HARNESS COMPONENT

It is aimed to provide a harness component capable of preventing liquid penetration from between conductors of wires to a mating connector on which a connector case is mounted, and improving workability and productivity during manufacturing. A harness component (1) includes a connector case (7), a plurality of connector terminals (2) arranged in the connector case (7), a plurality of wires (3) electrically connected to the connector terminals (2) and sealing members (5) arranged in clearances between mounting portions (24) formed on the respective connector terminals (2) and the connector case (7). An outer peripheral surface of the mounting portion (24) and an inner peripheral surface of the sealing member (5) and an outer peripheral surface of the sealing member (5) and an inner peripheral surface of the connector case (7) are in close contact with each other. The connector terminal (2) is formed with a penetration preventing portion (251) for preventing liquid penetration.

BACKGROUND

Field of the Invention

The invention relates to a harness component in which wires are arranged in a connector case via connector terminals.

Related Art

A harness component is used for wiring to a control device in various electronic devices used in automotive vehicles. The harness component is composed of wires formed by stranded wires, connector terminals connected to the respective wires and a connector case having the connector terminals arranged therein. Some of electronic devices wired using a harness component may be exposed to liquid, such as oil or water. Liquid that contacts an end part of the wire connected to the electronic device is known to penetrate between strands of the wire by a capillary phenomenon, for example, as described in Japanese Unexamined Patent Publication No. 2009-272188.

The liquid penetrated between the conductors from the end part of the wire on the electronic device side penetrates to an opposite end part of the wire and may intrude into the control device via the connector terminal and the connector case. Accordingly, Japanese Unexamined Patent Publication No. 2009-272188 discloses filling a water sealant between the strands (conductors) of the core exposed portion on the end part of the wire on the control device side, and the core exposed. that has been filled with the water sealant is covered by a waterproof sheet. The sealant prevents penetration of the liquid to the connector terminal provided on the end part of the wire and prevents intrusion of the liquid into the control device.

However, Japanese Unexamined Patent Publication No. 2009-272188 requires an insulation coating to be removed at an intermediate position of the wire to form the core exposed portion. This removal is made while leaving the insulation coating on the end part of the wire, and work efficiency is poor. Further, Japanese Unexamined Patent Publication No. 2009-272188 requires an operation of curing the water sealant and covering the core exposed portion filled with the water sealant by the waterproof sheet after the water sealant is filled between the strands of the core exposed portion. Thus, many labor-hours are required to manufacture the harness component and productivity is poor.

The present invention was developed in view of such a problem, and an object of the invention is to provide a harness component capable of preventing liquid penetration between conductors of a wire to a mating connector, on which a connector case is mounted and improving work efficiency and productivity during manufacturing.

SUMMARY

One aspect of the invention is directed to a harness component with a connector case, connector terminals arranged in the connector case, wires respectively electrically connected to the connector terminals, and a sealing member arranged in a clearance between the connector case and either a mounting portion formed on the connector terminal, a solid conductor portion of the wire or a relay conductor composed of one conductor for relaying the connector terminal and the wire.

In the harness component of the above aspect, the mounting portion is formed on the connector terminal, the solid conductor portion in the wire or the relay conductor for relaying the connector terminal and the wire. The mounting portion is made of a material as one lump and hence is distinct from bundled conductors of a stranded wire or the like.

In this way, even if the wire is a stranded wire or the like including plural conductors, liquid, such as oil or water, cannot penetrate between the conductors and into the mounting portion by a capillary phenomenon. Further, if the wire is a single-core wire or the like including one conductor, liquid penetrating by a capillary phenomenon to a clearance between the conductor and an insulating coating layer coating the conductor can be prevented from penetrating into the mounting portion. Thus, liquid cannot penetrate to the inside of the connector terminal and a mating connector, and the liquid cannot intrude into a control device or the like to which the mating connector is wired or mounted.

Further, the connector terminal and the conductor portion of the wire can be connected electrically by various means, such as crimping, welding and soldering. Further, the number of processes required to arrange the sealing member in the clearance between the mounting portion and the connector case is small. Thus, work efficiency in electrical connection and the arrangement of the sealing member is improved and productivity in manufacturing the harness component also is improved.

Therefore, according to the harness component of the above aspect, it is possible to prevent the penetration of the liquid from between the conductors of the wires to the mating connector on which the connector case is mounted and to improve work efficiency and productivity during manufacturing.

Note that the harness component can be used for electrical wiring in an automotive vehicle and the like. An assembly of the connector terminal, the wire, the sealing member and the like before being arranged in the connector case is referred to as a terminal-equipped wire.

Harness components are divided into the following three aspects.

In a harness component of a first aspect, the sealing member is arranged in the clearance between the mounting portion of the connector terminal and the connector case, a penetration preventing portion for preventing liquid penetration is formed in the mounting portion or a part located on a side opposite to a side connected to the wire across the mounting portion in the connector terminal, and an outer peripheral surface of the mounting portion and an inner peripheral surface of the sealing member are in close contact with each other while an outer peripheral surface of the sealing member and an inner peripheral surface of the connector case are in close contact with each other.

In a harness component of a second aspect, the sealing member is arranged in the clearance between the mounting portion of the conductor and the connector case, the mounting portion is made of a solid material preventing liquid penetration, and an outer peripheral surface of the mounting portion and an inner peripheral surface of the sealing member are in close contact with each other while an outer peripheral surface of the sealing member and an inner peripheral surface of the connector case are in close contact with each other.

In a harness component of a third aspect, the sealing member is arranged in the clearance between the mounting portion of the relay conductor and the connector case, and an outer peripheral surface of the mounting portion and an inner peripheral surface of the sealing member are in close contact with each other while an outer peripheral surface of the sealing member and an inner peripheral surface of the connector case are in close contact with each other.

In the harness components of these various aspects, the mounting portion is formed on the connector terminal, the conductor of the wire or the relay conductor. Thus, no clearance through which liquid can penetrate is formed between the mounting portion and the sealing member when the sealing member is arranged in the clearance between the mounting portion and the connector case. The outer peripheral surface of the mounting portion and the inner peripheral surface of the sealing member are in close contact with each other. Further, no clearance through which liquid can penetrate is formed between the sealing member and the connector case, and the outer peripheral surface of the sealing member and the inner peripheral surface of the connector case are in close contact with each other.

In the harness components of the various aspects, the wire may be composed of bundled conductors like a stranded wire. When liquid, such as oil or water, penetrates between the conductors of the wire from an end part of the wire on an electronic device side in the harness component, this liquid penetrates to the conductor located on an end part of the wire on the connector terminal side by a capillary phenomenon. However, the connector terminal is formed with the penetration preventing portion in the harness component of the first aspect. Thus, the liquid penetrated to the conductor cannot pass through the inside of the connector terminal. Further, the mounting portion is formed in the harness components of the second and third aspects. Thus, the liquid penetrated to the conductor cannot pass through the inside of the connector terminal.

Further, in the harness component of the second aspect, the wire may be composed of one conductor like a single-core wire. In this case, liquid does not penetrate into the conductor of the wire. Further, if the liquid penetrates between the conductor of the wire and an insulating coating layer coating the conductor in this case, this liquid cannot pass through the inside of the connector terminal due to the conductor portion serving as the mounting portion.

Note that, in the harness component of the first aspect, the penetration preventing portion may be formed inside the mounting portion or may be located on a side to be connected to the mating connector rather than the inside of the mounting portion. Further, in the harness component of the first aspect, the wire may be partially located inside the mounting portion.

Further, in the harness components of the various aspects, the liquid prevented from penetrating into the connector terminal by the penetration preventing portion or the mounting portion, or the liquid penetrated to the conductor portion is going to penetrate to the mating connector, on which the connector case is mounted, along the outer peripheral surface of the connector terminal or the outer peripheral surface of the sealing member. At this time, the outer peripheral surface of the mounting portion and the inner peripheral surface of the sealing member are in close contact with each other, and the outer peripheral surface of the sealing member and the inner peripheral surface of the connector case also are in close contact with each other. Thus, the liquid cannot penetrate to the mating connector. In this way, the liquid cannot intrude from the connector terminal and the connector case into a control device or the like that is wired to the mating connector.

DETAILED DESCRIPTION

Preferred embodiments according to the aforementioned harness component are described with reference to the drawings.

First Embodiment

A harness component1of this embodiment includes a connector case7, connector terminals2, wires3and sealing members5, as shown inFIGS. 1 and 3. The connector case7is mounted on a mating connector connected to a control device. The connector terminals2are arranged in alignment in the connector case7. The wires3are connected respectively to the connector terminals2. The sealing member5is arranged in a clearance between a mounting portion24formed in each connector terminal2and the connector case7.

As shown inFIGS. 3 and 4, a penetration preventing portion251for preventing liquid penetration is formed in a part of the connector terminal2located on a side opposite to a side connected to the wire3across the mounting portion24. The outer peripheral surface of the mounting portion24and the inner peripheral surface of the sealing member5are in close contact with each other, and the outer peripheral surface of the sealing member5and the inner peripheral surface of the connector case7are in close contact with each other. Further, the sealing member5closes a clearance51between the inner peripheral surface of the sealing member5and the outer peripheral surface of the mounting portion24and also closes a clearance S2between the outer peripheral surface of the sealing member5and the inner peripheral surface of an insertion hole71.

The harness component1of this embodiment is described in detail below.

The harness component1is used to wire an electronic device such as an actuator or sensor used in an automotive vehicle, such as a four-wheeled automobile or two-wheeled automobile, to a control device for controlling the electronic device. Terminal-equipped wires10composed of the connector terminals2and the wires3are mounted into the connector case7.

The harness component1of this embodiment is used to connect an automatic transmission serving as the electronic device installed in the automotive vehicle to an electronic control unit (ECU) serving as the control device. Oil (working oil) for an automatic shift control operation is used in the automatic transmission. An end part of each wire3on the electronic device side in the harness component1is connected to a valve body of the automatic transmission. This end part of the wire3on the electronic device side is immersed in the oil. The valve body is for controlling an operation in a hydraulic circuit of the automatic transmission and includes solenoid valves serving as actuators and spool valves configured to slide by turning on and off energization to the solenoid valves.

As shown inFIGS. 1 and 2, the connector case7is arranged on the automatic transmission or the like and mounted on the mating connector provided in the electronic control unit. The connector case7is made of insulating resin. The connector case7includes a body73, a flange74for mounting projecting from the body73, and a mounting hole741provided in the flange74.

Further, a sealing members (O-rings)731A,731B are mounted on the body73of the connector case7. The sealing member731A provides sealing between the connector case7and the mating connector when connecting the connector case7and the mating connector, and the sealing member731B provides sealing between the connector case7and a case of the automatic transmission when connecting the connector case7and the case of the automatic transmission.

Insertion holes71are formed laterally side by side in the connector case7and receive the respective connector terminals2. Conductor pins to be connected to the respective connector terminals2are provided in the mating connector. A tapered guiding portion711is formed on a tip part of the insertion hole71for guiding the conductor pin of the mating connector. The connector terminal2arranged in the insertion hole71is prevented from coming out toward the mating connector by an end wall712formed with the tapered guiding portion711.

Note that each connector terminal2arranged in the connector case7may be connected to the electronic control unit via the mating connector and the wire3. Further, the connector case7and the mating connector can be used as a relay connector for electrically connecting the valve body and the electronic control unit.

As shown inFIGS. 4 and 5, the wire3is formed by a stranded wire in which bundled conductors31are stranded. An insulating coating layer32made of insulating rubber, resin or the like is provided on the entire outer peripheries of the conductors31. The insulating coating layer32is removed on an end part of the wire3to be connected to the connector terminal2, and a conductor portion310in which the outer peripheries of the conductors31are exposed is formed on this end part. Note that the exposure of the conductors31means that the conductors31constitute an outermost peripheral part of the wire3when the wire3is viewed as a single component. Further, the conductor portion310means an assembly of parts of the conductors31projecting from an end part of the insulating coating layer32.

As shown inFIG. 4, the connector terminal2is made of a conductive metal formed as a bent plate. The connector terminal2includes an inlet hole20into which the conductor pin of the mating connector is inserted, and functions as a female terminal. Note that the connector terminal2may be formed as a male terminal such as a conductor pin, and a female terminal into which the male terminal is inserted may be provided in the mating connector.

Further, as shown inFIG. 3, the connector terminal2is crimped to the outer peripheries of the conductor portion310and the insulating coating layer32of the wire3. Specifically, the connector terminal2is formed with a first terminal connecting portion21and a second terminal connecting portion22. The first terminal connecting portion21is to be connected to the outer periphery of a tip part of the conductor portion310. The second terminal connecting portion22is adjacent to the first terminal connecting portion21and is to be connected to the outer periphery of the insulating coating layer32of the wire3. The first and second terminal connecting portions21,22of this embodiment are formed as crimping portions. The second terminal connecting portion2is formed to embrace the insulating coating layer32of the wire3from opposite circumferential sides.

By directly crimping the connector terminal2to the conductor portion310and the insulating coating layer32of the wire3, there are four types of components in the harness component1, i.e. the connector case7, the wires3, the connector terminals2and the sealing members5. In this way, the manufacturing and component management of the harness component1can be facilitated.

A biting portion211is formed in a circumferential part of the inner periphery of the first terminal connecting portion21and is configured to bite into the outer periphery of a tip part of the conductor portion310. The connector terminal2of this embodiment is formed as a crimping terminal to be crimped to the conductor portion310. The connector terminal2may be joined to the conductor portion310by welding, soldering or the like instead of by crimping.

As shown inFIGS. 4 and 5, the mounting portion24of the connector terminal2is in a part of the connector terminal2in a longitudinal direction L and has a tubular shape. The mounting portion24is made unitarily of a material as one lump. The connector terminal2is formed by bending a plate, and the mounting portion24is a tubular portion23formed by rolling the plate into a tube. The connector terminal2is formed with an insertion part201that is formed with the inlet hole20and into which the conductor pin is inserted, and an accommodating part202that is formed with an arrangement hole25. The accommodating part202is the tubular portion23.

The penetration preventing portion251of this embodiment is formed as a bottom portion251in the arrangement hole25in which the conductor portion310of the wire3is arranged. The penetration preventing portion251and the bottom portion251are denoted by the same reference sign. The arrangement hole25including the bottom portion251prevents liquid penetrated to the conductor portion310from passing through the inside of the connector terminal2. The arrangement hole25is formed continuously from the inside of the first terminal connecting portion21to the inside of the mounting portion24inside the tubular portion23. Further, the arrangement hole25of this embodiment is formed up to a position closer to the inlet hole20than the inside of the mounting portion24.

As shown inFIGS. 3 and 4, the bottom portion251of the arrangement hole25is formed by a closing portion (constricted portion)26closed by deforming a part of the tubular portion23. The closing portion26can be formed easily by deforming the plate that is used to make the connector terminal2. The closing portion26separates a space by the inlet hole20from a space by the arrangement hole25Clearances in a part of the tubular portion23where end surfaces of the plate butt against each other and in a part of the tubular portion23where the closing portion26is formed are filled up by welding, soldering or the like to prevent the liquid pooled in the arrangement hole25from leakage.

The closing portion26is formed by deforming (squeezing) a part of the tubular portion23having a circular cross-section into a part having a flat cross-section. The closing portion26is formed by overlapping parts of the material of the plate that form the tubular portion23, and a clearance between these parts of the material is filled up by a metal material used in welding, soldering or the like.

The end surfaces of the plate butt against each other when the plate is rolled into a tube. A clearance may be formed between the end surfaces butting against each other. In this case, welding, soldering or the like is performed to eliminate the clearance.

As shown inFIG. 5, the mounting portion24on which the sealing member5is mounted is formed on the outer periphery of a part of the tubular portion23. The outer peripheral surface of the mounting portion24is a cylindrical molding surface having a circular cross-section and is formed using a die so as to be in close contact with the inner periphery of the sealing member5. Although not shown, the outer peripheral surface of the mounting portion24can be made smaller than the outer peripheral surface of the tubular portion23in parts located on both sides of the mounting portion24in the longitudinal direction L. By making the outer peripheral surface of the mounting portion24smaller than the surrounding outer peripheral surfaces, the sealing member5mounted on the mounting portion24can be positioned with respect to the longitudinal direction L of the connector terminal2.

As shown inFIG. 4, in this embodiment, a surface252of the arrangement hole25is located inside the mounting portion24, and the bottom portion251of the arrangement hole25is located closer to a side that is to be connected to the mating connector than the inside of the mounting portion24. The bottomed arrangement hole25prevents any liquid that enters the connector terminal2from penetrating to a side closer to the mating connector (insertion part201) than the mounting portion24.

The bottomed arrangement hole25may be formed into any shape provided that any liquid entering the mounting portion24is prevented from passing to the inlet hole20of the connector terminal2(or the mating connector). For example, the bottom portion251of the arrangement hole25may be formed by arranging a hole filling member made of rubber, resin, metal or the like inside the tubular portion23(in the arrangement hole25). Further, the bottom portion251of the arrangement hole25may be located inside the mounting portion24. Further, the conductor portion310may be partially in the arrangement hole25.

The tubular portion23, the closing portion26and the mounting portion24also can be formed by a method other than the aforementioned processing method using the plate. For example, the tubular portion23and the mounting portion24can be formed by drawing.

As shown inFIGS. 1, 4 and 5, the sealing members5of this embodiment are mounted individually on the mounting portion24of each of the of connector terminals2and individually are arranged in each of the insertion holes71of the connector case7. Each sealing member5is in close contact with the outer peripheral surface of each of the mounting portions24and the inner peripheral surface of each of the insertion holes71.

Each sealing member5is formed as a molded article of a resiliently deformable material such as rubber or resin and includes a sealing portion51for closing the insertion hole71. The sealing portion51is provided over the entire circumference of the respective sealing member5and contacts the entire circumference of the insertion hole71of the connector case7. A center hole52into which the mounting portion24is inserted is formed in a central part of each sealing member5. An outer diameter of the sealing portion51of the sealing member5is largest in the entire terminal-equipped wire10in the longitudinal direction L. A maximum width of the connector terminal2in a direction perpendicular to the longitudinal direction (axial direction) L is smaller than the outer diameter of the sealing portion51.

The harness component1can be manufactured (assembled) as follows.

The connector terminal2is shaped to include the terminal connecting portions21,22, the mounting portion24, the bottomed arrangement hole25and the like by bending the plate and performing shaping, welding and the like.

Further, the insulating coating layer32on the end part of the wire3on the side of the connector terminal2is removed to expose the conductors31in this end part as the conductor portion310. Subsequently, the sealing member5is mounted on the outer periphery of the mounting portion24of the connector terminal2. At this time, the sealing member5is expanded resiliently in diameter and mounted on the mounting portion24of the connector terminal2.

Subsequently, the tip part of the conductor portion310is arranged inside the first terminal connecting portion21of the connector terminal2and the insulating coating layer32on the end part of the wire3is arranged inside the second terminal connecting portion22. The terminal connecting portions21,22are deformed using a tool or the like. Thus, the first terminal connecting portion21is crimped to the outer periphery of the tip part of the conductor portion310and the second terminal connecting portion22is crimped to the outer periphery of the insulating coating layer32of the wire3. In this way, the terminal-equipped wire11in which the connector terminal2and the sealing member5are arranged on the end part of the wire3is formed. The terminal-equipped wires10are formed in numbers corresponding to the number of the insertion holes71in the connector case7.

Subsequently, the connector terminal2and the sealing member5of the terminal-equipped wire10are inserted respectively into the insertion holes71of the connector case7. At this time, the clearance S2between the outer peripheral surface of the sealing member5and the inner peripheral surface of the insertion hole71is closed. Further, the sealing member5is compressed by the insertion hole71so that the inner peripheral surface of the sealing member5and the outer peripheral surface of the mounting portion24are held in closer contact with each other. In this way, the harness component1in which the terminal-equipped wires10are mounted in the connector case7is manufactured.

Next, functions and effects of the harness component1of this embodiment are described.

In the harness component1of this embodiment, the penetration of liquid from the wires3to the mating connector, on which the connector case7is mounted, is prevented by devising the shape of the connector terminals2and using the connector terminals2and sealing members5mounted on the mounting portions24of the connector terminals2.

The end part of the wire3on the electronic device side in the harness component1is connected to the solenoid valve in the valve body, and this end part is immersed in oil serving as the liquid used in the valve body. Further, if the oil serving as the liquid penetrates between the conductors31of the wire3from the end part of the wire3on the electronic device side in the harness component1, this oil penetrates to the conductor portion310located on the end part of the wire3on the side of the connector terminal2by a capillary phenomenon. The arrangement hole25including the bottom portion251is formed inside the mounting portion24. Thus, the oil penetrated to the conductor portion310cannot pass through the inside of the connector terminal2toward the inlet hole20. This oil is pooled in the arrangement hole25.

The oil pooled in the arrangement hole25or the oil penetrated to the conductor portion310is going to penetrate along the outer surface of the connector terminal2to the mating connector on which the connector case7is mounted. However, the clearance S1between the inner peripheral surface of the sealing member5and the outer peripheral surface of the mounting portion24, and the clearance S2between the outer peripheral surface of the sealing member5and the inner peripheral surface of the insertion hole71are closed using the sealing member5mounted on the mounting portion24of the connector terminal2, as shown inFIG. 4. Thus, the oil cannot penetrate to the mating connector. In this way, the liquid cannot intrude from the connector terminal2and the connector case7into the electronic control unit wired to the mating connector.

Further, the connector terminal2and the wire3can be connected electrically by crimping the respective terminal connecting portions21,22of the connector terminal2. Further, the sealing member5can be mounted easily on the outer periphery of the mounting portion24of the connector terminal2by being resiliently deformed. The sealing member5can be mounted by one process and the number of processes is small. Thus, work efficiency in electrical connection and mounting is improved and productivity in manufacturing the harness component1also is improved.

Therefore, according to the harness component1of this embodiment, it is possible to prevent the penetration of the liquid from between the conductors31of the wire3to the mating connector on which the mating connector is mounted and to facilitate work and improve productivity during manufacturing.

Besides automatic transmissions, the harness component1can be used in various electronic devices using liquid, such as oil or water. The liquid penetrating between the conductors31of each wire3in the harness component1may be liquids other than oil, such as coolant (cooling liquid).

Further, if liquid, such as oil or water, splashes on the connector case7or the harness component1from outside, the sealing member5can also prevent this liquid from penetrating to the mating connector via the connector terminal2. In this case, the intrusion of the liquid into the mating connector via the connector terminal2is hindered both on the inner periphery and the outer periphery of the sealing member5.

Further, the liquid such as oil is thought to penetrate not only between the conductors31, but also between the conductors31and the insulating coating layer32. The penetration of the liquid between the conductors31and the insulating coating layer32to the mating connector via the connector terminal2also is prevented by the configuration of the harness component1using the connector terminals2and the sealing members5.

Second Embodiment

This embodiment has a sealing member5arranged in a clearance between a mounting portion33of a conductor portion310of a wire3and a connector case7, as shown inFIGS. 6 to 8.

The mounting portion33of this embodiment is made of a solid material as a part of the conductor portion310of the wire3to prevent liquid penetration. The wire3of this embodiment is a single-core wire composed of one solid conductor31and an insulating coating layer32coating the conductor31. The mounting portion33is a part of the conductor31forming the conductor portion310, and the conductor portion310is a part of the conductor31projecting from an end part of the insulating coating layer32.

The sealing member5is mounted on the outer periphery of the mounting portion33in the conductor portion310and is arranged in an insertion hole71. The sealing member5closes a clearance S1between the inner peripheral surface of the sealing member5and the outer peripheral surface of the conductor portion310and also closes a clearance S2between the outer peripheral surface of the sealing member5and the inner peripheral surface of the insertion hole71. The outer peripheral surface of the mounting portion33and the inner peripheral surface of the sealing member5are in close contact with each other, and the outer peripheral surface of the sealing member5and the inner peripheral surface of the connector case7also are in close contact with each other.

As shown inFIGS. 6 and 8, a connector terminal2is formed with a first terminal connecting portion21to be connected to the outer periphery of a tip part of the conductor portion310and a second terminal connecting portion22adjacent to the first terminal connecting portion21and to be connected to the outer periphery of the sealing member5. A biting portion211is formed on an end part of the first terminal connecting portion21and is configured to bite into the outer periphery of the tip part of the conductor portion310. Note that the connector terminal2may be joined to the conductor portion310by welding, soldering or the like.

Further, the sealing member5includes a sealing portion51for closing the insertion hole71, a center hole52into which the mounting portion33is inserted, and a connecting outer peripheral portion53with an outer periphery to which the second terminal connecting portion22provided in the connector terminal2is connected.

Further, the wire3can be a stranded wire including bundled conductors31instead of being a single-core wire, and a solid mounting portion33can be formed by molding in a part of the conductor portion310of the wire3in a longitudinal direction L. This mounting portion33is made of a conductive material that fills up clearances among the conductors31in the conductor portion310and covers the entire conductor portion310.

More specifically, the conductor portion310can be processed partially or entirely in the longitudinal direction L to mold the mounting portion33having an outer peripheral surface (cylindrical surface) for mounting the sealing member5. The outer peripheral surface of the mounting portion33can be molded by sandwiching a part of the conductor portion310having the conductive material applied thereto by a die.

Note that the mounting portion33can also be formed using an insulating material instead of using the conductive material. In this case, there is no problem even if the part of the conductor portion310other than the conductors31is made of the insulating material since the conductors31in the conductor portion310are conductive. Further, in this case, the mounting portion33is formed only in a part of the conductor portion310on which the sealing member5is mounted, and the conductors31are exposed in the tip part of the conductor portion310to which the connector terminal2is connected.

In a harness component1of this embodiment, oil is unlikely to penetrate into the wire3from an end part of the wire3on an electronic device side in the harness component1since the wire3is a single-core wire. However, this oil may enter the clearance between the conductor31and the insulating coating layer32, and might penetrate to an end part of the wire3on the side of the connector terminal2by a capillary phenomenon.

If the oil penetrating into the clearance between the conductor31and the insulating coating layer32reaches the conductor portion310, this oil is going to penetrate to the connector terminal2along the outer periphery of the conductor portion310. However, the sealing member5closes the clearance S1between the inner peripheral surface of the sealing member5and the outer peripheral surface of the conductor portion310and also closes the clearance S2between the outer peripheral surface of the sealing member5and the inner peripheral surface of the insertion hole71, as shown inFIG. 7. Thus, the oil cannot penetrate to a mating connector via either an inner peripheral side of the sealing member5or an outer peripheral side of the sealing member5. In this way, the intrusion of the liquid into an electronic control unit from the connector terminal2and the connector case7is prevented.

The other configuration, functions, effects and the like of the harness component1of this embodiment are similar to those of the first embodiment. Further, in this embodiment, constituent elements denoted by the same reference signs as in the first embodiment are the same as those in the first embodiment.

Third Embodiment

This embodiment provides a sealing member5in a clearance between a mounting portion44of a relay conductor4and a connector case7, as shown inFIGS. 9 to 11.

The relay conductor4is for relaying electrical connection between a connector terminal2and a conductor portion310of a wire3. The relay conductor4is made of a conductive metal material as one conductor. The relay conductor4includes a mounting shaft41on which the connector terminal2and the sealing member5are mounted, and also includes a conductor connecting portion42connected to an end part of the wire3on the side of the relay conductor4. The mounting portion44is part of the mounting shaft41in a longitudinal direction L.

The relay conductor4is formed as a solid shaft having a circular cross-sectional shape. A flange43is formed on the outer periphery of the mounting shaft41and holds the sealing member5between the flange43and the conductor connecting portion42in the longitudinal direction L. The conductor connecting portion42is formed into a bottomed cylindrical shape as a closed barrel. The conductor connecting portion42is formed with a bottomed arrangement hole421along an axial direction of the relay conductor4to arrange an end part of the wire3inside. Since the relay conductor4is formed of one conductor similarly to a single-core wire, liquid does not penetrate therein.

First and second terminal connecting portions21,22of the connector terminal2of this embodiment are connected to the outer periphery of the relay conductor4. A biting portion211configured to bite into the outer periphery of the relay conductor4is formed on an end part of the first terminal connecting portion21.

In this embodiment, oil that penetrates between conductors31in the wire3by a capillary phenomenon reaches the conductor connecting portion42of the relay conductor4. However, the relay conductor4is formed by one conductor, and therefore no clearance is formed inside. Accordingly, the oil that reaches the conductor connecting portion42does not penetrate into the solid mounting portion44. Nevertheless, there still is a concern that any oil that reaches the conductor connecting portion42may penetrate to the connector terminal2along the outer periphery of the relay conductor4. However, the sealing member5closes the clearance51between the inner peripheral surface of the sealing member5and the outer peripheral surface of the relay conductor4and also closes the clearance S2between the outer peripheral surface of the sealing member5and the inner peripheral surface of the insertion hole71, as shown inFIG. 10. Accordingly, the oil cannot penetrate to either an inner peripheral side of the sealing member5or an outer peripheral side of the sealing member5. Thus, the oil cannot penetrate to a mating connector via the connector terminal2. In this way, the intrusion of the liquid into an electronic control unit from the connector terminal2and the connector case7is prevented.

The other configuration, functions, effects and the like of the harness component1of this embodiment are similar to those of the first embodiment. Further, in this embodiment, constituent elements denoted by the same reference signs as in the first embodiment are the same as those in the first embodiment.

Fourth Embodiment

This embodiment has one sealing member5arranged for a connector case7and commonly used for mounting portions44of relay conductors4of terminal-equipped wires10, as shown inFIGS. 12 to 14. This embodiment shows the mounting portions44of the relay conductors4arranged in the sealing member5. However, mounting portions to be arranged in the sealing member5may be mounting portions24provided on connector terminals2of the terminal-equipped wires10or mounting portions33provided on conductor portions310of wires3of the terminal-equipped wires10.

As shown inFIGS. 12 and 14, the connector case7of this embodiment has insertion holes71that respectively receive the connector terminals2, and a communication hole72communicates with all of the insertion holes71. The communication hole72is a large hole in which the sealing member5is arranged. Further, the sealing member5of this embodiment includes seal arrangement holes54in which the mounting portions44respectively are arranged.

The sealing member5is arranged in the communication hole72formed in the connector case7. An outer peripheral sealing portion55is formed on the outer peripheral surface of the sealing member5and is configured to be resiliently deformed by contacting the communication hole72. An inner peripheral sealing portion541is formed in each seal arrangement hole54of the sealing member5and is configured to be resiliently deformed by contacting the outer peripheral surface of the mounting portion44. The sealing member5is formed to have a circular outer peripheral surface. However, the outer peripheral surface of the sealing member5may have a shape other than a circular shape.

Further, as shown inFIGS. 12 and 13, a plug8also is arranged in the communication hole72of the connector case7and presses the sealing member5for preventing the sealing member5from coming out of the communication hole72. The plug8is formed with arrangement holes81in which the wires3and the like are arranged. The arrangement holes81are at positions communicating with both the seal arrangement holes54in the sealing member5and the insertion holes71of the connector case7. Locking projections82are formed on the outer periphery of the plug8and are to be locked into latching holes732formed in a body73of the connector case7.

As shown inFIG. 14, the relay conductor4of this embodiment is formed into a shaft shape. The relay conductor4is formed by a solid round bar having a substantially constant cross-sectional area along an axial direction thereof. Further, a harness component1of this embodiment includes connection terminals45for connection (coupling) between the relay conductors4and the wires3. Each relay conductor4and the corresponding wire3are connected by crimping the connection terminal45. In this embodiment, the relay conductor4can have a simple shape, such as a round bar shape, by using the connection terminal45.

In manufacturing the harness component1of this embodiment, the of terminal-equipped wires10are formed by first connecting the connector terminals2and the wires3. Subsequently, the connector terminal2of each terminal-equipped wire10is inserted into each arrangement hole81of the plug8and each seal arrangement hole54of the sealing member5. At this time, the seal arrangement hole54can be expanded in diameter by resiliently deforming the inner peripheral sealing portion541by the connector terminal2. The mounting portion44in each relay conductor4is arranged in each seal arrangement hole54and the inner peripheral sealing portion541contacts each mounting portion44.

Subsequently, the sealing member5and the plug8having the terminal-equipped wires10arranged therein are arranged in the communication hole72of the connector case7. At this time, the outer peripheral sealing portion55is deformed resiliently by the communication hole72and the sealing member5is pushed into the communication hole72. When the sealing member5and the plug8are arranged in the communication hole72, a compression force acts in a radial direction of the sealing member5(direction perpendicular to a longitudinal direction L of the wires3) and the outer peripheral sealing portion55on the outer peripheral surface of the sealing member5and the inner peripheral surface of the communication hole72are held in close contact with each other. Further, the outer peripheral surface of each mounting portion44and the inner peripheral surface of each seal arrangement hole54are in close contact with each other.

In this way, clearances S1between the inner peripheral sealing portions541of the respective seal arrangement holes54of the sealing member5and the outer peripheral surfaces of the respective mounting portions44are closed, and a clearance S2between the outer peripheral sealing portion55of the sealing member5and the inner peripheral surface of the communication hole72also are closed. Then, the harness component1having the plurality of terminal-equipped wires10mounted in the connector case7is manufactured.

Also in this embodiment, an effect of preventing the intrusion of liquid into an electronic control unit from the connector terminals2and the connector case7by the sealing member5and the mounting portions44is obtained as in the first to third embodiments. Further, the terminal-equipped wire10that is used in the harness component1and in which the wire3is connected to the connector terminal2may be any one of those shown in the first to third embodiments.

The other configuration, functions, effects and the like of the harness component1of this embodiment are similar to those of the first to third embodiments. Further, also in this embodiment, constituent elements denoted by the same reference signs as in the first to third embodiments are the same as those in the first to third embodiments.

Fifth Embodiment

This embodiment has a harness component1that includes a connection terminal6for connection (coupling) between a relay conductor4and a wire3, as shown inFIGS. 15 to 23.

The connection terminal6of this embodiment includes a first connecting portion61to be connected to the relay conductor4having a shaft shape and a second connecting portion62to be connected to a conductor portion310on an end part of the wire3. The relay conductor4and the wire3are coupled by the connection terminal6. Further, a third connecting portion63to be connected to an insulating coating layer32of the wire3is formed at a position closer to the wire3than the second connecting portion62. In this embodiment, the relay conductor4can be formed by a round bar having a simple shape by using the connection terminal6.

As shown inFIG. 15, the connection terminal6of this embodiment is formed with a projection65configured to contact an insertion hole71of a connector case7. The projection65can support the connection terminal6in the insertion hole71by contact the insertion hole71. The projection65projects outward of the connection terminal6at a position between the first and second connecting portions61,62. Outward means a direction perpendicular to a longitudinal direction L of the connection terminal6, i.e. outward in a radial direction of the insertion hole71. Further, the projection65is formed by extending parts of a plate forming the connection terminal6toward both sides. The longitudinal direction L means an extending direction of the relay conductor4and the connection terminal6.

Note that there may be a tiny clearance between the projection65and the insertion hole71when a terminal part of a terminal-equipped wire10of the harness component1is inserted into the insertion hole71. Also in this case, the projection65contacts the insertion hole71due to vibration or the like when the harness component1is used.

The terminal-equipped wire10of the harness component1of this embodiment is supported in the insertion hole71of the connector case7by a sealing portion51of a sealing member5and the projection portion65of the connection terminal6. This can make the terminal-equipped wire10difficult to vibrate with respect to the connector case7. Thus, the relay conductor4can be made less likely to be damaged particularly in a part401near an end of the sealing member5on the side of the connection terminal6.

Further, the projection65can be formed into various shapes to contact the inside of the insertion hole71. In the case of using the connection terminal6, the terminal part of the terminal-equipped wire10becomes longer than in the case of not using the connection terminal6. Thus, it is effective to provide the projection65to make the terminal part of the terminal-equipped wire10less likely to vibrate due to vibration transmitted to the terminal-equipped wire10.

The projection portion65can be provided at a position maximally distant from the sealing member5in the longitudinal direction L, e.g. in an intermediate part of the connection terminal6in the longitudinal direction L or in a base part of the connection terminal6in the longitudinal direction L. The base part means a part near the wire3in the longitudinal direction L of the connection terminal6.

Further, the projection65can be formed into a resiliently deformable shape. In this case, a spring force caused by resilient deformation can be generated to the insertion hole71from the projection65when the projection65comes into contact with the insertion hole71. The projection portion65can be deformed resiliently in inserting the terminal part of the terminal-equipped wire10into the insertion hole71. The projection65can more reliably contact the insertion hole71by causing the projection65to generate the spring force while maintaining easy insertion of the terminal part of the terminal-equipped wire10into the insertion hole71.

As shown inFIGS. 16 and 17, a projection65A can be composed of strips652on both sides of slits (cutouts)651extending along the longitudinal direction L in an intermediate part of the connection terminal6in the longitudinal direction L. Each strip652is in the form of a beam having both ends in the longitudinal direction L supported on a body of the connection terminal6. In this case, an intermediate part of each strip652in the longitudinal direction L bulges out in a direction perpendicular to the longitudinal direction L to form a projecting apex653in this intermediate part, so that the strip652can be deformed resiliently. The projecting apex653can be formed by bending the strip652. Further, the projecting apex653of each strip652projects most outward in the direction perpendicular to the longitudinal direction L and contacts the insertion hole71.

The strips652shown inFIGS. 16 and 17are formed at three positions, i.e. on both sides in a width direction perpendicular to the longitudinal direction L and on one side in a height direction perpendicular to the width direction. The apices653enable all three strips652to be deformed resiliently. Besides this, the resiliently deformable strips652can be formed only on both sides in the width direction perpendicular to the longitudinal direction L or can be formed only on one side in the height direction.

Further, as shown inFIGS. 18 and 19, a reinforcing strip654not constituting the projection65A can be formed between the strips652. The reinforcing strip654can be parallel to the longitudinal direction L. The reinforcing strip654can be formed between the strips652in a direction about a center axis along the longitudinal direction L of the connection terminal6. Further, any one of the strips652may be used as the reinforcing strip654by not forming the projection65A.

By forming the slits651in the connection terminal6, an electrical resistance value of the connection terminal6may be increased and the strength of the connection terminal6may be reduced. Accordingly, the electrical resistance value of the connection terminal6can be kept low and the strength of the connection terminal6can be maintained as high as possible by forming both the reinforcing strip654and the strips652in the connection terminal6.

Further, as shown inFIGS. 20 and 21, projections65B also can be formed by being cut by one or more cutouts655formed in a base end part of the connection terminal6in the longitudinal direction L. The projections65B can be formed by being bent in directions perpendicular to the longitudinal direction L. The projections65B can be deformed resiliently by having a cantilever shape with one end supported on the body of the connection terminal6.

In this case, tips of the projections65B can be deformed resiliently when coming into contact with the insertion hole71while inserting the terminal part of the terminal-equipped wire10into the insertion hole71. Spring forces can be caused to act on the insertion hole71from the projection portions65B. One, two or more projections65B can be formed. A case in which three projections65B are formed is shown inFIGS. 20 and 21.

Further, as shown inFIGS. 22 and 23, a projection65C can be formed as a cantilever having one end in the longitudinal direction L supported on the body of the connection terminal6by cutting a part of the connection terminal6by a slit (cutout)656in an intermediate part of the connection terminal6in the longitudinal direction L and raising the cut part. In this case, conductive portions657constituting the body of the connection terminal6are formed on both sides of the projection65C in a direction perpendicular to the longitudinal direction L.

Also in this case, the projection65C is resiliently deformable and can contact the insertion hole71by causing a spring force to act. Further, the projection65C projects obliquely from the body of the connection terminal6from a tip side (side of the connection terminal2) toward a base end side (side of the wire3) along the longitudinal direction L to facilitate the insertion of the terminal part of the terminal-equipped wire10into the insertion hole71.

Note that the projections65,65A,65B and65C are not only those that are resiliently deformable, but also those that are hardly resiliently deformed. In this case, a tiny clearance is formed between the projections65and the insertion hole71when the terminal part of the terminal-equipped wire10is inserted into the insertion hole71. In other words, the projection can be not only the one that has a spring characteristic to be resiliently deformable, but also the one having no spring characteristic.

Also in this embodiment, the sealing member5may be used commonly for the mounting portions44of the relay conductors4of the terminal-equipped wires10similarly to the sealing member5shown in the fourth embodiment. The other configuration, functions, effects and the like of the harness component1of this embodiment are similar to those of the first to fourth embodiments. Further, also in this embodiment, constituent elements denoted by the same reference signs as in the first to fourth embodiments are the same as those in the first to fourth embodiments.

The invention is not limited only to the embodiments and further different embodiments can be employed without departing from the gist of the present invention. Further, the invention encompasses various modifications, modifications within the scope of equivalents and the like.