Exterior end portion cap and wire harness

An exterior end portion cap is configured to be attached to electrically conductive paths and an exterior member. The exterior end portion cap includes an external exposure portion having a first blocking portion and an internal insertion portion having a second block portion. The internal insertion portion has a slit. The second blocking portion has a convex portion that is fitted to a gap between the electrically conductive paths. The exterior end portion cap is configured to be divided into two divided parts. The slit is disposed in a position corresponding to a position of a divided surface of the two divided parts and is formed so as to bring the part of the outer surfaces of the electrically conductive paths into contact with an inner surface of the exterior member near the end portion of the exterior member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on Japanese Patent Application (No. 2016-236463) filed on Dec. 6, 2016, the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an exterior end portion cap which is attached to an end portion of an exterior member. The invention also relates to a wire harness which is configured to include the exterior end portion cap.

2. Description of the Related Art

A wire harness is used for electrically connecting devices mounted in a car to each other. The wire harness is configured to include an exterior member shaped like a tubular body, and one electrically conductive path or a plurality of electrically conductive paths housed in the exterior member. For example, a wire harness disclosed in JP-A-2011-254614 is routed to pass through a vehicle underfloor of a car. Of the wire harness, a portion corresponding to the vehicle underfloor is routed straightly. Such a wire harness is formed to have a long length. Incidentally, the following thing particularly about the straightly routed portion is described in JP-A-2011-254614. That is, it is known that there is a possibility that an electrically conductive path or electrically conductive paths inside an exterior member may shake due to vibration during running etc.

The above related art has the following problem. That is, when the electrically conductive path or each of the electrically conductive paths inside the exterior member shakes largely due to the vibration during running, a coating (a braid or metal foil in an outer side of the electrically conductive path when the electrically conductive path has a shield function) of the electrically conductive path may strike against a tubular inner surface (inner circumferential surface) of the exterior member. On that occasion, sand etc. may intrude into the exterior member. In this case, there is a problem that the coating, the braid, etc. may be damaged easily.

As a solution to this problem, the following structure is generally used. That is, taping is applied to an end portion of the exterior member to prevent sand etc. from intruding between the end portion and the electrically conductive path or paths. However, the structure has the following problem. That is, when, for example, the taping is not applied sufficiently, sand may intrude through a gap between adjacent ones of windings of the taping or a gap between adjacent ones of the electrically conductive paths. As a result, there is a problem that the intrusion of the sand may lead to the aforementioned damage.

SUMMARY OF THE INVENTION

The invention has been accomplished in consideration of the aforementioned circumstances. An object of the invention is to provide an exterior end portion cap which can prevent damage on an electrically conductive path inside an exterior member, and a wire harness which is configured to include the exterior end portion cap.

According to a first configuration of the invention which has been accomplished in order to attain the foregoing object, there is provided an exterior end portion cap to be attached to at least two electrically conductive paths and an exterior member having a tubular shape, and the at least two electrically conductive paths being led out from the exterior member, the exterior end portion cap including:

an external exposure portion having a first blocking portion and configured to be exposed to an outer side of the exterior member; and

an internal insertion portion having a second block portion, being continuous to the external exposure portion, and configured to be inserted into the exterior member, wherein:

the internal insertion portion has an electrically conductive path exposing slit by which a part of outer surfaces of the at least two electrically conductive paths can be made to function as a third blocking portion when the internal insertion portion is attached to the at least two electrically conductive paths;

the first blocking portion is disposed on a side to which the internal insertion portion is continuous, and has a planar portion configured to abut against an end portion of the exterior member;

the second blocking portion has a convex portion that is disposed so as to face to the at least two electrically conductive paths arranged side by side and that is fitted to a gap between the at least two electrically conductive paths arranged side by side;

the exterior end portion cap is configured to be divided into two divided parts for holding the at least two electrically conductive paths each shaped like a circle in section therebetween; and

the electrically conductive path exposing slit is disposed in a position corresponding to a position of a divided surface of the two divided parts and is formed so as to bring the part of the outer surfaces of the at least two electrically conductive paths into contact with an inner surface of the exterior member near the end portion of the exterior member in order to make the part of the outer surfaces of the at least two electrically conductive paths functions as the third blocking portion.

In addition, in order to attain the object, there is provided a wire harness including:

an exterior member having a tubular shape;

at least two electrically conductive paths that are arranged side by side and that are protected by the exterior member; and

the exterior end portion cap that is attached to the at least two electrically conductive paths arranged side by side and the end portion of the exterior member.

According to the above configuration of the invention, the end portion of the exterior member can be blocked by the first blocking portion of the exterior end portion cap. In addition, the gap between the electrically conductive paths arranged side by side can be also blocked by the second blocking portion of the exterior end portion cap. Further, the inner surface (inner surface in line with the positions of the divided surfaces) of the exterior member can be also blocked by the portion (functioning as the third blocking portion) of the electrically conductive paths exposed from the pair of electrically conductive path exposing slits of the exterior end portion cap. By the first to third blocking portions, for example, sand etc. can be prevented from intruding into the exterior member from the outside even if the sand etc. tries to intrude. Accordingly, when the exterior end portion cap according to the invention is used, an effect that sand etc. can be prevented from easily intruding into the exterior member is obtained, in comparison with a case where, for example, only taping is applied. According to the invention as understood from the above description, since the sand etc. is absent from the inside of the exterior member, an effect that the electrically conductive paths can be prevented from being damaged easily is obtained even when the electrically conductive paths shake, for example, due to vibration during running. Moreover, according to the invention, since the exterior end portion cap having the two-part structure is used, an effect that the exterior end portion cap can be easily attached to the electrically conductive paths arranged side by side is also obtained. In addition, according to the invention, an effect that the electrically conductive paths can be retained in an immovable state or an effect that the electrically conductive paths can be disposed substantially at the center of the exterior member is also obtained.

According to the above configuration of the invention, the wire harness is configured to include the exterior end portion cap. With this configuration, for example, sand etc. can be prevented from intruding into the exterior member from the outside even if the sand etc. tries to intrude. As a result, an effect that damage on the electrically conductive paths inside the exterior member can be prevented is obtained.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

A wire harness is configured to include an exterior member shaped like a tubular body, at least two electrically conductive paths protected by the exterior member, and exterior end portion caps. Each of the exterior end portion caps is a member having a two-part structure. The exterior end portion caps are attached to end portions of the exterior member out of which the electrically conductive paths are led. An external exposure portion having first blocking portions, and an internal insertion portion having second blocking portions are formed in each of such exterior end portion caps. The first blocking portions are formed into planarly shaped portions which abut against the corresponding end portion of the exterior member. The second blocking portions are formed into convexly shaped portions fitted to gaps between the electrically conductive paths arranged side by side. A pair of electrically conductive path exposing slits by which portions of outer surfaces of the electrically conductive paths are made to function as third blocking portions are also formed at positions of divided surfaces in the internal insertion portion.

Example

Example will be described below with reference to the drawings.FIGS. 1A and 1Bare views showing wire harnesses according to the invention.FIG. 1Ais a schematic view showing a state in which high-voltage wire harnesses are routed.FIG. 1Bis a schematic view showing a state in which a low-voltage wire harness different from those inFIG. 1Ais routed.FIG. 2is a view showing a state in which a path of one of the wire harnesses inFIG. 1Ais routed, and the configuration of the wire harness inFIG. 1A.FIG. 3is a longitudinal sectional view showing the configuration of an exterior end portion cap according to the invention in a harness terminal inFIG. 2.

FIG. 4is a view seen from a direction of an arrow A ofFIG. 3.FIG. 5is a view seen from a direction of an arrow B ofFIG. 3.FIGS. 6A and 6B,FIGS. 7A and 7BandFIG. 8are views of the exterior end portion cap.FIG. 9is a view showing a state immediately before the exterior end portion cap is attached to an end portion of an exterior member.FIG. 10is a view showing a state in which the exterior end portion cap has been attached to the end portion of the exterior member.FIGS. 11 and 12are views showing modifications.

The motor unit3is configured to include a motor and a generator. In addition, the inverter unit4is configured to include an inverter and a converter. The motor unit3is formed as a motor assembly including a shielding case. In addition, the inverter unit4is also formed as an inverter assembly including a shielding case. The battery5is of an Ni—MH type or an Li-ion type which is formed to be modularized. Incidentally, an electric storage device such as a capacitor may be used. It is a matter of course that any device may be used as the battery5without any particular limitation as long as the device can be used in the hybrid car1or an electric car.

InFIG. 1B, the reference sign15designates a wire harness. The wire harness15is a low-voltage wire harness (for low voltage use) which is provided for electrically connecting a low-voltage battery16of the car rear portion7in the hybrid car1to an accessory18(device) mounted in a car front portion17. The wire harness15is routed to pass through the vehicle underfloor11in the same manner as the wire harness9inFIG. 1A(This is merely an example. The wire harness15may be routed to pass through the cabin side). The reference sign19in the wire harness15designates a harness body. In addition, the reference sign20designates a connector.

As shown inFIGS. 1A and 1B, the high-voltage wire harnesses8and9and the low-voltage wire harness15are routed in the hybrid car1. The invention can be applied to any of these wire harnesses. However, the high-voltage wire harness9will be taken as a representative example and described below. The configuration and the structure of the wire harness9will be described first.

<About Configuration of Wire Harness9>

InFIG. 1AandFIG. 2, the long wire harness9routed to pass through the vehicle underfloor11is configured to include a harness body21and the shield connectors14(external connection pieces) which are provided and disposed on the opposite terminals (harness terminals13) of the harness body21respectively. In addition, the wire harness9is configured to include clamps C for routing the wire harness9to predetermined positions, and not-shown water sealing members (e.g. grommets etc.).

<About Configuration of Harness Body21>

InFIG. 2andFIG. 3, the harness body21is configured to include a long electrically conductive path22, an exterior member23which houses and protects the electrically conductive path22, and exterior end portion caps25according to the invention which are attached to end portions24of the exterior member23out of which the electrically conductive path22is led.

InFIG. 3andFIG. 6, the electrically conductive path22is configured to include an electrically conductive conductor26, an insulating insulator27with which the conductor is coated, a braid28(shield member) which is provided for fulfilling a shield function. That is, an electrically conductive path from which a sheath is absent (this is merely an example) is used as the electrically conductive path22. Due to absence of the sheath from the electrically conductive path22, it is a matter of course that the electrically conductive path22is light in weight accordingly (Since the electrically conductive path22is long, it is a matter of course that the weight of the electrically conductive path22can be reduced much more greatly than a background-art example).

InFIG. 3andFIG. 6, the conductor26is made of copper, a copper alloy, aluminum or an aluminum alloy and formed into a circular shape in section. The conductor26may be either a conductor having a conductor structure of twisted strands or a conductor having a sectionally circular (round) rod-like conductor structure (e.g. a conductor structure which serves as a round single core. In this case, the electrically conductive path itself is also shaped like a rod). The insulator27made of an insulating resin material is formed on an outer surface of the conductor26by extrusion molding.

InFIG. 3andFIG. 6, the insulator27is formed on the outer circumferential surface of the conductor26by extrusion molding out of a thermoplastic resin material. The insulator27is formed as a coating shaped like a circle in section. The insulator27is formed to have a predetermined thickness. Various known kinds of resins can be used as the aforementioned thermoplastic resin. For example, the thermoplastic resin may be selected suitably from high polymer materials such as a polyvinylchloride resin, a polyethylene resin and a polypropylene resin.

<About Configuration of Harness Body21>

InFIG. 2andFIG. 3, the harness body21is configured to include two long electrically conductive paths22, an exterior member23, and exterior end portion caps25according to the invention. The exterior member23houses and protects the two electrically conductive paths22. The exterior end portion caps25according to the invention are attached to end portions24of the exterior member23out of which the two electrically conductive paths22are led. Incidentally, the number of the electrically conductive paths22is exemplary to be at least two.

The braid28according to the Example is the outermost layer of the electrically conductive path22. Accordingly, one portion of the electrically conductive path22functions as a “third blocking portion” described in Claims (its details and reference sign will be described later).

InFIG. 2andFIG. 3, the exterior member23is formed into a straight tubular body shape (which is straight prior to use) by molding out of an insulating resin. In addition, the exterior member23is formed into an unslitted shape (in other words, formed into a shape having no slit (or formed into a shape which is not a split tube shape)). Further, the exterior member23is formed into a sectionally circular shape suited to shape of the electrically conductive path22.

Such an exterior member23has flexible pipe portions29having flexibility, and straight pipe portions30serving as portions where the electrically conductive path22is routed straightly (This configuration is merely an example. For example, the entire exterior member23may be a flexible pipe portion29). The flexible pipe portions29and the straight pipe portions30are formed in a pipe axial direction. In addition, the flexible pipe portions29and the straight pipe portions30are formed and disposed alternately.

InFIG. 2andFIG. 3, the flexible pipe portions29are disposed in accordance with a vehicle attachment shape (a shape of a destination to which the wire harness is routed, or a shape of an attachment subject49which will be described later). In addition, the flexible pipe portions29are formed to also have lengths suited to the vehicle attachment shape. The lengths of the flexible pipe portions29are not fixed but may be formed as required lengths suited to the vehicle attachment shape respectively. Such flexible pipe portions29are formed to be able to be flexed at desired angles respectively in a packed state and during transportation of the wire harness9, and further during routing of a path of the wire harness9in the vehicle. That is, the flexible pipe portions29are formed to be able to be flexed into bent shapes, and, of course, to be able to be returned to their original straight states (the states when the resin is molded). Each of the flexible pipe portions29according to the Example is formed into a corrugated pipe shape having bellows recesses and bellows protrusions (this is merely an example).

InFIG. 2andFIG. 3, the straight pipe portions30are formed as portions which do not have flexibility like the flexible pipe portions29. In addition, the straight pipe portions30are formed also as portions which do not bend in the packed state, during the transportation, and further during the routing of the path (the non-bending portions mean portions which do not have flexibility aggressively). The straight pipe portions30are formed into long straight pipe shapes. Each of outer circumferential surfaces of such straight pipe portions30is formed into a smooth shape (this is merely an example).

The straight pipe portions30are formed into rigid portions in comparison with the flexible pipe portions29. Each of such straight pipe portions30is formed at a position with a length in accordance with the vehicle attachment shape. Incidentally, of the straight pipe portions30, a longest one30is formed as a portion disposed on the vehicle underfloor11in the Example.

InFIGS. 2 to 8, the exterior end portion cap25is a resin molded item which is, for example, made of a resin material having weather resistance, heat resistance, etc. The exterior end portion cap25is not only attached to one electrically conductive path22but also attached to the exterior member23out of which the electrically conductive path22is led. The exterior end portion cap25is provided, for example, for preventing sand etc. from intruding into (an internal portion of) the exterior member23from the outside even if the sand etc. tries to intrude. In addition, the exterior end portion cap25is provided also for preventing damage on the electrically conductive path22inside the exterior member23. An external exposure portion31, an internal insertion portion32which is continuous to the external exposure portion31, and an electrically conductive path housing recess which extends across the external exposure portion31and the internal insertion portion32are formed in such an exterior end portion cap25.

InFIGS. 3 to 8, the external exposure portion31is formed as a portion exposed to an outer side of the exterior member23. The external exposure portion31is formed to be larger in size than the end portion24of the exterior member23. In addition, the external exposure portion31is also formed into a size large enough so that a worker can hold the external exposure portion31in his/her hand so as to perform insertion work of the exterior end portion cap25into the exterior member23. Such an external exposure portion31is formed substantially into a U-shape in section due to the presence of the electrically conductive path housing recess. A first blocking portion34is formed in the external exposure portion31. The first blocking portion34is formed as one of characteristic portions of the invention.

InFIGS. 3 to 8, the first blocking portion34is formed and disposed on a side opposed to the end portion24of the exterior member23. The first blocking portion34is formed into a plane which can abut against the end portion24to block the end portion24at the abutment portion (The first blocking portion34is formed into a planar shape. In addition thereto, the first blocking portion34may alternatively have a groove shape or a step shape into which the end portion24can be inserted).

Incidentally, in the Example, a bellows recess portion of the exterior member23is formed as the end portion24. However, the invention is not limited thereto. Alternatively, a bellows protrusion portion of the exterior member23may serve as the end portion24. The first blocking portion34is formed as a portion which abuts against such an end portion24to prevent, for example, sand etc. from intruding into (the internal portion of) the exterior member23from the outside even if the sand etc. tries to intrude.

InFIGS. 3 to 10, the exterior end portion cap25is a resin molded item which is, for example, made of a resin material having weather resistance, heat resistance, etc. The exterior end portion cap25is not only attached to the two electrically conductive paths22but also attached to the exterior member23out of which the electrically conductive paths22are led. In the Example, the exterior end portion cap25is attached to the exterior member23without looseness (the exterior end portion cap25may be slightly press-fitted into the exterior member23). The exterior end portion cap25is provided, for example, for preventing sand etc. from intruding into (an internal portion of) the exterior member23from the outside even if the sand etc. tries to intrude. In addition, the exterior end portion cap25is provided also for preventing damage on the electrically conductive paths22inside the exterior member23. An external exposure portion31and an internal insertion portion32which is continuous to the external exposure portion31are formed in such an exterior end portion cap25. The exterior end portion cap25according to the Example is formed into a two-part structure in which two divided parts of the exterior end portion cap25are connected to each other through a hinge33.

InFIGS. 3 to 10, the external exposure portion31is formed into a substantially circularly columnar (or substantially disk-like) portion exposed to the outer side of the exterior member23. The external exposure portion31is formed to have a diameter not smaller than an external diameter of the end portion24of the exterior member23. In addition, the external exposure portion31is formed to be also thick enough so that a worker can hold the external exposure portion31in his/her hand so as to perform insertion work of the exterior end portion cap25into the exterior member23. Electrically conductive path penetrating portions34aand34band first blocking portions35aand35bare formed in such an external exposure portion31. The two electrically conductive paths22penetrate the electrically conductive path penetrating portions34aand34b. The first blocking portions35aand35babut against the end portion24of the exterior member23to block the end portion24of the exterior member23. Incidentally, the reason why the reference signs are separated into one suffixed with “a” and the other suffixed with “b” is that the exterior end portion cap25has the two-part structure as described above, and the external exposure portion31is therefore also formed into a two-part structure (two-divided structure). In the external exposure portion31, the reference sign36adesignates an upper divided part and the reference sign36bdesignates a lower divided part. The upper divided part36aand the lower divided part36bare formed into semicircular shapes respectively (shapes viewed from the direction of the arrow A inFIG. 3) so as to be connected to each other through the hinge33. Engagement portions38aand38bare formed in divided surfaces37aand37bgenerated due to the two-part structure.

InFIG. 4,FIGS. 6A and 6B,FIGS. 7A and 7BandFIG. 8, the external exposure portion31is formed into a shape with which the external exposure portion31can hold the two electrically conductive paths22in a state in which the two electrically conductive paths22are arranged side by side adjacently. In addition, the electrically conductive path penetrating portions34aand34bare formed into shapes with which the electrically conductive path penetrating portions34aand34bmake contact with (tight contact with) the outermost layers (braids28) of the electrically conductive paths22. Therefore, the electrically conductive path penetrating portions34aand34bare formed into semicircular recesses respectively. The electrically conductive path penetrating portions34aand34bare formed as portions which do not cause looseness in the two electrically conductive paths22. Incidentally, the reference signs39aand39bdesignate second blocking portion extension parts.

<About Second Blocking Portion Extension Parts39aand39b>

InFIG. 3,FIG. 4,FIG. 6BandFIG. 8, the second blocking portion extension parts39aand39bare parts in which second blocking portions41aand41bwhich will be described later are extended to the position of the external exposure portion31. The second blocking portion extension parts39aand39bare formed into convex shapes fitted to gaps between the two electrically conductive paths22arranged side by side (gaps generated like approximate ginkgo leaf shapes in section between the two electrically conductive paths22when the two electrically conductive paths22are arranged side by side). The second blocking portion extension parts39aand39bare formed as the same function portions as the second blocking portions41aand41bwhich will be described later. Incidentally, since the second blocking portions41aand41bwhich will be described later are provided, formation of the second blocking portion extension parts39aand39bmay be optional (it is a matter of course that it is preferred to form the second blocking portion extension parts39aand39b).

InFIGS. 3 to 5,FIGS. 6A and 6BandFIGS. 7A and 7B, the first blocking portions35aand35bserving as a characteristic portion of the invention are disposed on a side opposed to the end portion24of the exterior member23. The first blocking portions35aand35bare formed as portions which abut against the end portion24to block the end portion24, as described above. The first blocking portions35aand35bare formed into annular planes (formed into planar shapes. In addition thereto, the first blocking portions35aand35bmay have annular groove shapes or annular step shapes into which the end portion24can be inserted).

Incidentally, in the Example, a bellows recess portion of the exterior member23is formed as the end portion24. However, the invention is not limited thereto. Alternatively, a bellows protrusion portion of the exterior member23may serve as the end portion24. The first blocking portions35aand35bare formed as portions which prevent, for example, sand etc. from intruding into (the internal portion of) the exterior member23from the outside even if the sand etc. tries to intrude.

InFIGS. 4 to 8, the engagement portions38aand38bare formed as concavely and convexly shaped portions disposed on the divided surfaces37aand37b. The concavely and convexly shaped engagement portions38aand38can be engaged with each other respectively, for example, by press fitting, so as to maintain a surface contact state between the divided surfaces37aand37b. The engagement portions38aand38bare formed as portions for restraining the external exposure portion31from returning to its divided state even when the hinge33is broken (As long as the external exposure portion31can be restrained from returning to its divided state, the state in which sand etc. is prevented from intruding into the exterior member23can be maintained). Incidentally, the illustrated shapes of the engagement portions38aand38bare exemplary. As long as the engagement portions38aand38bcan retrain the external exposure portion31from returning to its divided state, the shapes of the engagement portions38aand38bis not limited particularly. The engagement portions38aand38baccording to the Example are formed in positions opposite to and separate from the hinge33.

InFIGS. 3 to 10, the internal insertion portion32is continuous to the external exposure portion31and formed into a substantially circularly columnar portion which is smaller in diameter than the external exposure portion31. In addition, the internal insertion portion32is formed as a portion which has a diameter fitted to an internal diameter of the end portion24of the exterior member23, and which is inserted into the exterior member23. Electrically conductive path penetrating portions40aand40bwhich are penetrated by the two electrically conductive paths22, the second blocking portions41aand41bwhich are continuous to the electrically conductive path penetrating portions40aand40b, and a pair of electrically conductive path exposing slits42aand42bare formed in such an internal insertion portion32. Incidentally, the reason why the reference signs are separated into one suffixed with “a” and the other suffixed with “b” is that the exterior end portion cap25has the two-part structure as described above, and the internal insertion portion32is therefore also formed into a two-part structure (two-divided structure). In the internal insertion portion32, the reference sign43adesignates an upper divided part, and the reference sign43bdesignates a lower divided part. The upper divided part43aand the lower divided part43bare formed, for example, into substantially semicircularly columnar shapes respectively.

Tapered surfaces44aand44bguided by the end portion24of the exterior member23are formed at insertion front end portions of the internal insertion portion32inserted into the exterior member23. In addition, a detachment preventing portion45hooked on an inner surface of the exterior member23is formed at one place on an outer surface of the internal insertion portion32.

InFIGS. 5 to 8, the internal insertion portion32is formed into a shape with which the internal insertion portion32can hold the two electrically conductive paths22in a state in which the two electrically conductive paths22are arranged side by side adjacently. In addition, the electrically conductive path penetrating portions40aand40bare formed into shapes with which the electrically conductive path penetrating portions40aand40bmake contact with (make tight contact with) the outermost layers (braids28) of the electrically conductive paths22. The electrically conductive path penetrating portions40aand40bare formed into shapes of semicircular recesses respectively. In addition, the electrically conductive path penetrating portions40aand40bare also formed into shapes serving as retention portions which do not cause looseness in the two electrically conductive paths22.

InFIG. 3andFIGS. 5 to 8, the second blocking portions41aand41bserving as a characteristic portion of the invention are formed and disposed to be continuous to the electrically conductive path penetrating portions40aand40b, as described above. In addition, the second blocking portions41aand41bare formed so that the second blocking portion extension parts39aand39bin the external exposure portion31are also continuous to the second blocking portions41aand41b. The second blocking portions41aand41bare formed into convex shapes fitted to the gaps between the two electrically conductive paths22arranged side by side (the gaps generated like approximate ginkgo leaf shapes in section between the two electrically conductive paths22when the two electrically conductive paths22are arranged side by side). The second blocking portions41aand41bare formed as portions which prevent, for example, sand etc. from intruding into (the internal portion of) the exterior member23from the outside (from the aforementioned gaps) even if the sand etc. tries to intrude.

<About One Pair of Electrically Conductive Path Exposing Slits42aand42b>

InFIGS. 4 and 5,FIGS. 6A and 6B,FIGS. 7A and 7B, andFIGS. 9 and 10, the pair of electrically conductive path exposing slits42aand42bserving as a characteristic portion of the invention are formed as portions which can expose portions46of the outermost layers (braids28) of the electrically conductive paths22in line with the positions of the divided surfaces37aand37band in a pipe axial direction. In addition, the pair of electrically conductive path exposing slits42aand42bare formed also as portions in which the portions46can be brought into contact with an inner surface47of the exterior member23present in the vicinity of the end portion24. In the Example, the pair of electrically conductive path exposing slits42aand42bare formed and disposed all over positions of two, left and right side portions of the internal insertion portion32. The pair of electrically conductive path exposing slits42aand42bare formed into the illustrated slit shapes. Such a pair of electrically conductive path exposing slits42aand42bare formed as portions for making the portions46of the electrically conductive paths22function as third blocking portions48.

Incidentally, the function as the third blocking portions48is a function for preventing, for example, sand etc. from intruding into (the internal portion of) of the exterior member23from the outside even if the sand etc. tries to intrude. That is, the first blocking portions35aand35b, the second blocking portions41aand41band the third blocking portions48have the same function.

The internal insertion portion32has a structure in which the portions46of the electrically conductive paths22are made to function as the third blocking portions48. With this structure, the external diameter of the internal insertion portion32can be hence minimized. Therefore, it can be said that the internal insertion portion32has the structure effective in reducing the size.

InFIG. 3andFIGS. 5 to 8, the tapered surfaces44aand44bare formed as portions guided by the end portion24of the exterior member23, as described above, in order to contribute to reduction of an insertion load. The tapered surfaces44aand44bare formed to be inclined at a predetermined angle in each of the insertion front end portions of the internal insertion portion32.

InFIGS. 3 to 5,FIGS. 7A and 7BandFIGS. 9 and 10, the detachment preventing portion45is a convex portion hooked on the inner surface of the exterior member23, as described above. In the Example, the detachment preventing portion45is formed into a semispherical shape (As long as the detachment preventing portion45can be hooked, the shape of the detachment preventing portion45is not limited particularly). The detachment preventing portion45is formed and disposed at only one place on the outer surface of the lower divided part43b. In addition, the detachment preventing portion45is formed and disposed on a side near the external exposure portion31. Incidentally, the reason why the detachment preventing portion45is formed at one place is that an insertion load imposed on the exterior member23can be reduced. In addition, the reason why the detachment preventing portion45is formed into the semispherical shape is also that the insertion load can be reduced.

<About Attachment of Exterior End Portion Cap25>

InFIGS. 3 to 10, the exterior end portion cap25is attached to the two electrically conductive paths22arranged side by side, so as to hold predetermined positions of the two electrically conductive paths22from the illustrated upper and lower sides with the hinge33as a rotation center, and to engage the engagement portions38aand38bof the divided surfaces37aand37bwith each other respectively when the exterior end portion cap25holds the predetermined positions of the two electrically conductive paths22. On this occasion, the gaps between the two electrically conductive paths22arranged side by side are blocked by the second blocking portions41aand41bof the internal insertion portion32and the second blocking portion extension parts39aand39bof the external exposure portion31.

The exterior end portion cap25is set into a state where it can be inserted from the insertion front end portion side of the internal insertion portion32, i.e. from the side where the tapered surfaces44aand44bare provided. In such a state, the exterior end portion cap25is attached to the end portion24of the exterior member23. To attach the exterior end portion cap25to the end portion24, the outer surface (outer circumferential surface) of the internal insertion portion32and the portions46of the electrically conductive paths22exposed from the pair of electrically conductive path exposing slits42aand42bmove while sliding against the inner surface47(pipe inner surface (inner circumferential surface)) of the exterior member23. Then, the detachment preventing portion45of the internal insertion portion32passes through the end portion24of the exterior member23while slightly pushing and expanding the end portion24, so that the detachment preventing portion45is fitted into the recess of the inner surface47of the exterior member23. As soon as the detachment preventing portion45is hooked on the recess of the inner surface47to be prevented from being detached therefrom, the first blocking portions35aand35bof the external exposure portion31abut against (make surface contact with) the end portion24of the exterior member23. That is, as shown inFIG. 3andFIGS. 7A and 7B, the end portion24of the exterior member23is blocked by the first blocking portions35aand35bof the external exposure portion31. In addition, the inner surface47of the exterior member23is also blocked by the outer surface of the internal insertion portion32and the third blocking portions48.

<About Manufacturing to Path Routing of Wire Harness9>

In the aforementioned configuration and structure, a wire harness9is manufactured in the following manner (e.g. seeFIG. 2andFIG. 3). That is, the wire harness9is manufactured by inserting two electrically conductive paths22from an opening at one end of an exterior member23toward an opening at the other end of the exterior member23. The exterior member23is molded substantially linearly as a whole out of a resin. In addition, the wire harness9is manufactured by attaching clamps C, grommets, boots, etc. to predetermined positions of an outer surface of the exterior member23. Further, the wire harness9is manufactured by providing shield connectors14on terminal portions of the electrically conductive paths22.

Incidentally, it is a matter of course that the exterior end portion cap25can be attached to the exterior member23before the two electrically conductive paths22are inserted through the exterior member23. Alternatively, after the two electrically conductive paths22are inserted through the exterior member23, the exterior end portion cap25may be attached once in the vicinity of the end portion24and then slid to be attached to the end portion24.

After the wire harness9is manufactured in the aforementioned manner, predetermined flexible pipe portions29are bent to be folded. Thus, packing of the wire harness9is completed. The wire harness9in the packed state is compact so that the wire harness9can be transported in such a compact state to a vehicle assembling site.

In the vehicle assembling site, the wire harness9is attached to an attachment subject44(structure body) of a vehicle, starting at a long portion corresponding to a vehicle underfloor11. A longest straight pipe portion30of the exterior member23in the wire harness9is disposed on the long portion corresponding to the vehicle underfloor11. Accordingly, the wire harness9is attached in a state in which flexure of the wire harness9is suppressed. On this occasion, the wire harness9is attached with excellent workability. After the long portion corresponding to the vehicle underfloor11is fixed by the clamps C etc., the remaining portion of the exterior member23is attached while the flexible pipe portions29are flexed (bent). When a series of works relevant to the attachment are completed, the wire harness9is routed in a desired path.

<About Advantageous Effects of Invention>

When each of the exterior end portion caps25is used as described above with reference toFIGS. 1A and 1BandFIGS. 2 to 10, sand etc. can be prevented from being easily intruding into the exterior member23in comparison with a case where, for example, only taping is applied to the end portion of the exterior member. Accordingly, according to the invention, an effect that damage on the electrically conductive path22inside the exterior member23can be prevented is obtained.

Incidentally, as to a modification of the invention, taping50may be applied, as shown inFIG. 11(application of the taping50is optional). In addition, a clip portion51(fixation piece) may be provided integrally on the outer circumferential surface of the external exposure portion31, as shown inFIG. 12. The clip portion51is formed as a portion for fixing the exterior member23to an attachment subject49(structure body) during path routing.

Moreover, although not shown particularly, the invention can be also applied to a case where the sectional shape of the exterior member is elliptical, and, for example, three (or four or two) electrically conductive paths are arranged side by side and laterally in a line.

Here, the above embodiments are summarized as follows.

(1) There is provided an exterior end portion cap to be attached to at least two electrically conductive paths and an exterior member having a tubular shape, and the at least two electrically conductive paths being led out from the exterior member, the exterior end portion cap including:

an external exposure portion having a first blocking portion and configured to be exposed to an outer side of the exterior member; and

an internal insertion portion having a second block portion, being continuous to the external exposure portion, and configured to be inserted into the exterior member, wherein:

the internal insertion portion has an electrically conductive path exposing slit by which a part of outer surfaces of the at least two electrically conductive paths can be made to function as a third blocking portion when the internal insertion portion is attached to the at least two electrically conductive paths;

the first blocking portion is disposed on a side to which the internal insertion portion is continuous, and has a planar portion configured to abut against an end portion of the exterior member;

the second blocking portion has a convex portion that is disposed so as to face to the at least two electrically conductive paths arranged side by side and that is fitted to a gap between the at least two electrically conductive paths arranged side by side;

the exterior end portion cap is configured to be divided into two divided parts for holding the at least two electrically conductive paths each shaped like a circle in section therebetween; and

the electrically conductive path exposing slit is disposed in a position corresponding to a position of a divided surface of the two divided parts and is formed so as to bring the part of the outer surfaces of the at least two electrically conductive paths into contact with an inner surface of the exterior member near the end portion of the exterior member in order to make the part of the outer surfaces of the at least two electrically conductive paths functions as the third blocking portion.

(2) For example, the exterior end portion cap further includes a hinge that connects the two divided parts, and concavely and convexly shaped engagement portions are formed on first end portions of divided surfaces of two divided parts, second end portions of the divided surfaces of two divided parts are opposed to the first end portions and are closer to the hinge than the first end portions.
(3) For example, a detachment preventing portion configured to be engaged with the inner surface of the exterior member is provided on an outer surface of the internal insertion portion.
(4) For example, a tapered surface configured to be guided by the end portion of the exterior member is formed at an insertion front end portion of the internal insertion portion configured to be inserted into the exterior member.
(5) For example, a fixation piece for fixing the exterior member to a structure body during path routing is provided integrally on an outer surface of the external exposure portion.

In addition, there is provided a wire harness including:

an exterior member having a tubular shape;

at least two electrically conductive paths that are arranged side by side and that are protected by the exterior member; and

the exterior end portion cap according to any one of above first to fifth configurations that is attached to the at least two electrically conductive paths arranged side by side and the end portion of the exterior member.

According to the above item (1), the end portion of the exterior member can be blocked by the first blocking portion of the exterior end portion cap. In addition, the gap between the electrically conductive paths arranged side by side can be also blocked by the second blocking portion of the exterior end portion cap. Further, the inner surface (inner surface in line with the positions of the divided surfaces) of the exterior member can be also blocked by the portion (functioning as the third blocking portion) of the electrically conductive paths exposed from the pair of electrically conductive path exposing slits of the exterior end portion cap. By the first to third blocking portions, for example, sand etc. can be prevented from intruding into the exterior member from the outside even if the sand etc. tries to intrude. Accordingly, when the exterior end portion cap according to the invention is used, an effect that sand etc. can be prevented from easily intruding into the exterior member is obtained, in comparison with a case where, for example, only taping is applied. According to the invention as understood from the above description, since the sand etc. is absent from the inside of the exterior member, an effect that the electrically conductive paths can be prevented from being damaged easily is obtained even when the electrically conductive paths shake, for example, due to vibration during running. Moreover, according to the invention, since the exterior end portion cap having the two-part structure is used, an effect that the exterior end portion cap can be easily attached to the electrically conductive paths arranged side by side is also obtained. In addition, according to the invention, an effect that the electrically conductive paths can be retained in an immovable state or an effect that the electrically conductive paths can be disposed substantially at the center of the exterior member is also obtained.

According to the above item (2), the two divided parts of the exterior end portion cap are connected to each other through the hinge. With this configuration, an effect that the exterior end portion cap can be managed easily without increasing the number of components is obtained. In addition, according to the invention, the concavely and convexly shaped engagement portions are formed on the divided surfaces and engaged with each other, for example, in a press-fitted state. With this configuration, the exterior end portion cap can be prevented from returning to its divided state easily even when the hinge is broken. As a result, an effect that the state in which the sand etc. is prevented from intruding into the exterior member can be maintained is also obtained

According to the above item (3), the detachment preventing portion is formed on the outer surface of the internal insertion portion. With this configuration, an effect that the detachment preventing portion can be hooked on the inner surface of the exterior member when the exterior end portion cap is inserted into the exterior member is obtained. Accordingly, according to the invention, an effect that the exterior end portion cap can be prevented from being detached is obtained. Moreover, according to the invention, since the detachment preventing portion is formed at one place, an effect that insertion work becomes easier to consequently contribute to reduction of an insertion load is also obtained in comparison with a case where a plurality of detachment preventing portions are provided.

According to the above item (4), the tapered surface is formed at the insertion front end portion of the internal insertion portion. With this configuration, the tapered surface is guided by the end portion of the exterior member when the internal insertion portion is inserted into the exterior member. As a result, an effect that the provision of the tapered surface can contribute to reduction of the insertion load is obtained.

According to the above item (5), the fixation piece is provided integrally on the outer surface of the external exposure portion. Accordingly, when the fixation piece is configured to, for example, function as a clamp or clip portion, an effect that the exterior member can be fixed to the structure body during the path routing without using any other fixation component which is required to be retrofitted is obtained.

According to the above item (6), there is provided the wire harness is configured to include the exterior end portion cap. With this configuration, for example, sand etc. can be prevented from intruding into the exterior member from the outside even if the sand etc. tries to intrude. As a result, an effect that damage on the electrically conductive paths inside the exterior member can be prevented is obtained.

It is a matter of course that the invention can be changed and carried out variously without departing from the gist of the invention.