Wire harness

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.

BACKGROUND

The present disclosure relates to a wire harness including 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 member that covers an outer circumference of the insulating inner cover.

Some wire harnesses for vehicles include, for example, an electric wire that includes a core wire, an insulating inner cover that covers an outer circumference of the core wire, a conductive shield member that covers an outer circumference of the insulating inner cover, and an insulating outer cover that covers an outer circumference of the shield member. In addition, a structure in which a shield member is grounded has been proposed (see JP 2005-285748A, for example).

In the wire harness described in JP 2005-285748A, an end portion of the shield member is exposed from an end portion of the insulating outer cover, and the exposed portion is folded back to an outer circumferential side of the insulating outer cover.

A tubular member (shield sleeve) is provided between the outer circumferential surface of the end portion of the insulating outer cover and the folded-back portion of the shield member.

The folded-back portion of the shield member is fitted into a conductive tubular body (shield contact). The tubular body is inserted into an insertion hole of a plate-shaped ground member and attached to the ground member, and the ground member is attached to an attached body.

SUMMARY

In the wire harness described in JP 2005-285748A, the insertion hole of the ground member and the tubular body are separate bodies.

Also, in order to suppress deformation of the core wire when the folded-back portion of the shield member is fitted into the tubular body, a tubular member is provided between the insulating outer cover and the folded-back portion of the shield member.

Accordingly, the number of components for connecting the shield member to the ground increases, and the assembling operation becomes complicated.

An exemplary aspect of the disclosure provides a wire harness in which a shield member can be grounded with a simple configuration.

A wire harness according to an exemplary aspect 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, and the wire harness includes: a conductive bracket that includes a plate including an insertion hole through which the electric wire is inserted and a protrusion protruding from an edge of the insertion hole in the plate; and 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.

With this configuration, the shield of the electric wire is electrically connected to the bracket by folding back the portion of the shield of the electric wire protruding from the end of the protrusion of the plate to the outer circumferential side of the protrusion, and fastening the folded-back portion to the protrusion with the fastener. By attaching the bracket to a conductive attachment object, the shield can be grounded.

Here, because the protrusion is interposed between the fastener and the electric wire, deformation of the electric wire due to fastening by the fastener is suppressed.

Therefore, the shield can be grounded with a simple configuration.

In the above wire harness, it is preferable that the bracket includes a plurality of the insertion holes and a plurality of the protrusions respectively protruding from edges of the insertion holes.

With this configuration, the shields of the plurality of electric wires can be grounded by one bracket. Therefore, the number of components required for grounding the shield can be reduced.

In the above wire harness, it is preferable that the protrusion has a tubular shape.

With this configuration, because the protrusion is interposed between the fastener and the electric wire over the entire circumference, it is possible to further suppress deformation of the electric wire due to fastening by the fastener.

In the above wire harness, it is preferable that the wire harness further includes 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.

With this configuration, the body and the bracket form the attachment to be attached to a device to which the wire harness is to be attached.

Here, because the bracket is sandwiched by the body in the thickness direction, it is possible to prevent moisture or the like from entering from the outside to the inside of the housing of the device to which the attachment is to be attached through the insertion hole.

In the above wire harness, it is preferable that an annular groove is provided on an outer circumferential surface of the body, and an annular seal is fitted into the annular groove.

With this configuration, when the body of the attachment is inserted and attached to the attachment port of the housing of the device, the seal fitted into the annular groove of the body comes into intimate contact with the inner circumferential surface of the attachment port.

As a result, it is possible to prevent moisture or the like from entering the housing through a gap between the attachment port and the body.

According to the present disclosure, the shield can be grounded with a simple configuration.

DETAILED DESCRIPTION OF EMBODIMENTS

Hereinafter, an embodiment of a wire harness will be described with reference toFIGS. 1 to 6.

As shown inFIG. 1, a wire harness10is disposed in, for example, a hybrid vehicle or an electric vehicle, and electrically connects devices.

As shown inFIGS. 1 and 2, the wire harness10includes a plurality of (six in the present embodiment) electric wires11, and an attachment portion51(attachment) through which the electric wires11are inserted and that is to be attached to a housing91aof a device91.

The electric wires11that are led out from the attachment portion51are branched and respectively connected to devices (not shown).

As shown inFIGS. 2 and 3, the electric wires11each include a core wire11a, an insulating inner cover11bthat covers an outer circumference of the core wire11a, a conductive shield member11c(shield) that covers an outer circumference of the insulating inner cover11b, and an insulating outer cover11dthat covers an outer circumference of the shield member11c.

The core wire11ais, for example, a stranded wire formed by twisting a plurality of bare metal wires made of a copper alloy. A terminal12to be connected to the device91is fixed to an end portion of the core wire11a(seeFIG. 2).

The insulating inner cover11bis made of an electrically insulating synthetic resin material, and has a cylindrical shape.

The shield member11cis made of a braided wire in which conductive bare wires made of an aluminum alloy or the like are woven in a cylindrical shape.

The insulating outer cover11dis made of an electrically insulating synthetic resin material, and has a cylindrical shape.

As shown inFIG. 2, the attachment portion51is inserted to the attachment port of the housing91ato be attached, and includes a bracket30and a molded portion20(body) that sandwiches the bracket30from both sides in a thickness direction and is provided integrally with the bracket30.

The bracket30protrudes radially outward from the entire circumference of the molded portion20, and this protruding portion functions as a flange portion36(flange) of the attachment portion51.

The flange portion36is provided with attachment holes34for attaching it to the housing.

First, the configuration of the bracket30will be described. Hereinafter, the side of the bracket30that is closer to the terminals12, that is, a housing91aside may be referred to as an “inner side”, and the side away from the terminals12may be referred to as an “outer side”. A pair of surfaces of the bracket30extending in a direction intersecting or orthogonal to the longitudinal direction of the electric wires11may be referred to as a first surface30aand a second surface30b.

As shown inFIG. 4, the bracket30includes a rectangular plate-shaped plate portion31(plate). The plate portion31is provided with a plurality of insertion holes32through which the respective electric wires11are inserted, and a plurality of cylindrical protruding portions33(protrusion) protruding inward from circumferential edges of the respective insertion holes32.

The plate portion31is provided with a pair of communication holes35with the plurality of insertion holes32interposed therebetween.

The bracket30of the present embodiment is made of a metal material such as an aluminum alloy.

As shown inFIG. 3, the insulating outer cover11dis removed from a portion of each electric wire11that protrudes inward from the protruding portion33of the bracket30. A portion (also referred to as a predetermined-length end portion)11c1of the shield member11cthat protrudes inward from the protruding portion33is exposed from the insulating outer cover11d. The exposed end portion11c1of each shield member11cis folded back to form a folded-back portion11c2, and the folded-back portion11c2covers the outer circumferential surface of the protruding portion33. A conductive fastening member40(fastener) for fastening the folded-back portion11c2to the outer circumferential surface of the protruding portion33is provided on the outer circumference of the folded-back portion11c2of the shield member11c. The fastening member40is, for example, a crimp ring made of an aluminum alloy or the like.

Next, the configuration of the molded portion20will be described.

The molded portion20is made of an electrically insulating synthetic resin material, and includes an outer portion21A that is located outside the bracket30, an inner portion21B that is located inside the bracket30, and a pair of connecting portions (not shown) that are located in the pair of communication holes35of the bracket30and connecting the outer portion21A and the inner portion21B.

The outer portion21A and the inner portion21B have a substantially columnar shape.

An annular groove22is provided on an outer circumferential surface of the inner portion21B. An annular seal member23is fitted into the annular groove22. When the attachment portion51is attached to the housing91aby inserting the inner portion21B into the attachment port of the housing91a, the seal member23is brought into intimate contact with the inner circumferential surface of the attachment port.

Next, a method of manufacturing the wire harness10will be described with reference toFIGS. 5 and 6.

First, as shown inFIG. 5(a), a portion of the insulating outer cover11dhaving a predetermined length from the end portion is removed to expose the shield member11c.

Subsequently, of the exposed portion of the shield member11c, a portion having a predetermined length from the end portion is removed to expose the insulating inner cover11b.

Then, the electric wire11is inserted through the insertion hole32and the protruding portion33of the plate portion31in this order with the end portion where the insulating inner cover11bis exposed forward.

Subsequently, as shown inFIG. 5(b), the end portion11c1of the shield member11cexposed from the insulating outer cover11dis folded back to the outer circumferential side of the protruding portion33. As a result, the folded-back portion11c2of the shield member11cis formed.

Subsequently, as shown inFIGS. 5(c)and6, the folded-back portion11c2of the shield member11cis fastened to the outer circumferential surface of the protruding portion33with the fastening member40.

Thereafter, as indicated by the arrow inFIG. 5(d), the molded portion20is injection-molded by pouring molten plastic into a molding die20A. At this time, the molten resin also flows from the outside of the bracket30to the inside of the bracket30through the communication holes35.

As a result, part of the electric wires11, the protruding portions33of the bracket30, and the fastening members40are embedded in the molded portion20.

Also, a portion of the bracket30that is not covered by the molded portion20forms the flange portion36.

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

(1) A wire harness10includes: a conductive bracket30including a plate portion31that includes an insertion hole32through which an electric wire11is inserted and a protruding portion33protruding from an edge of the insertion hole32in the plate portion31; and a fastening member40that fastens a folded-back portion11c2of a shield member11cthat is folded back to an outer circumferential side of the protruding portion33to the protruding portion33.

With this configuration, an end portion11c1of the shield member11c, which is a portion of the shield member11cof the electric wire11protruding from an end portion of the protruding portion33of the plate portion31, is folded back to the outer circumferential side of the protruding portion33to form the folded-back portion11c2. The folded-back portion11c2is configured to cover the opening end and the outer circumferential surface of the protruding portion33. The shield member11cis electrically connected to the plate portion31by fastening the folded-back portion11c2to the outer circumferential surface of the protruding portion33with the fastening member40.

The shield member11ccan be grounded by attaching the plate portion31to a conductive housing91a.

Here, because the protruding portion33is interposed between the fastening member40and the electric wire11, deformation of the electric wire11due to fastening by the fastening member40is suppressed.

Therefore, the shield member11ccan be grounded with a simple configuration.

(2) The plate portion31includes a plurality of the insertion holes32and a plurality of the protruding portions33respectively protruding from edges of the insertion holes32.

With this configuration, the shield members11cof the plurality of electric wires11can be grounded with one plate portion31. Therefore, the number of components required for grounding the shield members11ccan be reduced.

(3) Because each protruding portion33has a cylindrical shape, the protruding portion33is interposed between the fastening member40and the electric wire11over the entire circumference. As a result, it is possible to effectively suppress deformation of the electric wire11due to fastening by the fastening member40.

(4) The wire harness10includes a molded portion20made of resin that sandwiches the bracket30in the thickness direction. The plate portion31includes a flange portion36protruding radially outward from the entire circumference of the molded portion20. The molded portion20and the bracket30constitute an attachment portion51.

With this configuration, the molded portion20and the bracket30constitute the attachment portion51of the wire harness10.

Here, because the bracket30is sandwiched by the molded portion20in the thickness direction, it is possible to prevent moisture or the like from entering form the outside to the inside of the housing91ato which the attachment portion51is to be attached through the insertion holes32.

(5) An annular groove22is provided on the outer circumferential surface of the molded portion20. An annular seal member23is fitted into the annular groove22.

With this configuration, when the molded portion20(inner portion21B) of the attachment portion51is inserted and attached to the attachment port51of the housing91a, the seal member23that is fitted into the annular groove22of the molded portion20comes into intimate contact with the inner circumferential surface of the attachment port.

As a result, it is possible to prevent moisture or the like from entering the housing91athrough a gap between the attachment port and the molded portion20.

(6) The plate portion31is provided with communication holes35that communicate with the bracket30in the thickness direction. The outer portion21A and the inner portion21B of the molded portion20are connected by the connecting portions filled in the communication holes35.

With this configuration, the molded portion20and the bracket30can be firmly integrated.

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.

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 inFIG. 7, “2**” to which “200” is added to the reference numerals is added in the modified example illustrated inFIGS. 8 and 9, and “3**” to which “300” is added to the reference numerals is added in the modified example illustrated inFIG. 10. In this manner, description that overlaps with the above embodiment will be omitted.As shown inFIG. 7, for example, the heights of adjacent protruding portions133aand133bcan be different. In this case, the work of attaching the fastening members40to the outer circumference of the folded-back portions11c2of the shield members11cthat are folded back is facilitated.As shown inFIG. 8, for example, insertion holes232may also have an oval shape. In this case, each protruding portion233is provided along the circumferential edge of the insertion hole232. Further, in this case, as shown inFIG. 9, if a notch211eis provided in a shield member211c, the shield member211ccan be folded back to the outer circumferential side of the protruding portion233. Also, the bracket may also be provided with only one insertion hole232.As shown inFIG. 10, a slit334extending along the axial direction can be provided on the side wall of each cylindrical protruding portion333.Instead of the molded portion20, a resin portion formed by potting or the like may also be provided.

The inner circumferential surface and the outer circumferential surface of various elongated members such as the insulating inner cover11bmay be referred to as a radially inward surface and a radially outward surface, respectively. The shield member11cmay be referred to as a braided tube made of conductive metals. The molded portion20may be referred to as a molded block.

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.

Additional Remark 1

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).

Additional Remark 2

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).

Additional Remark 3

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).

Additional Remark 4

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

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.