Wire harness

Abstract

A wire harness that includes an electric wire that includes a core wire, an insulating inner cover that covers an outer circumference of the core wire, and a conductive shield that covers an outer circumference of the insulating inner cover; a conductive bracket including a plate that includes an insertion hole through which the electric wire is inserted and a protrusion protruding from an edge of the insertion hole in the plate; a fastener that fastens a folded-back portion of the shield that is folded back to an outer circumferential side of the protrusion to the protrusion; and a body made of resin that sandwiches the plate in a thickness direction.

Claims

1. A wire harness comprising: an electric wire that includes a core wire, an insulating inner cover that covers an outer circumference of the core wire, and a conductive shield that covers an outer circumference of the insulating inner cover; a conductive bracket including a plate that includes an insertion hole through which the electric wire is inserted and a protrusion protruding from an edge of the insertion hole in the plate; a fastener that fastens a folded-back portion of the shield that is folded back to an outer circumferential side of the protrusion to the protrusion; and a body made of resin that sandwiches the plate in a thickness direction, wherein the plate of the bracket includes a flange protruding radially outward from an entire circumference of the body, and the body and the bracket form an attachment to be attached to a device to which the wire harness is to be attached.

2. The wire harness according to claim 1, wherein the insertion hole and the protrusion include a plurality of insertion holes and a plurality of protrusions respectively protruding from edges of the insertion holes.

3. The wire harness according to claim 1, wherein the protrusion has a tubular shape.

4. The wire harness according to claim 1, wherein an annular groove is provided on an outer circumferential surface of the body, and an annular seal is fitted into the annular groove.

5. The wire harness according to claim 1, wherein the shield is grounded via the bracket.

6. The wire harness according to claim 1, wherein the body includes a first body and a second body, and the bracket is disposed between the first body and the second body.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a plan view of a wire harness according to an embodiment of the present disclosure in a state where the wire harness is disposed between devices.

(2) FIG. 2 is an enlarged perspective view of the wire harness of the embodiment of FIG. 1, with the attachment portion as a center.

(3) FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2.

(4) FIG. 4 is a perspective view of a bracket in the wire harness of the embodiment of FIG. 1.

(5) FIGS. 5 (a) to 5(d) are schematic views sequentially showing steps of manufacturing the wire harness in the embodiment of FIG. 1.

(6) FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 5 (c).

(7) FIG. 7 is a perspective view of a bracket in a wire harness of a modified example.

(8) FIG. 8 is a perspective view of a bracket in a wire harness of another modified example.

(9) FIG. 9 is a cross-sectional view of the wire harness of FIG. 8, corresponding to FIG. 6.

(10) FIG. 10 is a perspective view of a bracket in the wire harness of the other modified example.

DETAILED DESCRIPTION OF EMBODIMENTS

(11) Hereinafter, an embodiment of a wire harness will be described with reference to FIGS. 1 to 6.

(12) As shown in FIG. 1, a wire harness 10 is disposed in, for example, a hybrid vehicle or an electric vehicle, and electrically connects devices.

(13) As shown in FIGS. 1 and 2, the wire harness 10 includes a plurality of (six in the present embodiment) electric wires 11, and an attachment portion 51 (attachment) through which the electric wires 11 are inserted and that is to be attached to a housing 91a of a device 91.

(14) The electric wires 11 that are led out from the attachment portion 51 are branched and respectively connected to devices (not shown).

(15) Electric Wire 11

(16) As shown in FIGS. 2 and 3, the electric wires 11 each include a core wire 11a, an insulating inner cover 11b that covers an outer circumference of the core wire 11a, a conductive shield member 11c (shield) that covers an outer circumference of the insulating inner cover 11b, and an insulating outer cover 11d that covers an outer circumference of the shield member 11c.

(17) The core wire 11a is, for example, a stranded wire formed by twisting a plurality of bare metal wires made of a copper alloy. A terminal 12 to be connected to the device 91 is fixed to an end portion of the core wire 11a (see FIG. 2).

(18) The insulating inner cover 11b is made of an electrically insulating synthetic resin material, and has a cylindrical shape.

(19) The shield member 11c is made of a braided wire in which conductive bare wires made of an aluminum alloy or the like are woven in a cylindrical shape.

(20) The insulating outer cover 11d is made of an electrically insulating synthetic resin material, and has a cylindrical shape.

(21) Attachment Portion 51

(22) As shown in FIG. 2, the attachment portion 51 is inserted to the attachment port of the housing 91a to be attached, and includes a bracket 30 and a molded portion 20 (body) that sandwiches the bracket 30 from both sides in a thickness direction and is provided integrally with the bracket 30.

(23) The bracket 30 protrudes radially outward from the entire circumference of the molded portion 20, and this protruding portion functions as a flange portion 36 (flange) of the attachment portion 51.

(24) The flange portion 36 is provided with attachment holes 34 for attaching it to the housing.

(25) First, the configuration of the bracket 30 will be described. Hereinafter, the side of the bracket 30 that is closer to the terminals 12, that is, a housing 91a side may be referred to as an “inner side”, and the side away from the terminals 12 may be referred to as an “outer side”. A pair of surfaces of the bracket 30 extending in a direction intersecting or orthogonal to the longitudinal direction of the electric wires 11 may be referred to as a first surface 30a and a second surface 30b.

(26) As shown in FIG. 4, the bracket 30 includes a rectangular plate-shaped plate portion 31 (plate). The plate portion 31 is provided with a plurality of insertion holes 32 through which the respective electric wires 11 are inserted, and a plurality of cylindrical protruding portions 33 (protrusion) protruding inward from circumferential edges of the respective insertion holes 32.

(27) The plate portion 31 is provided with a pair of communication holes 35 with the plurality of insertion holes 32 interposed therebetween.

(28) The bracket 30 of the present embodiment is made of a metal material such as an aluminum alloy.

(29) As shown in FIG. 3, the insulating outer cover 11d is removed from a portion of each electric wire 11 that protrudes inward from the protruding portion 33 of the bracket 30. A portion (also referred to as a predetermined-length end portion) 11c1 of the shield member 11c that protrudes inward from the protruding portion 33 is exposed from the insulating outer cover 11d. The exposed end portion 11c1 of each shield member 11c is folded back to form a folded-back portion 11c2, and the folded-back portion 11c2 covers the outer circumferential surface of the protruding portion 33. A conductive fastening member 40 (fastener) for fastening the folded-back portion 11c2 to the outer circumferential surface of the protruding portion 33 is provided on the outer circumference of the folded-back portion 11c2 of the shield member 11c. The fastening member 40 is, for example, a crimp ring made of an aluminum alloy or the like.

(30) Next, the configuration of the molded portion 20 will be described.

(31) The molded portion 20 is made of an electrically insulating synthetic resin material, and includes an outer portion 21A that is located outside the bracket 30, an inner portion 21B that is located inside the bracket 30, and a pair of connecting portions (not shown) that are located in the pair of communication holes 35 of the bracket 30 and connecting the outer portion 21A and the inner portion 21B.

(32) The outer portion 21A and the inner portion 21B have a substantially columnar shape.

(33) An annular groove 22 is provided on an outer circumferential surface of the inner portion 21B. An annular seal member 23 is fitted into the annular groove 22. When the attachment portion 51 is attached to the housing 91a by inserting the inner portion 21B into the attachment port of the housing 91a, the seal member 23 is brought into intimate contact with the inner circumferential surface of the attachment port.

(34) Next, a method of manufacturing the wire harness 10 will be described with reference to FIGS. 5 and 6.

(35) First, as shown in FIG. 5(a), a portion of the insulating outer cover 11d having a predetermined length from the end portion is removed to expose the shield member 11c.

(36) Subsequently, of the exposed portion of the shield member 11c, a portion having a predetermined length from the end portion is removed to expose the insulating inner cover 11b.

(37) Then, the electric wire 11 is inserted through the insertion hole 32 and the protruding portion 33 of the plate portion 31 in this order with the end portion where the insulating inner cover 11b is exposed forward.

(38) Subsequently, as shown in FIG. 5(b), the end portion 11c1 of the shield member 11c exposed from the insulating outer cover 11d is folded back to the outer circumferential side of the protruding portion 33. As a result, the folded-back portion 11c2 of the shield member 11c is formed.

(39) Subsequently, as shown in FIGS. 5(c) and 6, the folded-back portion 11c2 of the shield member 11c is fastened to the outer circumferential surface of the protruding portion 33 with the fastening member 40.

(40) Thereafter, as indicated by the arrow in FIG. 5(d), the molded portion 20 is injection-molded by pouring molten plastic into a molding die 20A. At this time, the molten resin also flows from the outside of the bracket 30 to the inside of the bracket 30 through the communication holes 35.

(41) As a result, part of the electric wires 11, the protruding portions 33 of the bracket 30, and the fastening members 40 are embedded in the molded portion 20.

(42) Also, a portion of the bracket 30 that is not covered by the molded portion 20 forms the flange portion 36.

(43) Next, the operation and effect of the present embodiment will be described.

(44) (1) A wire harness 10 includes: a conductive bracket 30 including a plate portion 31 that includes an insertion hole 32 through which an electric wire 11 is inserted and a protruding portion 33 protruding from an edge of the insertion hole 32 in the plate portion 31; and a fastening member 40 that fastens a folded-back portion 11c2 of a shield member 11c that is folded back to an outer circumferential side of the protruding portion 33 to the protruding portion 33.

(45) With this configuration, an end portion 11c1 of the shield member 11c, which is a portion of the shield member 11c of the electric wire 11 protruding from an end portion of the protruding portion 33 of the plate portion 31, is folded back to the outer circumferential side of the protruding portion 33 to form the folded-back portion 11c2. The folded-back portion 11c2 is configured to cover the opening end and the outer circumferential surface of the protruding portion 33. The shield member 11c is electrically connected to the plate portion 31 by fastening the folded-back portion 11c2 to the outer circumferential surface of the protruding portion 33 with the fastening member 40.

(46) The shield member 11c can be grounded by attaching the plate portion 31 to a conductive housing 91a.

(47) Here, because the protruding portion 33 is interposed between the fastening member 40 and the electric wire 11, deformation of the electric wire 11 due to fastening by the fastening member 40 is suppressed.

(48) Therefore, the shield member 11c can be grounded with a simple configuration.

(49) (2) The plate portion 31 includes a plurality of the insertion holes 32 and a plurality of the protruding portions 33 respectively protruding from edges of the insertion holes 32.

(50) With this configuration, the shield members 11c of the plurality of electric wires 11 can be grounded with one plate portion 31. Therefore, the number of components required for grounding the shield members 11c can be reduced.

(51) (3) Because each protruding portion 33 has a cylindrical shape, the protruding portion 33 is interposed between the fastening member 40 and the electric wire 11 over the entire circumference. As a result, it is possible to effectively suppress deformation of the electric wire 11 due to fastening by the fastening member 40.

(52) (4) The wire harness 10 includes a molded portion 20 made of resin that sandwiches the bracket 30 in the thickness direction. The plate portion 31 includes a flange portion 36 protruding radially outward from the entire circumference of the molded portion 20. The molded portion 20 and the bracket 30 constitute an attachment portion 51.

(53) With this configuration, the molded portion 20 and the bracket 30 constitute the attachment portion 51 of the wire harness 10.

(54) Here, because the bracket 30 is sandwiched by the molded portion 20 in the thickness direction, it is possible to prevent moisture or the like from entering form the outside to the inside of the housing 91a to which the attachment portion 51 is to be attached through the insertion holes 32.

(55) (5) An annular groove 22 is provided on the outer circumferential surface of the molded portion 20. An annular seal member 23 is fitted into the annular groove 22.

(56) With this configuration, when the molded portion 20 (inner portion 21B) of the attachment portion 51 is inserted and attached to the attachment port 51 of the housing 91a, the seal member 23 that is fitted into the annular groove 22 of the molded portion 20 comes into intimate contact with the inner circumferential surface of the attachment port.

(57) As a result, it is possible to prevent moisture or the like from entering the housing 91a through a gap between the attachment port and the molded portion 20.

(58) (6) The plate portion 31 is provided with communication holes 35 that communicate with the bracket 30 in the thickness direction. The outer portion 21A and the inner portion 21B of the molded portion 20 are connected by the connecting portions filled in the communication holes 35.

(59) With this configuration, the molded portion 20 and the bracket 30 can be firmly integrated.

(60) The present embodiment can be modified and implemented as follows. The present embodiment and the following modified examples can be implemented in combination with each other within a technically consistent range.

(61) In addition, in the following modified examples, the same components as those in the above embodiment are denoted by the same reference numerals. Further, with respect to the components corresponding to the above embodiment, “1**” to which “100” is added to the reference numerals is added in the modified example illustrated in FIG. 7, “2**” to which “200” is added to the reference numerals is added in the modified example illustrated in FIGS. 8 and 9, and “3**” to which “300” is added to the reference numerals is added in the modified example illustrated in FIG. 10. In this manner, description that overlaps with the above embodiment will be omitted. As shown in FIG. 7, for example, the heights of adjacent protruding portions 133a and 133b can be different. In this case, the work of attaching the fastening members 40 to the outer circumference of the folded-back portions 11c2 of the shield members 11c that are folded back is facilitated. As shown in FIG. 8, for example, insertion holes 232 may also have an oval shape. In this case, each protruding portion 233 is provided along the circumferential edge of the insertion hole 232. Further, in this case, as shown in FIG. 9, if a notch 211e is provided in a shield member 211c, the shield member 211c can be folded back to the outer circumferential side of the protruding portion 233. Also, the bracket may also be provided with only one insertion hole 232. As shown in FIG. 10, a slit 334 extending along the axial direction can be provided on the side wall of each cylindrical protruding portion 333. Instead of the molded portion 20, a resin portion formed by potting or the like may also be provided.

(62) The inner circumferential surface and the outer circumferential surface of various elongated members such as the insulating inner cover 11b may be referred to as a radially inward surface and a radially outward surface, respectively. The shield member 11c may be referred to as a braided tube made of conductive metals. The molded portion 20 may be referred to as a molded block.

(63) The present disclosure encompasses the following implementations. Reference numerals have been given to components of the embodiment as an aid to understanding, not for limitation.

(64) Additional Remark 1

(65) A wire harness (10) according to some implementations includes: an electric wire (11) including a conductive metal core wire (11a), an insulating inner cover (11b) that is in intimate contact with the entire circumference of a radially outward surface of the core wire (11a), and a shield member (11c) that is a conductive metal braided tube that covers a radially outward surface of the insulating inner cover (11b); a conductive metal bracket (30), the bracket (30) having a first surface (30a) extending to intersect a longitudinal direction of the electric wire (11), a second surface (30b) opposite to the first surface (30a), a protruding portion (33) that protrudes from the second surface (30b) and includes an opening end, and an insertion hole (32) that linearly extends from the first surface (30a) to the opening end of the protruding portion (33) of the bracket (30), and the electric wire (11) being inserted through the insertion hole (32), and a radially outward surface of the protruding portion (33) extending between the opening end of the protruding portion (33) and the second surface (30b) of the bracket (30); and a molded block (20) that is made of an insulating resin and constitutes an attachment portion (51) for fixedly attaching the wire harness (10) to an electric device (91) in cooperation with the bracket (30), wherein the shield member (11c) includes a predetermined-length end portion (11c1) that is separated radially outward from the radially outward surface of the insulting inner cover (11b), the predetermined-length end portion (11c1) of the shield member (11c) covers the opening end of the protruding portion (33) and the radially outward surface of the protruding portion (33), and forms a folded-back portion (11c2) that electrically contacts at least the radially outward surface of the protruding portion (33), the wire harness (10) further includes a fastening member (40) for fixedly fastening the folded-back portion (11c2) of the shield member (11c) to the radially outward surface of the protruding portion (33), and the protruding portion (33) of the bracket (30), the folded-back portion (11c2) of the shield member (11c), and the fastening member (40) are embedded in the molded block (20).

(66) Additional Remark 2

(67) The wire harness (10) according to some implementations further includes an insulating outer cover (11d) that covers the shield member (11c) and that is in contact with an entire circumference of a radially inward surface of the insertion hole (32) of the bracket (30).

(68) Additional Remark 3

(69) In the wire harness (10) according to some implementations, the insulating outer cover (11d) terminates at the opening end of the protruding portion (33) of the bracket (30), and does not protrude in the axial direction from the opening end of the protruding portion (33) of the bracket (30).

(70) Additional Remark 4

(71) In some implementations, the protruding portion (33) is a tubular protruding portion.

(72) It will be apparent to those skilled in the art that the present disclosure may be embodied in other specific forms without departing from the technical idea thereof. Some of the components described in the embodiment (or one or more aspects thereof) may be omitted, or some components may be combined, for example. The scope of the present disclosure should be determined with reference to the appended claims, along with the full scope of equivalents to which the claims are entitled.