Wire harness with sheathing member and path regulators

A wire harness includes a wire bundle and a sheathing member covering the wire bundle and configured from a nonwoven member that has been hot-pressed. The sheathing member includes a plurality of path regulators along each of an extension direction and a circumference direction of the wire bundle, the path regulators being capable of regulating a path of a long member to be arranged along a surface of the sheathing member.

FIELD OF THE INVENTION

The present invention relates to a wire harness.

BACKGROUND OF THE INVENTION

Conventionally, various technologies have been proposed in relation to a wire harness. For example, a wire harness in which a wire bundle is covered by a sheathing member is described in Patent Literature 1. The sheathing member described in Patent Literature 1 is fabricated by hot-pressing a nonwoven member. In the wire harness described in Patent Literature 1, a long member fixation portion is provided to the sheathing member, the long member fixation portion holding a long member such as a washer fluid hose supplying washer fluid.

RELATED ART

Patent Literature

SUMMARY OF THE INVENTION

Problems to Be Solved by the Invention

In a case where the long member is held by the long member fixation portion described in Patent Literature 1, the long member can only be arranged along an extension direction of the wire bundle. In other words, there is no freedom for a path of the long member. Accordingly, even in cases where there is a change to a layout of components within a vehicle to which the wire harness is routed or a path of the wire harness within the vehicle is changed, and the long member held by the long member fixation portion interferes with surrounding objects, the path of the long member cannot be defined to a path where the long member will not interfere with surrounding objects.

The present invention has been conceived in view of the above points, and seeks to provide a technology capable of improving a degree of freedom for a path of a long member arranged along a surface of a sheathing member covering a wire bundle.

Means for Solving the Problems

A wire harness according to a first aspect includes a wire bundle; a sheathing member covering the wire bundle and configured from a nonwoven member that has been hot-pressed, and a long member to be arranged along a surface of the sheathing member. The sheathing member includes a plurality of path regulators along each of an extension direction and a circumference direction of the wire bundle, the path regulators being capable of regulating a path of the long member to be arranged along the surface of the sheathing member. The sheathing member includes a line formed by the plurality of path regulators provided along the extension direction of the wire bundle, a plurality of which lines are provided along the circumference direction of the wire bundle. The path of the long member is regulated by a portion of the plurality of path regulators configuring a first line included in the plurality of lines, and by a portion of the plurality of path regulators configuring a second line included in the plurality of lines and different from the first line, such that the long member does not interfere with surrounding objects.

A wire harness according to a second aspect is the wire harness according to the first aspect, in which the path regulator is a portion of the sheathing member which rises away from the surface of the sheathing member.

A wire harness according to a third aspect is the wire harness according to the first aspect, in which the path regulator is formed by punching out a portion of the sheathing member.

Effect of the Invention

According to the first through third aspects, the plurality of path regulators are provided along each of the extension direction and the circumference direction of the wire bundle, the path regulators being capable of regulating the path of the long member to be arranged along the surface of the sheathing member. Therefore, a degree of freedom for the path of the long member can be improved.

According to the second aspect in particular, the path regulator is a portion of the sheathing member which rises away from the surface of the sheathing member. Therefore, the path regulator can easily be formed on the sheathing member.

According to the third aspect in particular, the path regulator is a portion which has been punched out of the sheathing member. Therefore, the path regulator can easily be formed on the sheathing member and, in addition, can be inhibited from interfering with surrounding objects.

Also, according to the first through third aspects, the sheathing member includes the line formed by the plurality of path regulators provided along the extension direction of the wire bundle, a plurality of which lines are provided along the circumference direction of the wire bundle. Therefore, the degree of freedom for the path of the long member can be further improved.

The purpose(s), characteristic feature(s), aspect(s), and advantage(s) of the present invention are further explicated by the following detailed description and attached drawings.

MODE FOR CARRYING OUT THE INVENTION

FIG. 1is a perspective view illustrating a wire harness1according to an embodiment.FIG. 2illustrates a cross-sectional structure of the wire harness1in a direction perpendicular to an extension direction of the wire harness1. The wire harness1according to the present embodiment is routed, for example, in an interior of a vehicle such as an automobile.

As shown inFIGS. 1 and 2, the wire harness1includes a wire bundle2in which a plurality of electric wires are bundled together, and a sheathing member3covering the wire bundle2. A plurality of path regulators4are provided on a surface30(exterior surface) of the sheathing member3, the path regulators4being capable of regulating a path of a long member to be arranged along the surface30.

The sheathing member3has a function of regulating the path of the wire bundle2when the wire harness1is routed in the vehicle, as well as a function of protecting the wire bundle2from interference by objects in a vicinity of the wire harness1. The sheathing member3is formed with a nonwoven member (e.g., a nonwoven fabric) which has been hot-pressed. Herein, hot-pressing refers to a process of inserting a nonwoven member between dies and applying pressure to the dies in a heated state to mold the nonwoven member. A nonwoven member capable of hardening when subjected to a heating process can be used as the nonwoven member. A nonwoven member that includes elementary fibers and an adhesive resin (also referred to as a binder) interlaced with the elementary fibers can be used as such a nonwoven member. The adhesive resin is a resin having a melting point (for example, 110° C.-115° C.) lower than that of the elementary fibers. When the nonwoven member is heated to a processing temperature lower than the melting point of the elementary fibers and higher than the melting point of the adhesive resin, the adhesive resin melts and soaks in between the elementary fibers. Thereafter, when the nonwoven member cools to a temperature below the melting point of the adhesive resin, the adhesive resin solidifies in a state bonding the elementary fibers with one another. As a result, the nonwoven member becomes harder than in the state prior to heating and is maintained in a shape molded during heating.

The elementary fibers may be any fiber capable of maintaining a fiber state at the melting point of the adhesive resin. Thus, in addition to resin fiber, various fibers can be used as the elementary fibers. Further, a thermoplastic resin fiber having a melting point lower than the melting point of the elementary fibers can be used as the adhesive resin. The adhesive resin may be granular or fibrous. Further, it is also possible to configure a binder fiber by forming an adhesive resin layer on an outer circumference of a core fiber and to interweave the binder fiber with the elementary fibers. A fiber of the same material as the above elementary fiber can be used as the core fiber in such a case.

An example of the combination of the elementary fiber and the adhesive resin is using a resin fiber of PET (polyethylene terephthalate) as the elementary fiber and a copolymer resin of PET and PEI (polyethylene isophthalate) as the adhesive resin. In this case, the melting point of the elementary fiber is about 250° C. and the melting point of the adhesive resin is 110° C.-150° C. Therefore, when the nonwoven member is heated to a temperature of 110° C.-250° C., the adhesive resin melts and soaks in between the elementary fibers, which maintain a fibrous shape and do not melt. Then, when the nonwoven member cools to a temperature below the melting point of the adhesive resin, the adhesive resin solidifies in a state bonding the elementary fibers with one another and the nonwoven member stiffens, maintaining the shape molded during the heating.

An exemplary method of covering the circumference of the wire bundle2with the nonwoven member which may be employed is a method in which a strip-like, sheet-like nonwoven member having a narrow width is wrapped around the wire bundle2in a partially overlapping spiral. Alternatively, a method may be employed in which a strip-like, sheet-like nonwoven member has a width equal to a length of a portion of the wire bundle2covered by the sheathing member3, and is wrapped once or a plurality of times around the wire bundle2such that both width-direction ends are gathered.

The shape of the die used in the hot-pressing may match, or may not match, the shape of the wire bundle2after the wire harness1has been routed within the vehicle and the like. In the former case, simultaneous with the conclusion of hot-pressing, the shape of the sheathing member3is molded so as to match the shape of the wire bundle2after routing of the wire harness1. Meanwhile, in the latter case, hot-pressing concludes and, before the nonwoven member hardens, the shape of the sheathing member3is molded so as to match the shape of the wire bundle2after routing of the wire harness1.

Each path regulator4is formed with resin, for example, and is provided as a component distinct from the sheathing member3. A plurality of the path regulators4are provided away from one another across the entire surface30of the sheathing member3. The plurality of path regulators4(four path regulators4in the example ofFIG. 1) positioned away from one another along the extension direction of the wire bundle2form a line on the surface30of the sheathing member3, and a plurality of these lines are provided along a circumference direction of the wire bundle2. Put another way, the plurality of path regulators4positioned away from one another along the circumference direction of the wire bundle2form a line on the surface30of the sheathing member3, and a plurality of these lines are provided along the extension direction of the wire bundle2. When viewing the extension direction of the wire bundle2as, for example, a row direction and the circumference direction of the wire bundle2as, for example, a column direction, the plurality of path regulators4are arranged in a matrix on the surface30of the sheathing member3. Thereby, the plurality of path regulators4are arranged along the extension direction of the wire bundle2and are also arranged along the circumference direction of the wire bundle2.

Hereafter, the line formed by the plurality of path regulators4(four path regulators4in the present example) aligned in the extension direction of the wire bundle2is referred to as an “extension direction path regulator group.” A plurality of the extension direction path regulator groups are provided to the sheathing member3along the circumference direction of the wire bundle2.

Each of the path regulators4has a shape capable of holding a long member to be arranged along the surface30of the sheathing member3. Each of the path regulators4has a shape in which a plate-like member is bent into a squared “U” shape, and each is configured by a bottom plate40to be attached to the sheathing member3and a pair of side plates41standing upright at two end portions of the bottom plate40so as to face each other. A screw is attached to a reverse surface of the bottom plate40and, by tightening the screw to the sheathing member3, the bottom plate40is attached to the sheathing member3. The long member arranged along the surface30of the sheathing member3is held by the path regulator4by being sandwiched between the pair of side plates41of the path regulator4.

In each of the extension direction path regulator groups, the plurality of path regulators4aligned in the extension direction of the wire bundle2which configure the extension direction path regulator group are arranged such that the pair of side plates41on each of the plurality of path regulators4face each other in the circumference direction of the wire bundle2. Thereby, the plurality of path regulators4aligned in the extension direction of the wire bundle2can hold the long member such that the long member is arranged along the extension direction of the wire bundle2.

FIG. 3illustrates a path of a long member10, which is arranged along the surface30of the sheathing member3, being regulated by the path regulators4.FIG. 4illustrates a cross-sectional structure of the wire harness1in a direction perpendicular to the extension direction of the wire harness1shown inFIG. 3.

The long member10may be, for example, an antenna feeder wire, a trunk opener cable, or a washer fluid tube. When the wire harness1is routed in the vehicle, the path of the long member10arranged along the surface30of the sheathing member3of the wire harness1is regulated by the path regulators4provided to the sheathing member3such that the long member10does not interfere with surrounding objects.

In the example ofFIGS. 3 and 4, the long member10is held by a single extension direction path regulator group. Accordingly, the path of the long member10is regulated by the four path regulators4configuring the extension direction path regulator group so as to follow the extension direction of the wire bundle2. The long member10includes a portion10aarranged along a surface of a portion of the wire bundle2not covered by the sheathing member3, and the portion10ais fixated to the wire bundle2by an adhesive tape11, for example.

When a layout of components within the vehicle (vehicle layout) on which the wire harness1is routed is changed, or a routing path of the wire harness1is changed, the long member10arranged along the surface30of the sheathing member3of the wire harness1may come to interfere with surrounding objects. The wire harness1according to the present embodiment is configured to be capable of readily defining the path of the long member10, in such a case, to a path in which the long member10does not interfere with surrounding objects.

FIG. 5illustrates a situation where the path of the long member10has been changed for the wire harness1shown inFIG. 3to which the long member10was attached. An interfering pipe15is shown inFIG. 5located in the vicinity of the wire harness1.

When the pipe15comes to be positioned proximate to the wire harness1, as shown inFIG. 5, due to changing the vehicle layout or changing the routed path of the wire harness1, the pipe15and the long member10will interfere with each other on the path of the long member10shown inFIG. 3. Accordingly, the path of the long member10shown inFIG. 5is defined to a path in which the long member10does not interfere with the pipe15. In the example shown inFIG. 5, the long member10is held by the two end path regulators4of the four path regulators4configuring one extension direction path regulator group, and by the two middle path regulators4of the four path regulators4configuring a different extension direction path regulator group adjacent, in the circumference direction of the wire bundle2, to the first extension direction path regulator group. Thereby, the path of the long member10is changed from the straight-line path ofFIG. 3to a path diverted in the circumference direction of the wire bundle2so as to avoid the pipe15.

In this way, in the wire harness1according to the present embodiment, the plurality of path regulators4are provided to the sheathing member3along each of the extension direction and the circumference direction of the wire bundle2, the path regulators4being capable of regulating the path of the long member10to be arranged along the surface30of the sheathing member3. Therefore, the long member10can be arranged along each of the extension direction and the circumference direction of the wire bundle2. Accordingly, a degree of freedom in the path of the long member10is improved. Thus, the path of the long member10can be determined according to circumstances in the vicinity of the wire harness1. As a result, the long member10can be reliably prevented from interfering with surrounding objects.

Further, in the present embodiment, the plurality of path regulators4arranged along the extension direction of the wire bundle2form a line, and a plurality of these lines are provided along the circumference direction of the wire bundle2, or, put another way, the plurality of path regulators4arranged along the circumference direction of the wire bundle2form a line, and a plurality of these lines are provided along the extension direction of the wire bundle2. Thereby, the degree of freedom of the path of the long member10can be further improved. Thus, the long member10can be more reliably prevented from interfering with surrounding objects.

Moreover, the path regulator4may be configured such that a distance between the pair of side plates41is made larger than a diameter of the long member10and the long member10is not sandwiched between the pair of side plates41. Even in such a case, by passing the long member10through a space between the pair of side plates41of the path regulator4, the path of the long member10can be regulated by the path regulator4.

In addition, the long member10may be attached to the wire harness1after the wire harness1has been routed within the vehicle, or may be attached to the wire harness1before the wire harness1is routed within the vehicle.

VARIOUS MODIFICATIONS

First Modification

FIG. 6is a perspective view illustrating a wire harness1aaccording to a first modification. InFIG. 6, the wire harness1ais shown with the long member10attached. The wire harness1aaccording to the present modification provides a path regulator14instead of the path regulator4of the wire harness1according to the above-described embodiment. Hereafter, the description will focus on differences between the wire harness1aaccording to the present modification and the wire harness1.

Each of the path regulators14is integrally formed with the sheathing member3and a surface shape thereof forms a bow-shaped (a portion of a circle bounded by an arc and a bowstring linking two ends thereof) plate-like portion. Each of the path regulators14is configured to be capable of pinching and holding the long member10between the path regulator14and the sheathing member3.

Each of the path regulators14is configured by a portion of the sheathing member3which rises away from the surface30of the sheathing member3. An angle of rise for each of the path regulators14is an acute angle. An arced incision14ais formed in the surface30of the sheathing member3, the arced incision14apenetrating the sheathing member3in a thickness direction thereof, and a portion of the sheathing member3on an interior side of the incision14ais raised. The raised portion forms the path regulator14. Accordingly, a bowstring portion of the bow shape formed by each of the path regulators14is connected to the sheathing member3.

In each of the path regulators14, a portion of the sheathing member3configuring that path regulator14is raised along the circumference direction of the wire bundle2. Thereby, the plurality of path regulators14aligned in the extension direction of the wire bundle2are configured to be capable of pinching and holding the long member10between the path regulators14and the sheathing member3such that the long member10follows the extension direction of the wire bundle2.

In the example ofFIG. 6, the long member10is held by four path regulators14arranged along the extension direction of the wire bundle2. Accordingly, the path of the long member10is regulated by the four path regulators14so as to follow the extension direction of the wire bundle2.

Next, a method of manufacturing the wire harness1aaccording to the present modification is described. First, as shown inFIG. 7, a plurality of arced incisions101are provided in a matrix pattern to a surface100aof a sheet-like nonwoven member100, which will become the sheathing member3. Each of the incisions101passes through the nonwoven member100in a thickness direction. The incision101will become the incision14ain the surface30of the sheathing member3.

Next, as shown inFIG. 8, bow-shaped plate-like portions102of the nonwoven member100, which are bounded by each of the incisions101, are raised away from the surface100a. The bow-shaped plate-like portions102will become the path regulators14.

Next, the nonwoven member100is wrapped around the wire bundle2such that the plurality of raised bow-shaped plate-like portions102are positioned on the exterior. Then, the nonwoven member100is hot pressed. Thereby, the wire harness1ais completed, the wire harness1aincluding the wire bundle2and the sheathing member3covering the wire bundle2.

Moreover, the nonwoven member100may be wrapped around the wire bundle2immediately after the plurality of incisions101are provided in the nonwoven member100. When the nonwoven member100provided with the incisions101is wrapped around the wire bundle2, the bow-shaped plate-like portions102on the nonwoven member100, which are bounded by the incisions101, are configured to rise away naturally, and therefore there is no strict necessity of raising the bow-shaped plate-like portions102prior to wrapping the nonwoven member100around the wire bundle2.

When the pipe15comes to be positioned proximate to the wire harness1aand the pipe15and the long member10, which is attached to the wire harness1a, interfere with each other due to changing the vehicle layout or changing the routed path of the wire harness1a, the path of the long member10can be changed from that shown inFIG. 6to that shown inFIG. 9. In the example ofFIG. 9, the path of the long member10is changed from the straight-line path ofFIG. 6to a path diverted in the circumference direction of the wire bundle2so as to avoid the pipe15.

In this way, in the wire harness1aaccording to the present modification, similar to the wire harness1described above, the plurality of path regulators14are provided to the sheathing member3along each of the extension direction and the circumference direction of the wire bundle2, the path regulators14being capable of regulating the path of the long member10to be arranged along the surface30of the sheathing member3. Therefore, the degree of freedom for the path of the long member10can be improved. Thus, the long member10can be reliably prevented from interfering with surrounding objects.

Moreover, in the present modification, the path regulators14are portions of the sheathing member3which rise away from the surface30of the sheathing member3. Therefore, as noted above, the path regulators14can be easily formed on the sheathing member3.

Second Modification

FIG. 10is a perspective view illustrating a wire harness1baccording to a second modification. InFIG. 10, the wire harness1bis shown with the long member10attached. The wire harness1baccording to the present modification provides a path regulator24instead of the path regulator4of the wire harness1according to the above-described embodiment. Hereafter, the description will focus on differences between the wire harness1baccording to the present modification and the wire harness1.

FIG. 11is an expanded view of the path regulator24. Each of the path regulators24is formed by punching out a portion of the sheathing member3, for example in an “H” shape. Each of the path regulators24is configured by a through-hole24ahaving a square shape in a plan view and provided to the surface30of the sheathing member3, and a pair of projections24bprojecting from side walls of the through-hole24aso as to face each other with a gap therebetween. The pair of projections24bin each of the path regulators24are integrally formed with the sheathing member3. In each of the path regulators24, the distance between the pair of projections24bis slightly smaller than a diameter of the long member10, and the pair of projections24bare configured to be capable of pinching and holding the long member10.

Each of the path regulators24is provided to the sheathing member3such that the pair of projections24boppose each other in the circumference direction of the wire bundle2. Thereby, the plurality of path regulators24aligned in the extension direction of the wire bundle2can hold the long member10such that the long member10follows the extension direction of the wire bundle2.

In the example ofFIG. 10, the long member10is held by four path regulators24arranged along the extension direction of the wire bundle2. Accordingly, the path of the long member10is regulated by the four path regulators24so as to follow the extension direction of the wire bundle2.

Next, a method of manufacturing the wire harness1baccording to the present modification is described. First, as shown inFIG. 12, portions of a sheet-like nonwoven member200, which will become the sheathing member3, are punched out in the thickness direction of the nonwoven member200using an H-shaped die300, and a through-hole201having an “H” shape in a plan view (hereafter referred to as an H-shaped through-hole201) is formed in a surface200aof the nonwoven member200. Thereby, a through-hole210and a pair of projections211are formed in the nonwoven member200, the through-hole210having a square shape in a plan view and passing through the nonwoven member200in the thickness direction, and the pair of projections211projecting from side walls of the through-hole210so as to face each other with a gap therebetween. The through-hole210and the pair of projections211will become, respectively, the through-hole24aand the pair of projections24bof the path regulator24. A plurality of the H-shaped through-holes201are formed on the nonwoven member200in a matrix shape.

Next, the nonwoven member200having the plurality of H-shaped through-holes201formed thereon is wrapped around the wire bundle2. Then, the nonwoven member200is hot pressed. The wire harness1bis then completed, the wire harness1bincluding the wire bundle2and the sheathing member3covering the wire bundle2.

When the pipe15comes to be positioned proximate to the wire harness1band the pipe15and the long member10, which is attached to the wire harness1b, interfere with each other due to changing the vehicle layout or changing the routed path of the wire harness1b, the path of the long member10can be changed from that shown inFIG. 10to that shown inFIG. 13. In the example ofFIG. 13, the path of the long member10is changed from the straight-line path ofFIG. 10to a path diverted in the circumference direction of the wire bundle2so as to avoid the pipe15.

In this way, in the wire harness1baccording to the present modification, the plurality of path regulators24are provided to the sheathing member3along each of the extension direction and the circumference direction of the wire bundle2, the path regulators24being capable of regulating the path of the long member10to be arranged along the surface30of the sheathing member3. Therefore, the degree of freedom for the path of the long member10can be improved. Thus, the long member10can be reliably prevented from interfering with surrounding objects.

Moreover, in the present modification, the path regulators24are portions of the sheathing member3which have been punched out. Therefore, as noted above, the path regulators24can be easily formed on the sheathing member3and, in addition, the path regulators24can be inhibited from interfering with surrounding objects.

Third Modification

FIG. 14is a perspective view illustrating a wire harness1caccording to a third modification. InFIG. 14, the wire harness1cis shown with the long member10attached. The wire harness1c, according to the present modification provides a path regulator34instead of the path regulator4of the wire harness1according to the above-described embodiment.

Each of the path regulators34is configured by a projection provided upright on the surface30of the sheathing member3. Each of the path regulators34is, for example, a rectangular plate-shaped projection and is provided such that a longitudinal direction thereof is parallel in the extension direction of the wire bundle2. The path regulators34may be integrally formed with the sheathing member3, or may be formed separately from the sheathing member3.

As shown inFIG. 14, in the wire harness1chaving a plurality of the path regulators34of this kind, by catching the long member10on the path regulators34(projections) while dragging the long member10along the surface30of the sheathing member3, the long member10can be arranged along the surface30of the sheathing member3while regulating the path of the long member10.

In this way, unlike in the above-described embodiment and in the first and second modifications, even when the path regulators34cannot themselves hold the long member10, the long member10can be regulated by the path regulators34.

In the above, the present invention is described in detail. However, the above description is in all aspects exemplary and the present invention is not limited by the description. Numerous modifications not given as examples are understood to be conceivable without departing from the scope of the present invention.

DESCRIPTION OF REFERENCE NUMERALS