 is re-fed after the wire 130 is once taken up and 130 is provided. Can be Further, since the holding portion 130 can be provided on the outer periphery of the electric wire 20 and the holding portion 130 and the sheet material 12 can be welded immediately, the holding portion 130 is not provided along the circumferential direction of the electric wire 20 It is possible to suppress welding of the portion to the sheet material 12.

According to this aspect, since the holding portion 130 is provided only in a partial region along the circumferential direction of the electric wire 20, material saving, weight reduction, and the like can be achieved.

{Third Embodiment}
A wire harness according to a third embodiment will be described. FIG. 8 is a perspective view showing a wire harness 210 according to the third embodiment. FIG. 9 is a cross-sectional view taken along line IX-IX of FIG. 9 is a cross-sectional view of a portion where the holding portion 230 is not provided along the longitudinal direction of the electric wire 20. As shown in FIG. Further, in the description of the present embodiment, the same components as those described above are denoted by the same reference numerals, and the description thereof is omitted.

In the wire harness 210 according to the present embodiment, the shape of the holding portion 230 is different from the shape of the holding portion 30 of the wire harness 10 described above.

Specifically, the holding portion 230 is intermittently provided along the longitudinal direction of the electric wire 20. Here, each divided unit of the holding unit 230 is referred to as a holding piece 234. In the example shown in FIG. 8, the holding pieces 234 are provided at a constant pitch along the longitudinal direction of the electric wire 20, but may be provided at different pitches.

When the holding portion 230 is intermittently provided along the longitudinal direction of the electric wire 20, all the holding pieces 234 may be welded to the sheet material 12 or the holding pieces 234 not welded to the sheet material 12 May exist.

Each holding piece 234 is provided over the entire circumference of the electric wire 20 while including the intervening portion 232, like the holding portion 30 of the wire harness 10 according to the first embodiment. Under the present circumstances, although each holding piece 234 has fixed thickness in the circumferential direction, it has a part from which thickness differs in the circumferential direction similarly to the holding part 30 of the wire harness 10 which concerns on 1st Embodiment. May be

The holding portion 230 can be formed, for example, by coating the electric wire 20 with a resin, similarly to the holding portion 130 according to the second embodiment. More specifically, the wire 20 being fed is alternately repeated when being coated and when not being coated. In addition, when the resin is coated, the entire circumference of the electric wire 20 is coated.

According to this aspect, since the holding portion 230 is provided intermittently along the longitudinal direction of the electric wire 20, material saving, weight reduction, and the like can be achieved.

{Fourth embodiment}
A wire harness 310 according to a fourth embodiment will be described. FIG. 10 is a perspective view showing a wire harness 310 according to the fourth embodiment. 11 is a cross-sectional view taken along the line XI-XI of FIG. FIG. 11 is a cross-sectional view of a portion where the holding portion 330 is not provided along the longitudinal direction of the electric wire 20. As shown in FIG. Further, in the description of the present embodiment, the same components as those described above are denoted by the same reference numerals, and the description thereof is omitted.

In the wire harness 310 according to the present embodiment, the shape of the holding portion 330 is different from the shape of the holding portion 30 of the wire harness 10 described above.

Here, the holding portion 330 is provided intermittently along the longitudinal direction of the electric wire 20. Further, the holding portion 330 is provided only in a partial region along the circumferential direction of the electric wire 20. Therefore, the holding portion 330 includes a plurality of holding pieces 334 provided at intervals along the longitudinal direction of the electric wire 20. Each holding piece 334 covers only a partial area while including the intervening portion 332 along the circumferential direction of the electric wire 20.

The holding portion 330 can be formed, for example, by coating the electric wire 20 with a resin, as in the case of the holding portion 130 according to the second embodiment. More specifically, the wire 20 being fed is alternately repeated when being coated and when not being coated. Moreover, when resin is coated, it coats a partial area of the electric wire 20.

According to this aspect, since the holding portion 330 is provided intermittently along the longitudinal direction of the electric wire 20, material saving, weight reduction, and the like can be achieved.

Moreover, since the holding | maintenance part 330 is provided only in the one part area | region along the circumferential direction of the electric wire 20, material saving, weight reduction, etc. can be achieved.

{Fifth embodiment}
A wire harness 410 according to a fifth embodiment will be described. FIG. 12 is a cross-sectional view showing a wire harness 410 according to the fifth embodiment. FIG. 13 is an explanatory view showing a state of manufacturing the wire harness 410 according to the fifth embodiment. Further, in the description of the present embodiment, the same components as those described above are denoted by the same reference numerals, and the description thereof is omitted.

The wire harness 410 according to the fifth embodiment differs from the wire harnesses 10, 110, 210, and 310 in that the holding portion 430 is provided on the sheet material 12.

The holding portion 430 is an example of a sheet material side holding portion provided on the sheet material 12 for fixing the sheet material 12 to the electric wire 20. It is conceivable that the holding portion 430 is provided, for example, over the entire main surface 12 a of the sheet material 12. For example, it is also conceivable that the holding portion 430 is provided on a part of the one main surface 12 a of the sheet material 12 including the portion where the electric wire 20 is disposed. At this time, the holding portion 430 may be formed to have a uniform thickness, or may have a portion having a different thickness.

The holding portion 430 is formed of, for example, a material containing a thermoplastic resin. The holding portion 430 is formed, for example, by applying a material containing a thermoplastic resin to the one main surface 12 a of the sheet material 12. Also, for example, the holding portion 430 is formed by two-color molding or extrusion molding with the sheet material 12. From these, the sheet material 12 and the holding portion 430 are joined and integrated.

The holding portion 430 is formed based on the same resin as the resin serving as the base of the sheet material 12. At this time, the holding portion 430 is formed softer than the sheet material 12. Here, the base resin is PVC, and the holding portion 430 is softer than the sheet material 12 by increasing the proportion of the plasticizer to be added. The type of the plasticizer is not particularly limited. For example, plasticizers such as phthalic acid ester, trimellitic acid ester, pyromellitic acid ester, fatty acid ester, and fatty acid polyester can be used. A plasticizer may be used individually by 1 type, and multiple types may be used together. However, the means for making the base resin and the holding portion 430 softer than the sheet material 12 is not limited to this. For example, PE, PP, PET, etc. can be considered as the base resin. Also, the means for making the holding portion 430 softer than the sheet material 12 is set according to the base resin, for example, to lower the density of the base resin, to copolymerize another resin, or to be flexible. Means are also conceivable, such as adding modifiers which can be increased (for example thermoplastic elastomers such as olefinic or styrenic).

Also, the resin that is the base of the insulating coating 24 here is the same as the resin that is the base of the holding portion 430. Thereby, the insulation coating 24 and the holding portion 430 are welded well. However, the resin used as the base of the insulating coating 24 may be different from the resin used as the base of the holding portion 430.

When joining the electric wire 20 to the sheet material 12 provided with the holding portion 430, ultrasonic welding is performed on the intervening portion 432 in the holding portion 430 and the insulating coating 24 in a state where the electric wire 20 is disposed on the holding portion 430. Alternatively, laser welding (in the example shown in FIG. 5, ultrasonic welding) is conceivable. At this time, when the electric wire 20 and the intervening portion 432 are sandwiched and pressed from both sides, the holding portion 430 is softer than the sheet material 12 and the core 22, so the intervening portion 432 is bent and the electric wire 20 is in the intervening portion 432 of the holding portion 430. It is located on the sheet material 12 side than the surrounding part of In this state, by welding, the electric wire 20 is buried in the holding portion 430, and the welding region in the circumferential direction of the electric wire 20 is enlarged. As a result, the bonding strength can be improved by increasing the area to be welded.

Under the present circumstances, it is thought that the amount of embedding of the electric wire 20 is decided by the thickness of the holding part 430, a softness | flexibility, pushing pressure force, etc. FIG. Since the area to be welded becomes larger as the amount of embedded wire 20 is larger, it is preferable that the amount of embedded wire 20 is larger. For example, in the example illustrated in FIG. 12, the electric wire 20 is filled with a region of not less than one-fourth and less than a half. At this time, it is also conceivable that the region of a half turn or more of the electric wire 20 is formed to be filled. In this case, since the convex portion is fitted in the concave portion where the inlet is narrowed, it becomes difficult to fall off even if the welding state of the holding portion 430 and the insulating coating 24 is cancelled. From this point of view, it is also conceivable that the region of the entire circumference of the electric wire 20 is formed to be filled. In this case, the thickness of the holding portion 430 provided in advance on the sheet material 12 is equal to or greater than the diameter of the electric wire.

However, the structure in which the electric wire 20 is embedded in the holding portion 430 after welding is not essential, and the electric wire 20 may not be embedded in the holding portion 430.

Moreover, in order to make the structure in which the electric wire 20 is buried in the holding portion 430 after welding, it is conceivable to form a recess in the holding portion 430 in advance and weld in a state where the electric wire is stored in the recess 20. In this case, the holding portion 430 does not have to be softer than the sheet material 12.

Further, from the viewpoint of insulation, it is preferable that the insulating coating 24 does not melt as much as possible when the holding portion 430 and the insulating coating 24 are welded. In this case, for example, it is conceivable to make the melting point (softening point) of the holding portion 430 lower than the melting point (softening point) of the insulating coating 24.

Also according to the wire harness 410 configured in this manner, the holding portion 430 interposed between the electric wire 20 and the sheet material 12 is formed of a material having good bonding with the other side of ultrasonic welding or laser welding, or the like. The bonding between the electric wire 20 and the sheet material 12 using ultrasonic welding or laser welding can be strengthened.

In particular, the sheet material 12 and the electric wire 20 can be ultrasonically welded or laser welded using the holding portion 430 provided in advance on the sheet material 12.

Further, since at least a part of the electric wire 20 is embedded in the holding portion 430, the welding area between the electric wire 20 and the holding portion 430 can be increased. Thereby, the bonding strength can be improved.

Further, since the holding portion 430 is formed softer than the sheet material 12 while being based on the same resin as the base resin of the sheet material 12, the holding portion 430 is formed between the electric wire 20 and the sheet material 12 at the time of ultrasonic welding or laser welding. A structure in which the electric wire 20 is buried in the holding portion 430 can be formed simply by pressing the joint portion and welding while the holding portion 430 is bent.

In addition, since the resin that is the base of the insulating coating 24 is the same as the resin that is the base of the holding portion 430, welding of the electric wire 20 and the holding portion 430 is facilitated. Thereby, the bonding strength can be improved.

{Modification}
In the first embodiment, the welding means between the holding portion 30 and the sheet material 12 has been described as ultrasonic welding, but this is not essential. The welding means between the holding portion 30 and the sheet material 12 may be laser welding. The same applies to the other embodiments. In this case, the laser beam is irradiated from one side of the holding portion 30 and the sheet material 12 toward the boundary between the two. The side irradiated with the laser beam is formed of a material capable of transmitting the laser beam. In addition, the surface of at least the boundary portion in the other can absorb more laser light than that of one. As a result, the laser light is absorbed at the boundary portion, and the holding portion 30 and the sheet material 12 are welded by the absorbed light. The transmission side may be the holding portion 30 or the sheet material 12.

Further, it is also conceivable to use a resin material with good thermal conductivity as the material of the holding portion 30. Thereby, the effect of radiating the heat of the electric wire 20 can be enhanced. As a resin material with good thermal conductivity, for example, one obtained by blending a thermally conductive filler such as alumina or boron nitride with the above-mentioned resin is mentioned.

Further, in the manufacturing method according to each embodiment, the sheet material 12 may be fed in a long state and cut into a predetermined dimension after the electric wire 20 with the holding portion 30 is welded. The electric wire 20 with the holding portion 30 may be welded to the sheet material 12 cut to a predetermined size.

When a part of the electric wire 20 extends from the sheet material 12, the holding portion 30 may not be provided at a portion of the electric wire 20 extending outward of the sheet material 12.

In the fourth embodiment, the holding portion 430 is described as being formed based on the same resin as the resin serving as the base of the sheet material 12, but this is not an essential configuration. The holding portion 430 may be formed based on a resin different from the resin that is the base of the sheet material 12. In this case, it is considered that the combination of materials of the holding portion 430, the sheet material 12, and the insulating coating 24 is, for example, the same combination as that described in the first embodiment.

Although ultrasonic welding and laser welding have been exemplified as welding means, welding may also be performed using heating means such as condensing heating, hot air heating, induction heating, dielectric heating and the like.

In addition, each structure demonstrated by said each embodiment and each modification can be combined suitably, as long as there is no contradiction mutually. For example, in one wire harness, both the electric wire side holding portion and the sheet material side holding portion may be employed. In this case, the wire side holding portion and the sheet material side holding portion are welded.

As mentioned above, although this invention was explained in detail, the above-mentioned explanation is illustration in all the aspects, and this invention is not limited to it. It is understood that countless variations not illustrated are conceivable without departing from the scope of the present invention.

DESCRIPTION OF SYMBOLS 10 wire harness 12 sheet material 12a one main surface 12b other main surface 14 horn mark 20 electric wire 22 core wire 24 insulation coating 26 connector 30 holding part 32 intervening part 34 holding piece 60 electric wire accommodating part 70 resin supply part 80 ultrasonic welding machine 82 horn 84 anvil

Claims (15)

Sheet material,
A wire including a core wire and an insulation coating directly covering the periphery of the core wire, and arranged along the sheet material;
A holding portion at least a part of which is interposed between the electric wire and the sheet material and which mediates the bonding between the sheet material and the electric wire by welding;
, Wire harness. A wire harness according to claim 1, wherein
The said holding | maintenance part is a wire harness containing the sheet | seat material side holding | maintenance part provided in the said sheet | seat material. The wire harness according to claim 2, wherein
A wire harness, wherein at least a part of the electric wire is embedded in the sheet material side holding portion. The wire harness according to claim 3, wherein
The wire harness, wherein the sheet material side holding portion is formed softer than the sheet material, while being based on the same resin as the resin serving as the base of the sheet material. The wire harness according to claim 4, wherein
A resin as a base of the insulation coating is the same as a resin as a base of the sheet material side holding portion. The wire harness according to any one of claims 1 to 5, wherein
The said holding | maintenance part is a wire harness provided in the said electric wire and containing the electric wire side holding | maintenance part which fixes the said electric wire with respect to the said sheet material. The wire harness according to claim 6, wherein
The wire harness in which the said electric wire side holding | maintenance part is continuously provided along the longitudinal direction of the said electric wire. The wire harness according to claim 6, wherein
The wire harness in which the said electric wire side holding | maintenance part is intermittently provided along the longitudinal direction of the said electric wire. A wire harness according to any one of claims 6 to 8, wherein
The wire harness in which the said electric wire side holding | maintenance part is provided over the perimeter of the said electric wire. A wire harness according to any one of claims 6 to 8, wherein
The wire harness by which the said electric wire side holding | maintenance part is provided only in the one part area | region along the circumferential direction of the said electric wire. The wire harness according to any one of claims 6 to 10, wherein
The insulation coating and the sheet material are formed of different materials;
The wire harness by which the said electric wire side holding | maintenance part is formed with the material which is easy to weld to the said sheet material rather than the said insulation coating. The wire harness according to any one of claims 1 to 11, wherein
The said holding | maintenance part mediates joining of the said sheet material and the said electric wire by ultrasonic welding or laser welding. (A) providing a holding portion on at least one of the sheet material and the electric wire;
(B) interposing and melting the holding portion between the sheet material and the electric wire, and bonding the sheet material and the electric wire through the holding portion;
A method of manufacturing a wire harness, comprising: A method of manufacturing a wire harness according to claim 13, wherein
In the step (a),
(A1) The manufacturing method of a wire harness including the process of providing the holding part in the sheet material. A method of manufacturing a wire harness according to claim 13 or claim 14, wherein
In the step (a),
(A2) including the step of providing the holding portion around the wire;
The manufacturing method of a wire harness which performs the said process (a2) and the said process (b) in the same electric wire delivery process.

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