Abstract:
A wiring protector that controls the direction of exiting branch wires, secures a tube over the branch wires, and adjusts the length of the branch wires. Wire protector, which includes main body and a passageway formed therein through which trunk wires pass, is placed over a wire harness and attached to a vehicle body. Exit ports for branch wires are formed within the main body, and disk-shaped guide members or a clamp are attached to the internal region of the main body to control the exit direction of the branch wires and to determine the length of the branch wires.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to a wiring protector, and more particularly to a wiring protector positioned over branch joints of a wiring harness that may be attached to a vehicle. The wiring protector establishes the direction that branch wires extend from the wiring harness, secures tubes attached to the branch wires, and adjusts the length of the branch wires.  
         [0003]     2. Description of Background Information  
         [0004]     As shown in  FIG. 8  and described by Japanese Kokai (Laid Open) Patent H9-117032, protector  1  is an example of a prior art wiring protector that fits over the branching wire locations of a wire harness attached to an automobile. Protector  1  is a one-piece structure that includes open-ended main body  2  which is placed around trunk wires w 1  of wire harness WH at the location where branch wires separate therefrom, and lid  3  that exposes or covers the upper portion of main body  2  by pivoting on flexible hinge portion  4 . Cutout portion  2   b  is formed in sidewall  2   a  on main body  2  to allow the passage of branch wires w 2  therethrough.  
         [0005]     The design of the prior art protector does not regulate the extending direction of branch wires w 2  because branch wires  2   w  are merely pulled through cutout portion  2   b  in main body  2 . Also, because a protective tube is placed over the exposed portion of branch wires w 2  exiting protector  1 , tape must be wrapped around the tube to prevent it from becoming displaced in the axial direction along branch wires w 2 . Moreover, connector  5  is attached to the end of branch wires w 2  to connect the branch wires to a terminal device (not shown in the drawing). Branch wires w 2  can become slack in the region external to protector  1  after connector  5  is attached to the terminal device, and the slack portion may interfere with other components. This slackness can also result in the branch wires generating noise induced by vehicle vibration.  
       SUMMARY OF THE INVENTION  
       [0006]     Taking the above-noted shortcomings into consideration, the wiring protector of the present invention is constructed at least to control the direction from which branch wires exit the wiring protector, to securely fix the tubes covering the branch wires, and to adjust the length of the branch wires.  
         [0007]     In order to resolve the shortcomings in the prior art, the wiring protector of the present invention controls the length and direction of branch wires extending from the trunk wires of a wiring harness attached to a vehicle through the following structure. A passageway is provided in a main body for the passage of the trunk wires, branch wire exit ports are formed within and aligned along the front wall of the main body in the lengthwise direction, and disk-shaped adjusting members are formed within the part of the main body connecting to the exit ports. The branch wires are wrapped around the radial perimeter of the adjusting member to an extent that achieves the desired branch wire length.  
         [0008]     Because the construction of the present invention adjusts the length of the branch wire by wrapping the branch wire around the radial perimeter of the adjusting member, damage to the branch wires, which would otherwise result from loosely hanging branch wires contacting components external to the wiring protector, is prevented. The construction of the present invention also prevents loosely hanging branch wires generating noise as a result of vehicle vibrations. Moreover, should the adjusting member be formed of an elastic material, pulling on the branch wire to connect the terminal end to a device connector has the effect of radially compressing the adjusting member. After the connection is made, the elastic material expands to its original condition, thereby removing the looseness from the branch wire.  
         [0009]     Additionally, the wiring protector of the present invention controls the length and exiting direction of branch wires extending from the trunk wires of a wiring harness attached to a vehicle. A passageway is provided in the main body for the passage of the trunk wires, branch wire exit ports are formed within and aligned along the front wall of the main body in the lengthwise direction, and disk-shaped adjusting members are formed within the part of the main body connecting to the exit ports, each adjusting member having branch wire guide channels formed therein in a radial pattern extending outwardly from the center. The length of a branch wire and its exiting direction are controlled by wrapping the branch wire around the radial perimeter of the adjusting member or pulling the branch wire through the desired guide channel.  
         [0010]     The construction of the present invention, through which the adjusting member determines the direction that a branch wire exits the wiring protector, is thus able to control the direction of a branch wire and to ease the connection of branch wire terminal ends to devices.  
         [0011]     The branch wire may be placed within an enclosing tube, and the branch wire, together with the enclosing tube, inserted into and secured within the branch wire guide channel. This construction of the present invention not only determines the direction that the branch wire exits the adjusting member, but also pinches the tube-enclosed branch wire between the sidewalls of the branch wire guide channel in the adjusting member, thus preventing displacement of the tube without the need to secure the tube with a tape wrapping.  
         [0012]     The adjusting member of the present invention may be formed separately from the wiring protector, the adjusting member being fixedly attached to a box structure having open upper and front sides, a branch wire passage port provided at the rear side of the box structure, and a pair of leg portions, on which lock fingers are formed at the extremities, extending from the bottom. Holes for the insertion of the leg portions are provided adjacent to the branch wire exit ports on the main body, and the lock fingers secure the leg portions within the holes.  
         [0013]     This construction of the present invention allows the adjusting members to be attached to the wiring protector at any location where the direction and length of the branch wire are to be regulated.  
         [0014]     Further, the wiring protector of the present invention controls the length and exiting direction of branch wires extending from the trunk wires of a wiring harness attached to a vehicle. A passageway is provided within the main body for the passage of the trunk wires. Branch wire exit ports are formed within and aligned along the front wall of the main body in the lengthwise direction, and a pair of gripping parts are located adjacent to an exit port. A branch wire exiting from the exit port is covered by a tube, the tube-covered branch wire being inserted and fixedly held between the gripping parts.  
         [0015]     The construction of the present invention employs gripping parts to compress the tube enclosing the branch wire, therefore preventing displacement of the tube without the use of a tape wrapping.  
         [0016]     As previously noted, the wiring protector of the present invention adjusts the length of a branch wire by wrapping the branch wire around the perimeter of the adjusting member, and therefore is able to prevent damage caused by loosely hanging branch wires contacting objects external to the wiring protector and from generating noise induced by vehicle vibration. Moreover, if the adjusting member is made of an elastic material, pulling on the branch wire, at the time when the terminal connector of the branch wire is to be connected to a device, has the effect of radially compressing the adjusting member. After the connection is made, the elastic material expands and returns to its original shape, thereby removing any residual looseness in the branch wire.  
         [0017]     According to an aspect of the present invention, a wiring protector that determines length and exit direction of branch wires that extend from trunk wires of a wiring harness is provided, the wiring protector including a main body including a passageway provided for passage of the trunk wires; a branch wire exit port provided within and aligned along a front wall of the main body; and an adjusting member provided in the main body and connecting to the branch wire exit port; wherein the branch wires are wrapped around a perimeter of the adjusting member to an extent that establishes a desired branch wire length. Further, the wiring protector may include a plurality of branch wire exit ports provided within and aligned along a front wall of the main body; and a plurality of adjusting members provided in the main body, each the adjusting member connecting to one of the plurality of branch wire exit ports. Further, the adjusting member is disk shaped, so that the branch wires are wrapped around a circular perimeter of the adjusting member. The adjusting member may be constructed of an elastic material, and pulling the branch wires wrapped around the adjusting member reduces the diameter of the adjusting member to connect the ends of the branch wires to a device, and release of the branch wires wrapped around the adjusting member allows the adjusting member to return substantially to its original diameter. Further, a bracket extending from an external surface of the main body is provided; and the bracket may be configured to attach the wiring protector to a vehicle body.  
         [0018]     A further aspect of the present invention provides a wiring protector that determines length and exit direction of branch wires that extend from trunk wires of a wiring harness, the wiring protector including a main body including a passageway provided for passage of the trunk wires; at least one branch wire exit port formed within and aligned along a front wall of the main body; and at least one disk shaped adjusting member provided within the main body, each the disk shaped adjusting member connecting to a respective branch wire exit port, each the adjusting member including branch wire guide channels arranged in a radial pattern extending outward from the center of the disk shaped adjusting member; wherein the length of a branch wire and its exit direction are determined by wrapping the branch wire around the perimeter of the adjusting member or positioning the branch wire within a branch wire guide channel. Further, the branch wires are covered by tubes, each the branch wire guide channel further including two sidewalls, the two sidewalls configured to pinch and secure the tube covered branch wires therebetween. The adjusting member may further include a box structure fixedly attached to the adjusting member, the box structure including open upper and front sides, a branch wire passage port formed within a rear side of the box structure, and a pair of leg parts including lock fingers formed at extremities thereof and extending from a bottom side of the box structure; and the main body further including apertures provided adjacent to the branch wire exit ports, the apertures configured for insertion of the leg parts therein to lock the leg parts into the apertures through the lock fingers. The adjusting member may further include a box structure fixedly attached to the adjusting member, the box structure including open upper and front sides, a branch wire passage port formed within a rear side of the box structure, and a pair of leg parts including lock fingers formed at extremities thereof and extending from a bottom side of the box structure; and the main body further including apertures provided adjacent to the branch wire exit ports, the apertures configured for insertion of the leg parts therein to lock the leg parts into the apertures through the lock fingers. In a further aspect of the present invention, wiring protector that determines length and exit direction of branch wires that extend from trunk wires of a wiring harness is provided, the wiring protector including a main body including a passageway provided for passage of the trunk wires; branch wire exit ports formed within and aligned along a front wall of the main body; and a pair of grip parts provided in the main body and adjacent to an exit port, the pair of grip parts configured to receive the branch wires therebetween. Further, the branch wires are covered by tubes, and the pair of grip parts configured to fixedly hold the tube covered branch wires therebetween. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]     The above, and other objects, features and advantages of the present invention will be made apparent from the following description of the preferred embodiments, given as nonlimiting examples, with reference to the accompanying drawings in which:  
         [0020]      FIG. 1  is a perspective view of the wiring protector of a first embodiment of the present invention;  
         [0021]      FIG. 2A  is a perspective view of a directional regulator in the wiring protector of the embodiment of  FIG. 1 ;  
         [0022]      FIG. 2B  is a plan view of the directional regulator in the wiring protector of the embodiment of  FIG. 1 ;  
         [0023]      FIG. 2C  is a plan view of the directional regulator in the wiring protector of the embodiment of  FIG. 1 , showing branch wires;  
         [0024]      FIG. 3  is a plan view of the wiring protector of the embodiment of  FIG. 1 , showing the arrangement of the wire harness within the wiring protector;  
         [0025]      FIG. 4  is a perspective view of the wiring protector of the embodiment of  FIG. 1  provided in a vehicle body panel;  
         [0026]      FIG. 5A  is a perspective view of a wire clamp of a second embodiment of the present invention;  
         [0027]      FIG. 5B  is a plan view of the wire clamp of the embodiment  FIG. 5A ;  
         [0028]      FIG. 6  is a plan view of the wiring protector of a third embodiment of the present invention, showing the arrangement of the wire harness within the wiring protector;  
         [0029]      FIG. 7A  is a perspective view of the length adjustment element of the embodiment of  FIG. 6 ;  
         [0030]      FIG. 7B  a plan view of the length adjustment element of the embodiment of  FIG. 6 , showing the branch wire installed without tension;  
         [0031]      FIG. 7C  is a plan view of the length adjustment element of the embodiment of  FIG. 6 , showing the branch wire provided in a tensioned condition; and  
         [0032]      FIG. 8  is a perspective view of a known wiring protector. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0033]     The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description is taken with the drawings making apparent to those skilled in the art how the forms of the present invention may be embodied in practice.  
         [0034]     The following will describe the preferred embodiments with reference to the drawings.  FIGS. 1, 2 ,  3 , and  4  illustrate the first embodiment.  
         [0035]      FIG. 1  illustrates wiring protector  10  as a component that may be installed in the engine compartment of an automobile at a location where wires branch off from wire harness WH. Wiring protector  10  may be constructed of any suitable material such as, for example, resin. Wiring protector  10  may be formed unitarily and in one piece including main body  11  which contains branch points T 1 , T 2 , T 3  at which branch wires w 2 , w 3 , w 4 , w 5 , w 6 , w 7  extend away from trunk wires w 1  of wire harness WH, cover portion  12  that seals the upper side of main body  11  (which houses trunk wires w 1  of wire harness WH), and hinge part  13 . The hinge part  13  may be a thinly formed flexible portion of the wiring protector  10 . The wire harness WH used in the present invention includes a plurality of branch points and a plurality of branch wires, and in the present embodiment, includes branch points T 1 , T 2 , T 3  and includes branch wires w 2 , w 3 , w 4 , w 5 , w 6 , w 7 .  
         [0036]     Main body  11  includes trunk wire passage  11   a , and substantially planar branch wire exit portion  11   b  that extends horizontally outward from the upper edge of sidewall  11   a - 1  of trunk wire passage  11   a . Multiple apertures  11   b - 1  are provided near the edge of branch wire exit portion  11   b  for the installation of directional regulators  20  (to be subsequently described). The present invention includes a suitable number of apertures  11   b - 1  for mounting a suitable number of directional regulators  20 , and in this embodiment provides two apertures  11   b - 1  for the installation of each directional regulator  20 , and a total of eight apertures  11   b - 1  for the installation of four directional regulators  20 . Cover  12  extends from the upper edge of sidewall  11   a - 2  of main body  11  through flexible hinge part  13 , sidewall  11   a - 2  located on the side of main body  11  opposite to sidewall  11   a - 1 . Moreover, bracket  11   c  extends externally from main body  11  as a member through which wiring protector  10  is secured to the vehicle body. Bracket  11   c  may include any suitable member for attachment to the vehicle body such as, for example, a bolt hole that receives a bolt.  
         [0037]     Cover  12  includes upper wall  12   a  that forms the top part of main body  11 , flexible hinge part  13  of upper wall  12   a , and side wall  12   b  that extends from the periphery of cover  12  except for the edge portion of cover  12  that connects to flexible hinge part  13 . With cover  12  placed in a closed position over main body  11  by pivoting flexible hinge part  13 , front wall  12   b - 1 , which is formed as part of sidewall  12  at the edge of branch wire exit portion  11   b , aligns with the edge of branch wire exit portion  11   b . Branch wire exit ports  12   c  are formed in sidewall  12 , at locations corresponding to the installation positions of directional regulators  20  on main body  11 , in order to allow the branch wires to exit. Branch wire exit ports  12   c  are formed in any suitable manner such as, for example, by being formed as cut out portions of the sidewall  12 .  
         [0038]     As illustrated in  FIG. 2A , directional regulator  20 , which is mounted to branch wire exit portion  11   b  of main body  11 , includes disc-shaped guide member  22  formed within box  21 . The disc shaped guide member  22  may be formed integrally and in one piece with the box  21 . Box  21  includes rectangular floor portion  23  that connects to the lower surface of guide member  22 , and frame member  24  that extends upward from the edge of floor portion  23 . One of the four sides of frame member  24  is open to form branch wire exit port  25 , and passage port  26  is formed in frame member  24 , opposite to exit port  25 , in order to allow branch wires to pass into directional regulator  20 . Passage ports  26  are formed in any suitable manner such as, for example, by being formed as cut out portions of the frame member  24 .  
         [0039]     As shown in  FIG. 2B , guide channels  27  are formed within the upper surface of disc-shaped guide member  22  and radiate outward from the center of the guide member. In the present embodiment, each guide channel  27  is radially spaced 60 degrees from adjacent channels, and all guide channels mutually intersect at the center of guide member  22 . Alternatively, the disc-shaped guide member  22  may include a fewer number of guide channels  27 , or a greater number of guide channels  27 . Further, the guide channels  27  may be radially spaced from adjacent guide channels  27  a distance other than 60 degrees. Directional regulator  20  is able to regulate the direction of the branch wires, as shown in  FIG. 2C , for example, by guiding branch wires w 2  through guide channel  27  on the upper side of guide member  22 , and guiding branch wires w 2  along the radial peripheral surface of guide member  22 . Furthermore, leg portions  28 , which extend downward from the lower surface of floor portion  23  of box  21 , include lock fingers  29  formed on their extremities.  
         [0040]     As shown in  FIG. 3 , wire harness WH, which is enclosed by wiring protector  10 , may include any suitable number of branch locations and in the present embodiment includes the three branch locations of T 1 , T 2 , and T 3 . Branch wires w 2  and w 3  separate from the harness at branch location T 1 , branch wires w 4  separate at branch location T 2 , and branch wires w 5 , w 6 , and w 7  separate at branch location T 3 . PVC tube  50  is placed over branch wires w 2 -w 7 , and connector C is attached to the terminal ends. In the present embodiment, three directional regulators  20  are fixedly attached to branch wire exit portion  11   b  of main body  11  at locations corresponding to the three branch points T 1 -T 3 . The remaining attachment aperture  11   b - 1  is, in this embodiment, an optional attachment position to which a directional regulator  20  has not been installed. Additionally, main body  11  may include any suitable number of branch wire exit ports  12   c.    
         [0041]     With trunk wires w 1  of wire harness WH placed within trunk wire passage  11   a  of main body  1 , the direction of each group of branch wires w 2 -w 7  (which branch off from trunk wires w 1 ) is controlled by the branch wires being attached to a respective directional regulator  20 . As previously noted, branch wires w 2  are inserted into guide channel  27  while branch wires w 3  pass around the radial perimeter of guide member  22 . Branch wires w 4  wrap completely around the radial perimeter of guide member  22  and exit from branch wire exit port  25 . Branch wires w 6  run straight through guide channel  22  while branch wires w 5  and w 7  pass around opposing sides of the radial perimeter of guide member  22 . Branch wires w 5 -w 7  exit from branch wire exit port  25 .  
         [0042]     After wire harness WH has been arranged within main body  11 , cover  12  pivots on thinly formed hinge part  13  and encloses the upper part of and locks against main body  11 . In this configuration, as shown in  FIG. 4 , wiring protector  10  is attached to panel ‘P’ of the engine compartment through bracket  11   c  with the connectors of branch wires w 2 -w 7 , which extend from wiring protector  10 , connected to the connectors of corresponding electrical devices which are not shown in the drawing.  
         [0043]     The construction of the present invention uses directional regulators  20  to control the direction that branch wires w 2 -w 7  exit from wiring protector  10 , and in doing so is able to freely establish the directions in which branch wires w 2 -w 7  extend, thus allowing the terminal connectors of branch wires w 2 -w 7  to be easily connected to their corresponding devices. Moreover, because PVC tube  50 , which covers branch wires w 2  and w 6 , is pinched between the two walls of guide channel  27  of guide member  22 , PVC tube  50  is securely attached to branch wires w 2  and w 6  without the need for tape wrapping. Although this embodiment describes directional regulators  20  as separately formed components to be attached to wiring protector  10 , directional regulators  20  may also be formed unitarily and in one piece with the wiring protector  10 .  
         [0044]      FIG. 5A  illustrates a second embodiment of the invention wherein the wire attachment part is provided in the form of wire clamp  30  (shown in  FIG. 5A ), which differs from the wire attachment part described by the first embodiment, attached to branch wire exit portion  11   b  of main body  11 . Branch wire clamp  30  includes gripping portions  33  that extend inward from the two sidewalls  32  of box  31 , which is of the same general configuration as box  21  of the first embodiment. The width of each grip portion  33  continually narrows as the block extends inward along the horizontal plane. Wire passage  34  provides passage for branch wire w 2  between the tip parts of gripping portion  33 , the width of wire passage  34  being established to a dimension slightly larger than the width of branch wires w 2 .  
         [0045]     Branch wires w 2 , which are enclosed within PVC tube  50 , are pulled into wire clamp  30 , and the part of branch wire w 2  covered by PVC tube  50  is inserted into wire passage  34  between gripping portions  33 . The compression of PVC tube  50  between gripping portions  33  securely holds branch wires w 2  in place.  
         [0046]     The construction of the present invention eliminates the need to secure PVC tube  50  to branch wires w 2  through tape wrapping because PVC tube  50  (which encloses branch wires w 2 ) is compressed between gripping parts  33  of wire clamp  30 . Elements shared by the first and second embodiments are identified by the same element numbers.  
         [0047]      FIGS. 6 and 7  illustrate a third embodiment of the invention wherein the extending directions of branch wires w 2 , w 3 , w 5 , w 6 , and w 7 , which lead away from trunk wires w 1  of wire harness WH, are controlled by directional regulators  20  as described in the first embodiment. Branch wires w 8 , which extend from branch point T 4 , are held within wire clamp  30  as described in the second embodiment. The length of branch wires w 4  is adjusted by length adjuster  40 .  
         [0048]     Length adjuster  40 , as shown in  FIG. 7A , includes disk-shaped adjuster element  42  which is formed within box  41  in a similar configuration to directional regulator  20 . Length adjuster  42 , which is made from an elastic material, connects to box  41  through a post (not shown) that projects from the center of the lower surface of length adjuster  42 . As shown in  FIG. 7B , branch wires w 4  are typically wrapped around adjuster element  42  to an extent that establishes the desired length. When the terminal connector on the end of branch wires w 4  is to be connected to a specific device, branch wires  4 , as shown in  FIG. 7C , are pulled out toward the device, thus reducing the diameter of adjuster element  42  as a result of the compression applied by the tightened coil of wire. After branch wires w 4  have been connected to the device, length adjuster element  40  returns to its original diameter from the reduced tension applied to branch wires w 4 , thus eliminating any slack in branch wires w 4 .  
         [0049]     The construction of the present invention is able to adjust the length of branch wires w 4  by coiling the wires around adjuster element  42 . Therefore, damage to wires w 4 , which would otherwise result from their interference with adjacent structures, is prevented. Moreover, noise, which would otherwise result from loosely hanging wires w 4  coming into contact with a vibrating vehicle body, is also prevented. Moreover, because adjuster element  42  is made from an elastic material, applying axial tension to branch wires w 4 , at the time when the wire terminal connector is to be attached to its respective device, reduces the diameter of adjuster element  42 . After the connector has been connected, the reduction of axial tension on the wires allows adjuster element  42  to return to its original diameter, thus eliminating any remaining looseness in branch wires w 4 . Furthermore, in this third embodiment, the attachment of directional regulator  20 , wire clamp  30 , and length adjuster element  40  allow the wiring protector to provide the branch wire adjustment functions that these components make possible. Alternatively, adjuster element  42  may be constructed of a material such as, for example, the same hard resin as box  41 , and not from an elastic material. Descriptions of the structures and operational effects of this third embodiment identified by element numbers identical to those of the first embodiment have been omitted.  
         [0050]     Although the invention has been described with reference to an exemplary embodiment, it is understood that the words that have been used are words of description and illustration, rather than words of limitation. Changes may be made within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the invention in its aspects. Although the invention has been described with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed. Rather, the invention extends to all functionally equivalent structures, methods, and uses such as are within the scope of the appended claims.  
         [0051]     The present disclosure relates to subject matter contained in priority Japanese Application No. JP 2003-385867, filed on Nov. 14, 2003, which is herein expressly incorporated by reference in its entirety.