Sheath structure and wire harness

A sheath structure includes an outer member, and an inner member formed in a cylindrical shape in a state in which a first portion and a second portion are engaged with an engaging portion, and capable of being fitted into the outer member from an end portion of the outer member. In the inner member, the first portion and the second portion are not engaged with the engaging portion but interfere with the end portion of the outer member and are not capable of being fitted into the outer member, when a maximum insertable number of the predetermined routed members insertable into the outer member are inserted therein. The first portion and the second portion are engaged with the engaging portion and capable of being fitted into the outer member, when the predetermined routed members of a prescribed number smaller than the maximum insertable number are inserted therein.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims priority to and incorporates by reference the entire contents of Japanese Patent Application No. 2021-056838 filed in Japan on Mar. 30, 2021.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a sheath structure and a wire harness.

2. Description of the Related Art

For example, Japanese Patent Application Laid-open No. 2019-75946 discloses a protective member including a tubular section and an outer peripheral rib. The tubular section is fitted with an end portion of a corrugate tube, and harder than the corrugate tube. The outer peripheral rib is formed on the outer periphery of the tubular section to extend in a circumferential direction, and fitted into inner peripheral annular concave section in the end portion of the corrugate tube.

The protective member described above may be used or unused in accordance with, for example, the number of routed members inserted into the corrugate tube. It is desired to prevent improper use of the protective member and properly use the protective member.

SUMMARY OF THE INVENTION

The present invention has been made in view of the afore-mentioned circumstances, and an object of the present invention is to provide a sheath structure and a wire harness capable of using in a proper mode according to circumstances.

In order to achieve the above mentioned object, a sheath structure according to one aspect of the present invention includes an outer member formed in a cylindrical shape and into which routed members are insertable; and an inner member formed in a cylindrical shape in a state in which a first portion and a second portion are engaged with an engaging portion, capable of receiving the routed members inserted therein, and capable of being fitted into the outer member from an end portion of the outer member, wherein in the inner member, the first portion and the second portion are not engaged with the engaging portion but interfere with the end portion of the outer member and are not capable of being fitted into the outer member, when a maximum insertable number of the predetermined routed members insertable into the outer member are inserted therein, and the first portion and the second portion are engaged with the engaging portion and capable of being fitted into the outer member from the end portion of the outer member, when the predetermined routed members of a prescribed number smaller than the maximum insertable number are inserted therein.

In order to achieve the above mentioned object, a wire harness according to another aspect of the present invention includes routed members; and a sheath structure provided on the routed members from outside, the sheath structure including: an outer member formed in a cylindrical shape and into which the routed members are insertable; and an inner member formed in a cylindrical shape in a state in which a first portion and a second portion are engaged with an engaging portion, capable of receiving the routed members inserted therein, and capable of being fitted into the outer member from an end portion of the outer member, wherein in the inner member, the first portion and the second portion are not engaged with the engaging portion but interfere with the end portion of the outer member and are not capable of being fitted into the outer member, when a maximum insertable number of the predetermined routed members insertable into the outer member are inserted therein, and the first portion and the second portion are engaged with the engaging portion and capable of being fitted into the outer member from the end portion of the outer member, when the predetermined routed members of a prescribed number smaller than the maximum insertable number are inserted therein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An embodiment of the present invention will now be described hereinafter with reference to drawings. The present invention is not limited to the embodiment. Constituent elements in the following embodiment include elements that is obvious and can be replaced by a person skilled in the art, or substantially equivalent ones.

Embodiment

A sheath structure1illustrated inFIG.1andFIG.2is incorporated into a wire harness WH mounted on a vehicle or the like, and provided on routed members W having electrical conductivity from outside to protect the routed members W. In order to connect, for example, devices mounted on a vehicle, the wire harness WH is prepared by bundling a plurality of the routed members W used for power supply and/or signal communications into a module to connect the routed members W to each of the devices with connectors or the like. The wire harness WH includes the routed members W having electrical conductivity and a sheath structure1. The routed members W are, for example, insulated wires each having a structure in which a core wire acquired by bundling a plurality of metal wires is covered with an insulating coating portion. As another example, the routed members W may be an insulated metal bar acquired by coating a metal bar with an insulating coating portion. The sheath structure1has a structure in which the routed members W are inserted through the inside, and provided on the routed members W from outside. The wire harness WH may be configured to further include various components, such as a grommet, an electrical connection box, a fixture, and a connector.

The sheath structure1according to the present embodiment includes an outer member10and an inner member20. The inner member20is a member mounted inside the outer member10to prevent the outer member10from collapsing.

The inner member20may be used or unused due to, for example, a difference in number of routed members W inserted into the outer member10according to the required specifications. For example, when the number of routed members W inserted into the outer member10is large and a predetermined volume of the inside space of the outer member10is filled with many routed members W, the outer member10tends to be relatively hard to collapse by support from inside with the routed members W. In such a case, for example, there are cases where the inner member20does not require mounting to the outer member10in respect of required specifications.

The inner member20according to the present embodiment achieves a structure enabling use in a proper mode according to circumstances by adopting a structure preventing mounting to the outer member10erroneously in such a case. The following is a detailed explanation of each of structures of the sheath structure1with reference to drawings.

In the following explanation, three mutually crossing directions are referred to as “axis direction X”, “width direction Y”, and “height direction Z”, respectively. The axis direction X, the width direction Y, and the height direction Z are mutually orthogonal. The axis direction X typically corresponds to the insertion direction, the routing direction, and the extending direction of the routed members W and the axis direction of the sheath structure1and the like, in a state in which the sheath structure1is disposed in a straight-line manner without being bent. The width direction Y and the height direction Z correspond to crossing directions (orthogonal directions) crossing (orthogonal to) the axis direction X. Each of the directions used in the following explanation is explained as a direction in a state in which the units are mutually assembled, unless particularly mentioned.

Specifically, the outer member10is a sheath member formed in a cylindrical shape and into which the routed members W can be inserted, as illustrated inFIG.1andFIG.2. The outer member10is also referred to as corrugate or the like. The outer member10is formed of an insulating resin material or the like and in a substantially cylindrical shape having flexibility. The outer member10has a central axis C1extending along the axis direction X. The outer member10has a bellows-like shape in which convex and concave shapes are repeatedly and successively formed along the axis direction X. The outer member10is provided with a slit (notch) along the axis direction X such that the outer member10is expandable to a certain degree when the routed members W are inserted therein. The outer member10protects the routed members W inserted therein along the axis direction X. A plurality of the routed members W can be inserted into the outer member10.

The outer member10according to the present embodiment is, as an example, formed to receive three routed members W as the maximum insertable number of routed members W (seeFIG.5andFIG.6and the like). The maximum insertable number of routed members W in the outer member10is the maximum number of routed members W insertable into the outer member10, when the predetermined routed members W are inserted into the outer member10. In this example, the predetermined routed members W are routed members W in which an outer diameter, a material, or the like is predetermined in accordance with the required specifications or the like. In this example, the predetermined routed members W are typically illustrated as ones having mutually substantially equal outer diameters.

The inner member20is a structural member (frame member) formed in a cylindrical shape, capable of receiving routed members W inserted therein, and capable of being fitted into the outer member10from an end portion of the outer member10, as illustrated inFIG.1,FIG.2, andFIG.3. The inner member20is also referred to as corrugate inner or the like. The inner member20is formed in a substantially cylindrical shape and formed of an insulating resin material or the like having rigidity higher than that of the outer member10. The inner member20has a central axis C2substantially coaxial with the central axis C1of the outer member10and extending along the axis direction X, in a state in which the inner member20is mounted inside the outer member10.

The inner member20according to the present embodiment includes a first portion21, a second portion22, a hinge portion23, and an engaging portion24, and the portions are formed as one unitary piece. The inner member20is formed in a substantially cylindrical shape in a state in which the first portion21and the second portion22are engaged with the engaging portion24, and routed members W are insertable into the inner member20.

Each of the first portion21and the second portion22is a portion formed in a substantially semicircular gutter shape. The first portion21and the second portion22form a substantially cylindrical shape in a state in which they are mutually interlocked with their curved and recessed sides mutually opposed in the width direction Y. The first portion21includes an outer surface provided with circumferential ribs21a, axial ribs21b, and the like. In the same manner, the second portion22includes an outer surface provided with circumferential ribs22a, axial ribs22b, and the like. The circumferential ribs21aand22aare formed on the respective outer surfaces of the first portion21and the second portion22along the circumferential direction (direction around the central axis C2). A plurality of the circumferential ribs21aand a plurality of the circumferential ribs22aare provided at intervals therebetween in the axis direction X. Each of the circumferential ribs21aand22ais provided with a taper serving as a guide surface when the inner member20is fitted into the outer member10from the end portion of the outer member10. In the state in which the inner member20is fitted into the outer member10, the circumferential ribs21aand22aare engaged with the bellows-like shape (convex/concave shape) of the inner surface of the outer member10to position the inner member20inside the outer member10in the axis direction X (seeFIG.2). The axial ribs21band22bare formed on the respective outer surfaces of the first portion21and the second portion22along the axis direction X. The axial ribs21band22bare formed between the circumferential ribs21aand22a, respectively, to connect them. The axial ribs21band the axial ribs22bare provided at intervals therebetween in the circumferential direction. The first portion21and the second portion22are provided with flange portions21cand22c, respectively, on end portions (end portions on a side opposite to the side fitted into the outer member10) of a side in the axis direction X.

The hinge portion23is a portion interposed between the first portion21and the second portion22and connecting the first portion21and the second portion22relatively rotatably. In other words, the first portion21and the second portion22are relatively rotatably connected via the hinge portion23. The hinge portion23is formed as a thin portion (thin portion thinner than the thickness of the first portion21, the second portion22, and the like) extending in the axis direction X and interposed between end portions of the first portion21and the second portion22mutually opposed in the circumferential direction. With the structure, the hinge portion23forms a rotation axis extending along the axis direction X, and a rotation axis C3is set along the axial direction X. The rotation axis C3is an axis serving as a rotation center of the first portion21and the second portion22. The first portion21and the second portion22are rotatable (openable and closable) between a closed position (seeFIG.1) and an opened position (seeFIG.3) via the hinge portion23around the rotation axis C3serving as the rotation center. The closed position is a position in which the first portion21and the second portion22are mutually interlocked to form a substantially cylindrical shape. By contrast, the opened position is a position in which the first portion21and the second portion22are separated with a space therebetween at their end portions on a side opposite to the hinge portion23side.

The engaging portion24is a locking portion mutually engaging the first portion21and the second portion22. The engaging portion24engages (locks) the first portion21and the second portion22in a state in which the first portion21and the second portion22are in the closed position, that is, in a state in which the first portion21and the second portion22are mutually interlocked to form a substantially cylindrical shape. The engaging portion24engages the end portions of the first portion21and the second portion22on the side opposite to the hinge portion23side. In this example, the engaging portion24includes an engaging hook portion24aand an engaging arm portion24b. The engaging hook portion24ais formed as a hook-shaped projecting portion on an end portion of one of the first portion21and the second portion22. In this example, the engaging hook portion24ais formed on the end portion of the second portion22. The engaging arm portion24bis formed as a hook portion capable of locking the engaging hook portion24aon an end portion of the other of the first portion21and the second portion22. In this example, the engaging arm portion24bis formed on the end portion of the first portion21. The engaging portion24mutually engages the first portion21with the second portion22in a state in which they are in the closed position, by locking of the engaging hook portion24awith the engaging arm portion24b, and retains the state in which the first portion21and the second portion22are in the closed position.

In the second portion22, an end portion in which the engaging hook portion24ais formed projects in the circumferential direction to form a chevron-shaped projecting portion24c. In the first portion21, an end portion in which the engaging arm portion24bis formed is recessed in the circumferential direction to form a V-shaped recessed portion24d. The projecting portion24cand the recessed portion24dare formed in sizes and shapes with which the projecting portion24cis fitted into the recessed portion24din the state in which the first portion21and the second portion22are in the closed position. In other words, it can also be said that the first portion21and the second portion22have wavy shapes with which their end portions including the projecting portion24cand the recessed portion24dare mutually engaged on the engaging portion24side. This structure enables the projecting portion24cand the recessed portion24dof the inner member20to function as a guiding shape when the first portion21and the second portion22are rotated from the opened position to the closed position and the engaging hook portion24ais locked with the engaging arm portion24b. In this operation, the inner member20is able to also function as a portion regulating biting of the routed members W by the projecting portion24cand the recessed portion24d. Consequently, the inner member20enables smooth engagement of the first portion21and the second portion22via the engaging portion24. The wavy shaped portions including the projecting portion24cand the recessed portion24din the first portion21and the second portion22in the inner member20also function as protective portions protecting the engaging hook portion24aand the engaging arm portion24band preventing breakage. Consequently, the inner member20also enables improvement in durability.

The inner member20configured as described above has, as an erroneous mounting preventing structure, a structure with which the first portion21and the second portion22are not engaged with the engaging portion24but interfere with the end portion of the outer member10and cannot be fitted into the outer member10, when a maximum insertable number of predetermined routed members W insertable into the outer member10, that is, a maximum insertable number of routed members W are inserted therein, as illustrated inFIG.5andFIG.6. Specifically, when a maximum insertable number of routed members W are inserted into the inner member20, the first portion21and the second portion22are not engageable with the engaging portion24, but the inner member20interferes with the end portion of the outer member10and cannot be fitted into the outer member10when the inner member20in this state is to be inserted into the inside of the outer member10from the end portion of the outer member10.

By contrast, as illustrated inFIG.1andFIG.4, when predetermined routed members W of a prescribed number smaller than the maximum insertable number, that is, a normal prescribed number, are inserted into the inner member20, the first portion21and the second portion22are engaged with the engaging portion24, and the inner member20can be fitted into the outer member10from the end portion of the outer member10. In this example, the normal prescribed number is two or less which is smaller than three. Specifically, when a normal prescribed number of routed members W smaller than the maximum insertable number are inserted into the inner member20, the first portion21and the second portion22are engageable with the engaging portion24, and the inner member20does not interfere with the end portion of the outer member10but can be fitted into the outer member10when the inner member20in this state is to be inserted into the inside of the outer member10from the end portion of the outer member10.

Specifically, as illustrated inFIG.4, the inner member20is formed in a flat shape such that an interval of the inner surface thereof in the width direction Y (corresponding to the second direction) is narrower than a width L1of the inner surface in the height direction Z (corresponding to the first direction), in the state in which the first portion21and the second portion22are engaged with the engaging portion24. In this example, the inner member20is formed such that the inner surface thereof has a substantially oval shape in the state in which the first portion21and the second portion22are engaged with the engaging portion24. The major axis of the oval extends along the height direction Z (first direction), and the minor axis of the oval extends along the width direction Y (second direction).

In addition, as illustrated inFIG.5andFIG.6, when a maximum insertable number of routed members W are inserted into the inner member20, the first portion21and the second portion22interfere with the routed members W arranged in a line in the width direction Y and are not engageable with the engaging portion24. In this manner, the inner member20achieves the erroneous mounting preventing structure as described above.

By contrast, as illustrated inFIG.1andFIG.4, when a normal prescribed number of routed members W are inserted into the inner member20, the first portion21and the second portion22do not interfere with the routed members W but are engageable with the engaging portion24. In this case, the routed members W are not arranged in the width direction Y in the inner member20, and the inner member20does not interfere with the routed members W arranged in a line in the height direction Z.

The sheath structure1and the wire harness WH explained above can be used in a proper mode according to circumstances, even when the inner member20is used or unused due to a difference in number of routed members W inserted into the outer member10according to the required specifications or the like.

Specifically, the sheath structure1has a structure in which the first portion21and the second portion22in the inner member20are engaged with the engaging portion24when the number of routed members W to be inserted into the outer member10is the normal prescribed number or less, and the volume filled with the routed members W in the inner space of the sheath structure1is less than the predetermined volume. This structure enables the sheath structure1to cause the inner member20to be fitted into the outer member10from the end portion of the outer member10and mounted inside the outer member10. Consequently, the sheath structure1is able to support the outer member10from inside with the inner member20and prevent the outer member10from collapsing.

By contrast, when the number of routed members W inserted into the outer member10is the maximum insertable number and the volume filled with the routed members W in the inner space of the sheath structure1is the predetermined volume or more, the outer member10of the sheath structure1is supported from inside with the routed members W and is relatively hard to collapse even without using the inner member20. In such a case, in the sheath structure1, the first portion21and the second portion22are not engaged with the engaging portion24in the inner member20. In this manner, the outer shape of the inner member20is relatively larger than that in the state in which the first portion21and the second portion22are engaged with the engaging portion24. With this structure, the sheath structure1is able to cause the inner member20to interfere with the outer member10and be prevented from being mounted inside the outer member10even when the inner member20is to be fitted into the outer member10from the end portion of the outer member10. Consequently, the sheath structure1is able to prevent erroneous mounting of the inner member20when mounting of the inner member20to the outer member10is unnecessary.

As described above, the sheath structure1and the wire harness WH are able to prevent improper use of the inner member20in the case where the inner member20is unnecessary, and enable use of the inner member20in a proper mode according to circumstances.

The sheath structure1and the wire harness WH explained above have a structure in which the width L2of the inner surface of the inner member20in the width direction Y is narrower than the width L1of the inner surface of the inner member20in the height direction Z, in the state in which the first portion21and the second portion22are engaged with the engaging portion24. In this manner, the inner member20achieves the structure in which the first portion21and the second portion22interfere with the routed members W arranged in a line in the width direction Y and are not engageable with the engaging portion24when a maximum insertable number of routed members W are inserted into the inner member20, while the first portion21and the second portion22do not interfere with the routed members W and are engageable with the engaging portion24when a normal prescribed number of routed members W are inserted into the inner member20. With this structure, the sheath structure1achieves the structure in which the inner member20is physically unattachable to the outer member10as described above when the number of routed members W to be inserted into the outer member10is the maximum insertable number, and achieves the erroneous mounting preventing structure for the inner member20as described above. Consequently, the sheath structure1and the wire harness WH enable use in a proper mode according to circumstances as described above.

The sheath structure and the wire harness according to the embodiment of the present invention described above are not limited to the embodiment described above, but various changes are possible within a range described in the claims.

The explanation provided above illustrates that the inner member20includes the first portion21, the second portion22, the hinge portion23, and the engaging portion24, and is formed of the portions provided as one unitary piece, but the structure is not limited thereto. The inner member20may have a structure in which, for example, no hinge portion23is provided and the first portion21and the second portion22are formed as separate pieces and engaged and united into a cylindrical shape with a plurality of the engaging portions24.

The explanation provided above illustrates that the inner member20includes an inner surface having a substantially oval shape in a state in which the first portion21and the second portion22are engaged with the engaging portion24, but the structure is not limited thereto. The inner member20may be typically formed in a substantially rectangular shape, a substantially rhombic shape, or a substantially triangular shape, as long as the inner member20has a shape in which the width L2of the inner surface in the width direction Y is narrower than the width L1of the inner surface in the height direction Z.

As another example, the inner member20may have a shape in which the width L1of the inner surface in the height direction Z is narrower than the width L2of the inner surface in the width direction Y. In this case, in the inner member20, the width direction Y corresponds to the first direction and the height direction Z corresponds to the second direction. Specifically, in this case, the inner member20has the structure in which the first portion21and the second portion22interfere with the routed members W arranged in a line in the height direction Z and are not engageable with the engaging portion24when a maximum insertable number of routed members W are inserted into the inner member20, while the first portion21and the second portion22do not interfere with the routed members W but are engageable with the engaging portion24when a normal prescribed number of routed members W are inserted into the inner member20.

In addition, the explanation provided above illustrates that the routed members W are not arranged in the width direction Y in the inner member20, and the inner member20does not interfere with the routed members W arranged in a line in the height direction Z, but the structure is not limited thereto. In this case, the inner member20may have a structure in which a relatively small number of routed members W are arranged in the Y direction in comparison with the case where a maximum insertable number of routed members W are inserted into the inner member20and the inner member20does not interfere with the routed members W.

The sheath structure and the wire harness according to the present embodiment may be configured by proper combinations of constituent elements of the embodiment and/or the modification explained above.

The sheath structure and the wire harness according to the present embodiment produce the effect of enabling use in a proper mode according to circumstances.