JP3095084B2 - Flat wire harness - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flat wire harness used for electric wiring of a vehicle.

[0002]

2. Description of the Related Art The applicant of the present invention has previously sought to increase the size and weight of an electric wire bundle type wire harness in which a large number of conventional coated electric wires are bundled.
In order to solve such drawbacks, a flat wire harness as shown in FIG. 10 has been proposed (Japanese Patent Application No. 2-11582).
No. 7). In the drawing, reference numeral 1 denotes a long insulating plate made of synthetic resin, and a plurality of relay circuit boards 2, 2 ', 2 "at desired intervals.
... is fixed. The relay circuit board is a circuit board 3 made of a synthetic resin insulator, a plurality of junction bars 4 and connectors 5,
5 '.

The circuit board 3 has a plurality of slits 3a provided on the upper surface thereof in a direction perpendicular to the insulating plate 1, a concave portion 3b for fixing the insulating plate on the lower surface, and both ends orthogonal to the slit 3a. A connector supporting piece 3c protrudes from one of the edges, and a connector insertion piece 3c 'protrudes from the other. The junction bar 4 has a narrow band shape, tabs 4a as connector terminals are formed at both ends, and a slot 4c is formed at one side edge.
At least one pressure contact terminal portion 4b having a projection is provided. The connector 5 (5 ') has a plurality of terminal accommodating chambers 5 in the connector housing 5a at the same pitch as the slits 3a.
b, and a female-female relay terminal 6 is inserted into the room. In Figure 11, 3d is a locking projection, which engages the locking arm 5c Deflection variable of the connector 5. 5c 'is an insertion frame for the connector insertion piece 3c'.

To assemble the relay circuit board 2, a junction bar 4 is press-fitted and fixed to a slit 3 a of a circuit board 3 with its width direction vertical, and a tab 4 a protruding from an end surface of the board 3.
In a state where the relay terminal 6 is inserted into the group, the connectors 5, 5 '
Is mounted and locked. The assembled relay circuit boards 2, 2 ', 2 ",... Are coated with an adhesive in the recesses 3b, and are adhesively fixed at predetermined positions on the insulating plate 1 as shown in Fig. 10. Thereafter, an automatic motor (not shown) is mounted. Wiring is connected between desired junction bars 4 of different relay circuit boards 2, 2, 2 ″. The connection is performed by press-fitting the insulated wire 7 into the slot 4c of the press contact terminal portion 4b. Thereby, the terminals between the connectors 5, 5 ',... Are connected, and a desired circuit is formed. In FIG. 10, 8
Is a protective sheet for fixedly protecting the insulated wire 7 on the insulating plate 1, and 9 is a protective cover for the relay circuit board.

In the relay circuit board 2 shown in FIGS. 10 and 11, the press-contact terminal portion 4b of the junction bar 4 projects above the circuit board 3 and interferes with other wiring, or the wire 7 pressed by hooking is pulled out. May be done. Thus, as shown in FIG. 12, the circuit board 3 'may be composed of two members, a cover 14 for the junction bar 4 and a fixing plate 15. The cover 14 is connected to the press contact terminal 4b.
A fixing slit 14b for the press-contact terminal portion 4b is provided at the inner edge corresponding to the position, and a junction bar fixing slit 14c is formed on two sides of the cover 14.

In the case of the circuit board 3 ', the junction bar 4 is sandwiched and fixed between the cover 14 and the fixing plate 15, and the press contact terminal portion 4b is accommodated in the wire press-fitting hole 14a and fixed by the fixing slit 14b. .

[0007]

FIG. 1 shows a relay circuit board.
When using the circuit board 3 ', such as 2, press-connecting terminal portions 4
Since b is accommodated in the wire press-fitting hole 14a, it does not hinder the wiring, but the thickness of the relay circuit body becomes large and the weight increases. In addition, a large number of wire press-fit holes 14 must be formed corresponding to the press-contact portions of the wires, which complicates the mold. Further, there remain problems such as the wired wires crossing or crossing the other wire press-fitting holes 14, making it difficult to press-fit there, and limiting the degree of freedom of wiring.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and has a thin circuit board constituting a relay circuit board.
The present invention provides a flat wire harness that has a high degree of freedom in wiring as well as a reduction in weight and weight, eliminates the intersection of wires wired between relay circuit boards, simplifies the wiring form, and improves productivity. Aim .

[0009]

In order to achieve the object of the means for solving the problems], flat wire harness of the present invention, as described in claim 1, at the insulating plate long, the desired spacing thereon The relay circuit board includes a plurality of fixed relay circuit boards, and a plurality of electric wires connecting the relay circuit boards to each other to form a desired circuit.The relay circuit board includes a circuit board made of an electrical insulator, and an elongated board. Shape, and one side edge of the long side is
A plurality of jaws embedded in the circuit board so as to be placed
And a junction bar.
Of the circuit board so that the one side edge of the circuit board is exposed.
A guide portion for wire connection formed by cutting from is provided,
Means such as welding with a desired junction bar at both ends of the electric wire routed between the relay circuit boards at the guide portion
And a circuit is formed by permanent connection .

[0010]

According to the flat wire harness of the present invention, the junction bar in the relay circuit board does not have a press contact terminal portion,
Moreover , one side edge of the longer side is lower than the surface of the circuit board
Position, and this one side edge is exposed in the guide, and the electric wire is spot-welded or soldered in this guide.
For example, the connection is permanent, and the reliability of the connection is improved.

In addition, since the height of the junction bar is reduced by eliminating the press contact terminal portion, the thickness of the relay circuit board is reduced.
Reduction, it is possible to reduce the weight. Also, contact in a state the wire at any position of the junction bar, which moreover superposed
Since the wiring can be continued , the degree of freedom of the wiring is extremely large, the automation of the wiring by a machine is easy, and the productivity is greatly improved. Furthermore, by connecting at any position and overlapping, the relay circuit boards can be wired in parallel without intersecting the wires, and the wiring form can be simplified.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1, reference numeral 21 denotes a long insulating plate.
At desired intervals, the relay circuit boards 22, 22 ', 22 "...
Has been fixed. The insulating plate 21 is made of a synthetic resin insulator such as paper, phenol resin, or glass fiber reinforced epoxy resin, and has a bent portion 2 with respect to the straight portion 21a.
1b and a concave portion 21c are provided so as to follow the wiring route in the vehicle.

Each of the relay circuit boards includes a circuit board 23 made of a synthetic resin insulator, a plurality of junction bars 24, connectors 25 and 25 ', etc., as represented by reference numeral 22 in FIGS. Is done.

The circuit board 23 has a plurality of slits 23a arranged in parallel on the upper surface at right angles to the longitudinal direction of the insulating plate 21 and a concave portion 23b for fixing the insulating plate on the lower surface.
Of the side edges at both ends of the slit 23a, a connector supporting piece 23c protrudes on one side, and a connector insertion piece 23c 'protrudes on the other side, and further, locking projections 23d protrude on both left and right sides of the circuit board 23. Have been.

[0015] The above is shown in FIG. 11 also we have previously proposed
Is a basic configuration similar to that, in the present invention, an intermediate portion of the plurality of slits 23a are formed through the top and bottom are open at the lower part of the recess 23b, the upper opening tapered guide portion 23a ₁ is, wide width of the guide grooves 23a ₂ than the slit width in the lower opening is provided, respectively. In addition, the junction bar 24 has an elongated plate shape.
Although it has tabs 24a as connector terminals at both ends, it does not have the press-contact terminal portions as described above. In addition, as shown in FIG. 4, the width d of the junction bar 24 is such that one side edge of the long side of the junction bar is directed upward.
Become so when press-fitted into the slit 23a, it as the upper end surface 24b is located in the middle of the guide portion 23a _1. A guide slit 21d is formed in the insulating plate 21 in correspondence with the slit 23a penetrating vertically.

The connector 25 (25 '), similar to the case of FIG. 11, the connector housing 25a forming a plurality of terminal accommodating chambers 25b, flexible lock arm 25c or the connector insertion piece 23c' inset 25c against '. 26 denotes a female-female relay terminal.

Next, a manufacturing process of the flat wire harness will be described. First, each relay circuit board 22, 2
2 ', 22 "... are assembled.
After inserting one end of the relay terminal 26 into the tab 24a at each end of the junction bar 24, it is press-fitted and fixed to the slit 23a of the circuit board 23 as shown in FIG. Then
Connectors 25, 25 from the side surface of the circuit board 23 'is attached to and accommodate the relay terminals 26 groups each terminal accommodating chamber 25b, flexible lock arm 25c and the engaging protrusion 23d or connector insertion piece 23c' and plug Lock and fix by means such as a frame 25c '.

The assembled relay circuit boards 22, 22 ',
In the case of 22 ″, an adhesive is applied to the concave portion 23b of the circuit board 23 and is fixed to a predetermined position of the insulating plate 21 as shown in FIG. P ₀ is obtained.

As shown the harness P ₀ in FIG. 5, for connecting the wire 27 to the desired junction bar 24 placed on the wiring board 30 by wiring machine 31 between the relay circuit board each other. Wiring board 30, the relay circuit board 22 of the harness P _0,
A window 30a is provided at a position corresponding to 22 ', 22 "..., And is provided on a stand (not shown) so as to be able to travel in the X-Y axis direction.

The wiring machine 31 includes a wiring head 32, a pair of upper and lower electrodes 34 and 35, an electric wire cutter 36, a scraping top 37, and a fixed frame 3 for supporting these members.
Consists of eight. The wiring head 32 is provided on the lower surface of the upper plate 38a of the fixed frame 38 attached to the gantry so as to be able to move up and down. The wiring head 32 has an electric wire inlet tube 32a at an upper end and an electric wire supply tube 32b at a lower end. Accommodates a plurality of sets of wire holding rolls and feed rolls (not shown). Wire feed pipe 32b is inclined downward, its distal end 32b ₁ on almost 6, the lower electrode 34,3
5 is set to be on the axis Q passing through.

The upper electrode 34 is attached to the wiring head 32 so as to be able to move up and down, and the lower electrode 35 is provided to be able to move up and down on a lower plate 38 b of a fixed frame 38. The electric wire cutter 36 includes a pair of openable and closable cutting blades 36a, 36.
a, and the electric wire supply pipe 32
It is provided movably in the direction of arrow R in an inclined posture from the side opposite to b. As shown in FIG. 6, the squeezing top 37 includes a pair of left and right openable squeezing claws 37a and 37.
and is provided at the lower end of the front surface of the wiring head 32 so as to be able to move up and down.

Therefore, the wiring board 30 (see FIG. 5) is
By running the shaft, the predetermined relay circuit board 22 (22 ', 22 ")
..) Are arranged on the axis Q of the upper and lower electrodes 34 and 35 as shown in FIG. In FIG. 7, the insulating plate 21, the wiring plate 30 and the wiring head 3
2 and the like are omitted.

[0023] After positioning the junction bar 24, descends the wiring head 32, the end portion of the wire 27 which projects slightly from the distal end portion 32 b ₁ of the wire supply pipe 32b, as shown in FIG. 8, the slits Guide part 23a of 23a
After setting on the upper end face 24b of the junction bar 24 in _1, above, is brought closer to the lower electrodes 34, 35 the Jean
Energizing the action bar 24 from above and below pressurization clamping state, spot welding. After welding, the upper and lower electrodes 34 and 35 move away with the rise of the wiring head 32, and the wiring plate 30 can run in any direction.

Next, the wire holding plate and the feed roll of the wiring head 32 are operated to move the wiring plate 30 while feeding out the electric wire 27, and another relay circuit board 22 '.
A desired row of junction bars 24 (22 ″...) Is positioned between the upper and lower electrodes 34 and 35 as in FIG. 7 and spot-welded in the same manner as described above. One pair of the cutting blades 36a, 36a is cut, whereby one electric wire 27 is welded and fixed between the desired junction bars 24, 24 between the two relay circuit boards 22, 22 '.

Hereinafter, by repeating the above steps,
As shown in FIG. 1, desired relay circuit boards 22, 22 ', 2
Desired junction bars 24, 24 between 2 "...
A flat wire harness P as a finished product in which the electric wires 27 are routed therebetween is obtained. As shown in FIG. 1, the plurality of wired wires 27 are parallel to each other, and unlike the case of FIG. 10, the crossing portions can be eliminated. The reason is,
This is because the junction bar 24 does not have a press contact terminal portion (see FIGS. 11 and 12), and the electric wire 27 can be welded to an arbitrary position in its length direction , and lap welding can be performed. When wiring by the wiring machine 31,
Junction bar 2 to be welded with wired wires
In the case where a part of 4 is hidden, the scraping top 37 provided on the wiring head 32 is lowered to move the scraping claw 3.
By opening 7a and 37a, it can be opened and welded and fixed at a predetermined position.

FIG. 9 shows an example in which the electric wire 27 is joined and fixed together with the solder paste 40 by using a heating press head 39 instead of the method of spot welding the electric wire 27 by the upper and lower electrodes 34 and 35.

In the foregoing, an example has been described in which each relay circuit board is assembled by press-fitting a junction bar into a slit of a circuit board. However, the junction bar and the circuit board may be integrally molded and fixed.

[0028]

According to the flat wire harness of the present invention eliminates the pressure contact terminal portion of the junction bar, it is so arranged permanently connected by wires such as spot welding,
Not only the reliability of the connection portion is improved, but also the thickness and weight of the relay circuit board can be reduced. Also, contact wires at an arbitrary position of the junction bar by abolition of the pressure contact terminal portions
Since it continued stationary, the degree of freedom of the wiring is extremely large, it is easy to automate wiring by machine, productivity is improved by a large margin. Furthermore, since it is possible to eliminate the wires are wired to cross, of course wiring configuration is simplified, the ledge almost becomes not by wire crossing, attaching step of the protective sheet by the press roller is facilitated .

[Brief description of the drawings]

FIG. 1 is a perspective view of a flat wire harness showing one embodiment of the present invention.

FIG. 2 is a view illustrating a part of a manufacturing process of the flat wire harness of FIG. 1;

FIG. 3 is an exploded perspective view of the relay circuit board of FIG. 2;

FIG. 4 is a sectional view of a main part of the relay circuit board of FIG. 3;

FIG. 5 is a perspective view showing an example of a wiring device used in the manufacturing method of the present invention.

FIG. 6 is an enlarged perspective view of a main part of the wiring device of FIG. 5;

FIG. 7 is an explanatory diagram of a spot welding method of an electric wire and a junction bar by the wiring device of FIG. 5;

8 is a cross-sectional view of a main part of the relay circuit board at the time of spot welding in FIG. 7;

FIG. 9 is a cross-sectional view of a main part of a relay circuit board, illustrating another method of connecting an electric wire and a junction bar.

FIG. 10 is a perspective view showing a conventional flat wire harness.

11 is an exploded perspective view of the relay circuit board of FIG.

FIG. 12 is a perspective view showing another example of a conventional relay circuit board.

[Explanation of symbols]

P ₀ Unwired flat wire harness P Flat wire harness 21 Insulation plate 22 (22 '...) Relay circuit board 23 Circuit board 24 Junction bar 25, 25' Connector 23a Slit 23a ₁ Guide

────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Shinichi Okamoto 1500 Onjukucho, Susono-shi, Shizuoka Yazaki Sogyo Co., Ltd. (58) Field surveyed (Int.Cl. ⁷ , DB name) H01B 7/00 301 H01R 9 / 03 H01R 24/00 B60R 16/02 620

Claims (1)

(57) [Claims] 1. A long insulating plate, a plurality of relay circuit boards fixed thereon at desired intervals, and a plurality of relay circuits connecting these relay circuit boards to each other to form a desired circuit. The relay circuit board includes a circuit board made of an electrical insulator and an elongated board.
So that one side edge of the long side is located upward
A plurality of junctions embedded in the circuit board
A bar, and the one of the junction bars
Cut and cut from the front side of the circuit board so that the side edges are exposed
A guide portion for connecting the formed wire is provided, and both ends of the wire routed between the relay circuit boards are permanently fixed to the guide portion by means of a desired junction bar and welding.
A flat wire harness which is connected to form a circuit.