Abstract:
In a first flat harness, a plurality of first conductive wires are covered with a first insulating cover. In a second flat harness, a plurality of second conductive wires are covered with a second insulating cover. The second flat harness is intersectingly superposed on the first flat harness. Each second conductive wire is welded to one of the first conductive wires at one of intersecting points of each second conductive wire and the first conductive wires, through the first insulating cover and the second insulating cover.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates to a wire harness and a vehicle module assembly incorporating the same.  
           [0002]    As a first related-art, a wiring circuitry disclosed in Japanese Patent Publication No. 9-29445A will be described with reference to FIGS. 9A and 9B.  
           [0003]    This wiring circuitry  100  is manufactured in the following manner. First, conductors (round wires)  120  are respectively positioned and held in receiving grooves  112  formed in an upper face  111  of a fixing jig  110  in a lattice-like pattern. Through holes  140  are formed at each intersection of the receiving grooves  112 . Next, a pair of tips  130  of a resistance welding machine or an ultrasonic welding machine are inserted into each through hole  140  are inserted into each through hole  140  respectively from the upper and lower sides of the fixing jig  110  such that the conductors  120  are press-joined together.  
           [0004]    Since the conductors  120  are prevented from being displaced out of position, the intersecting conductors  120  can be welded together with accuracy.  
           [0005]    However, the conductors  120  must be mounted one by one in the respective receiving grooves  112 , and this is cumbersome.  
           [0006]    As a second related-art, an installing structure for a wire harness used in a reinforce of a vehicle module assembly will be described with reference to FIG. 10.  
           [0007]    A wire harness  220  comprises a main wire portion  220   a,  and a branch wire portion  220   b  branching off therefrom. The main wire portion  220   a  is mounted on a side wall of a reinforce  210  of a vehicle module assembly  200 . The branch wire portion  220   b  is connected to a branch portion of the main wire portion  220   a  by a connector  230 . A connector  240  for connection to an electrical equipment is mounted on the other or distal end of the branch wire portion  220   b.    
           [0008]    In this configuration, since the electrical connection at each branch portion and the electrical connection to the electrical equipment can be all effected through the connectors  230  and  240 , required time for the installing operation can be reduced, and besides the reliability of the wiring can be enhanced.  
           [0009]    However, in this configuration, since an interruption is provided not only between the main wire portion  220   a  and the branch wire portion  220   b,  but also in the main wire portion  220   a  because of the provision of the connector  230  through which the main wire portion  220   a  is connected to the branch wire portion  220   b.  Therefore, it is necessary to provide a separate connector even in the main wire portion  220   a.    
           [0010]    Furthermore, in the case where the main wire or the branch wire comprises many conductors twisted together, a meticulous attention is needed when connecting the conductors respectively to predetermined connector terminals. Hence, there is a probability that increased time is required for mounting the connector.  
         SUMMARY OF THE INVENTION  
         [0011]    It is therefore an object of the present invention to provide a wiring circuitry which can be easily manufactured and can provide the wiring having a reduced number of connectors.  
           [0012]    It is another object of the present invention to provide a wire harness using the wiring circuitry and a vehicle module assembly incorporating the wire harness, which can reduce wiring labor, wiring length, installation spaces in the vehicle.  
           [0013]    In order to achieve the above objects, according to the present invention, there is provided a wire harness, comprising:  
           [0014]    a first flat harness, in which a plurality of first conductive wires are covered with a first insulating cover; and  
           [0015]    a second flat harness, in which a plurality of second conductive wires are covered with a second insulating cover, the second flat harness being intersectingly superposed on the first flat harness,  
           [0016]    wherein each second conductive wire is welded to one of the first conductive wires at one of intersecting points of each second conductive wire and the first conductive wires, through the first insulating cover and the second insulating cover.  
           [0017]    According to the present invention, there is also provided a wire harness, comprising:  
           [0018]    a plurality of first flat harnesses, each in which a plurality of first conductive wires are covered with a first insulating cover; and  
           [0019]    a plurality of second flat harnesses, each in which a plurality of second conductive wires are covered with a second insulating cover, each of the second flat harnesses superposed on the first flat harnesses so as to intersect the first flat wire harnesses;  
           [0020]    wherein each second conductive wire is welded to one of the first conductive wires of at least one first flat harness at least one of intersecting points of each second conductive wire and the first conductive wires, through the first insulating cover and the second insulating cover.  
           [0021]    According to the present invention, there is also provided a method of manufacturing a wire harness, comprising the steps of:  
           [0022]    preparing a first flat harness, in which a plurality of first conductive wires are covered with a first insulating cover;  
           [0023]    preparing a second flat harness, in which a plurality of second conductive wires are covered with a second insulating cover,  
           [0024]    superposing the second flat harness intersectingly on the first flat harness; and  
           [0025]    welding each second conductive wire to one of the first conductive wires at one of intersecting points of each second conductive wire and the first conductive wires, through the first insulating cover and the second insulating cover.  
           [0026]    In the above configuration, there is no need to prepare any special jig, so that the cost can be saved. And besides, since the conductive wires are covered with the insulating cover, there can be saved the time and labor for mounting the conductors one by one in jig exemplified in the related-art, thereby the operation efficiency can be improved.  
           [0027]    Preferably, the wire harness further comprises a connector provided on at least one of both longitudinal ends of the second flat harness.  
           [0028]    In this case, the second flat harness serves as a branch harness. Therefore, a connector connection between the branch harness and the other wire harness can be omitted.  
           [0029]    Preferably, the welding step is performed by at least one of ultrasonic welding, laser beam welding and thermal welding.  
           [0030]    In this case, the welding operation can be effected without the need for any special skill and technique.  
           [0031]    Preferably, the first conductive wires and the second conductive wires are so welded that at least one of the first flat harness and the second flat harness is foldable.  
           [0032]    In this case, the wire harness can be flexed in accordance with the wiring situation. For example, the flat harness can be mounted in a compact manner on the side wall face of the reinforce or the like.  
           [0033]    According to the present invention, there is also provided a vehicle module assembly incorporating the wire harness.  
           [0034]    In this case, the shortest wiring can be achieved in accordance with the car kind variation, so that the modularized design of various portions of the vehicle can be further improved. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0035]    The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein:  
         [0036]    [0036]FIG. 1 is a perspective view of a vehicle module assembly;  
         [0037]    [0037]FIG. 2 is a plan view showing a wiring circuitry according to a first embodiment of the invention;  
         [0038]    [0038]FIG. 3 is a plan view showing a wiring circuitry according to a second embodiment of the invention;  
         [0039]    [0039]FIG. 4 is a perspective view showing the wiring circuitry in which a part of a main flat harness is folded;  
         [0040]    [0040]FIG. 5 is an enlarged perspective view of a jig for manufacturing the wiring circuitry;  
         [0041]    [0041]FIG. 6 is a schematic plan view showing the arrangement of the jigs for manufacturing the wiring circuitry;  
         [0042]    [0042]FIG. 7 is a perspective view of a welding machine used for manufacturing the wiring circuitry;  
         [0043]    [0043]FIG. 8 is a system diagram of a positioning apparatus for manufacturing the wiring circuitry;  
         [0044]    [0044]FIGS. 9A and 9B are views showing a method of manufacturing a related-art circuitry; and  
         [0045]    [0045]FIG. 10 is a perspective view of a related-art vehicle module assembly. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0046]    Preferred embodiments of a wire harness according to the present invention, as well as a vehicle module assembly incorporating wire harness, will now be described in detail with reference to the accompanying drawings.  
         [0047]    As shown in FIG. 1, a vehicle module assembly  1  comprises a combination of a modularized reinforce  2 , a wire harness  5 , and an electrical equipment  18 . The reinforce  2  comprises a steel plate processed into an elongated member having an H-shaped cross section, and upper and lower faces  3   a  and  3   b  of a flange  3  are oriented horizontally, and a main flat harness  6 , serving as a main bus of the wire harness  5 , is fixedly mounted on one side face  4   a  of a web  4  by clips (not shown). Self-fitting connectors  9  are mounted respectively on distal ends of branch flat harnesses (branch wires)  7  branching off from the main flat harness  6 .  
         [0048]    The required number of branch flat harness  7  ( 7   a,    7   b  and  7   c ) are provided for connection to various electrical equipments  18 , and are joined to the main flat harness  6 . The positions of joint of the branch flat harnesses  7  to the main flat harness  6  are predetermined by the reinforce  2  modularized in accordance with the car kind variation.  
         [0049]    Electrical equipments  18  such as a multi-media type electrical equipment are attaches at predetermined positions provided on the main flat harness  6 . The self-fitting connectors  9   a,    9   b  and  9   c  of the branch flat harnesses  7   a,    7   b  and  7   c  are connected to respective associated electrical equipments during this attaching process.  
         [0050]    The main flat harness  6  extends between opposite (right and left) ends of the reinforce  2 , and the opposite end portions thereof are so processed as to be connected to electric junction boxes, respectively.  
         [0051]    The reinforce  2  is mounted on junction box brackets  10  which are provided respectively at opposite side portions of a vehicle body, and serve also as mounting portions for the reinforce  2 . At this time, wire harnesses (not shown) on the vehicle body can be connected to the main flat harness  6  at the junction box brackets  10  in a one-touch manner.  
         [0052]    A through hole  4   c  is formed through the web  4 , and this through hole  4   c  is used when extending the branch flat harness  7   b  from the instrument panel to the vehicle body side (the engine room side). A plurality of such through holes  4   c  are provided regularly in accordance with the car kind variation.  
         [0053]    [0053]FIG. 2 shows a wiring circuitry according to a first embodiment. In the circuitry, a wire harness  5  comprises a main flat harness  6  and a branch flat harness  7  and ( 6   a  and  6   b ) which are arranged in a lattice-like manner. The branch flat harnesses and the main flat harnesses are joined at predetermined intersections  8  (indicated by black dots in the figure).  
         [0054]    Each main flat harness  6 , extending in the horizontal direction, comprises a plurality of parallel juxtaposed conductors  11   a  spaced at a predetermined pitch, and an insulating material  12   a  covering these conductors  11   a,  the insulating material  12   a  being a flexible material.  
         [0055]    Similarly, each branch flat harness  7 , extending in the vertical direction, comprises a plurality of parallel juxtaposed conductors  11   b,  spaced at a predetermined pitch, and an insulating material  12   b  covering these conductors  11   b,  the insulating material  12   b  being a flexible material.  
         [0056]    [0056]FIG. 3 shows a wiring circuitry according to a second embodiment. In the circuitry, three branch flat harnesses  7  ( 7   a,    7   b  and  7   c ) and two main flat harnesses  6  ( 6   a  and  6   b ) which are arranged in a matrix-like manner. The branch flat harnesses and the main flat harnesses are joined at predetermined intersections  8  (indicated by black dots in the figure).  
         [0057]    Reference numerals  9   d  and  9   e  denote movable-type multi-pole connectors.  
         [0058]    Since the insulating material  12   a  is flexible, at least one of the main flat harnesses  6  and the branch flat harnesses  7  can be folded as shown in FIG. 4 in accordance with the required wiring situation. In this figure, the branch flat harness  7   a  is folded to bundle the main flat harnesses  6   a  and  6   b.  For the better understanding, only the branch flat harness  7   a  among the branch flat harnesses  7   a,    7   b  and  7   c  is depicted.  
         [0059]    [0059]FIGS. 5 and 6 shows a jig  20  for the main flat harness  6  and a jig  21  for the branch flat harness  21  which are used for manufacturing the wiring circuitry.  
         [0060]    As shown in FIG. 5, the jig  20  (which is similar to the jig  21  as shown in the figure) comprises a box-like member formed by hollowing out a long steel stock, and longitudinal openings  20   c  ( 21   c ) are formed respectively in upper and lower faces  20   a  and  20   b  ( 21   a  and  21   b ) thereof, and passage ports  20   d  ( 21   d ) are formed in opposite longitudinal ends thereof, respectively.  
         [0061]    The passage port  20   d  ( 21   d ) serves as an opening, through which the main flat harness  6  (the branch flat harness  7 ) is led out from the jig  20  ( 21 ), and also serves as an entry port for a torch of a welding machine (described later).  
         [0062]    On the other hand, the passage ports  20   d  ( 21   d ) serve as guide members for the insertion of the main flat harness  6  (the branch flat harness  7 ), and enable the welding machine to positively effect the joining operation, and also serve to prevent the flat harness  6  ( 7 ) in the matrix from meandering and rising halfway.  
         [0063]    In order to more positively prevent such meandering and halfway-rising, clip devices (not shown) may be provided adjacent respectively to the passage ports  20   d  ( 21   d ) so as to support the flat harness  6  ( 7 ) so that the flat harness  6  ( 7 ) can be made tense within the passage ports  20   d  ( 21   d ) provided respectively at the opposite ends of the jig.  
         [0064]    [0064]FIG. 6 corresponds to FIG. 3, and the jigs  20  for the main flat harnesses  6  are fixed to a square frame (not shown), while the jigs  21  for the branch flat harnesses  7  are movable in a direction of an X-axis of coordinates in this figure.  
         [0065]    [0065]FIG. 7 is a perspective view of the welding machine  30  for joining the conductors  11   a  and  11   b  of the main and branch flat harnesses  6  and  7 , and FIG. 8 is a schematic diagram of a system for driving the welding machine  30  and the jigs  20  ( 21 ) simultaneously and relative to each other so as to effect the working.  
         [0066]    In the welding machine  30 , the laser torch  31  for effecting the laser beam welding is fixedly mounted on and extends downwardly from a lower face of a movable X-Y table  33 . An X-axis direction servomotor  34  and a Y-axis direction servomotor  35 , which provide a drive system, are mounted on the movable X-Y table  33 , and with these servomotors, a nozzle  32  of the laser torch  32  can be located sequentially at the intersections of the conductors  11   a  and  11   b  of the main and branch flat wire harnesses  6  and  7  (at each of which the conductors  11   a  and  11   b  are to be joined together) in coordinate relation to the movement of the jig  20  ( 21 ).  
         [0067]    A control system for driving the movable X-Y table  33  includes a laser beam oscillator  36  for emitting a laser beam, and a laser control power source  37  for supplying electric power to the laser beam oscillator  36 .  
         [0068]    With respect to a control system for driving the X-axis direction servomotor  34  and the Y-axis direction servomotor  35 , an X-axis servo-amplifier  38  and a Y-axis servo-amplifier  39  are connected to the X-axis direction servomotor  34  and the Y-axis direction servomotor  35 , respectively, and the X-axis servo-amplifier  38  and the Y-axis servo-amplifier  39  are connected to a computer  40 . These amplifiers transmit a position signal, fed thereto from the computer  40 , so as to drive the X-axis direction servomotor  34  and the Y-axis direction servomotor  35  so that the nozzle  32  of the laser torch  31  can be moved into the intersection of the predetermined conductors  11   a  and  11   b.  In this manner, the microcomputer control is effected.  
         [0069]    On the other hand, servomotors  50  ( 50   a,    50   b  and  50   c ), servo-amplifiers  51  ( 51   a,    51   b  and  51   c ) and computers  52  ( 52   a,    52   b  and  52   c ) are provided at the jigs  20  ( 21 ) in order to move the jigs in coordinate relation to the movement of the laser torch  31 .  
         [0070]    The computer  40  and the computers  52  ( 52   a,    52   b  and  52   c ) are beforehand so set that when the position signal is inputted into the computer  40 , the computers  52  ( 52   a,    52   b  and  52   c ) compute this position signal so as to bring the intersection of the conductors  11   a  and  11   b  of the main and branch flat harnesses  6  and  7  (which are to be joined together) into vertical registry with the nozzle  32  of the laser torch  31 .  
         [0071]    Each servo system can effect the two-axis linear interpolation in combination with the computer, and can effect the high-speed, high-precision positioning.  
         [0072]    In this embodiment, although the laser beam welding machine, which can suppress the scattering of sputter, is used as the welding machine  30 , the welding machine is not limited to it, but an ultrasonic welding machine or a thermal welding machine may be used.  
         [0073]    A method of producing the above wire harness  5  will be briefly described, and then a method of using it will be described.  
         [0074]    First, the main flat harnesses  6  are passed respectively through the jigs  20 , and the branch flat harnesses  7  are passed respectively through the jigs  21 , thus effecting the presetting operation.  
         [0075]    Then, electric power is supplied, and the necessary positioning information is inputted into the computer  40  and the computers  52  ( 52   a,    52   b  and  52   c ). The essential input information includes the information relating a reference position on the X-axis relative to the origin of the coordinates and a move amount in the X-axis direction thereof. Since the position of each branch flat harness  7  relative to the main flat harnesses  6  is determined in accordance with the car kind variation, the above information is set in accordance with the variation.  
         [0076]    Namely, the modularized wire harness  5  is obtained by the above information. Then, the X-Y table  33  is moved to the intersection of the conductors  11   a  and  11   b  to be connected together.  
         [0077]    Then, a work table (not shown), supporting the harness fixing jigs  20  and  21 , ascends, so that the conductors  11   a  and  11   b  are pressed into contact with the nozzle  32  at their intersection, and after this is confirmed, the conductors  11   a  and  11   b  are welded together at their intersection by a laser beam. This welding operation is effected sequentially at the other intersections of the conductors  11   a  and  11   b  to be connected.  
         [0078]    When all of the required welding operations are thus completed, the movable X-Y table  33  is returned to its initial position, and the work table is also returned to its initial position.  
         [0079]    The main and branch flat harnesses  6  and  7 , thus welded together, are removed from their respective harness fixing jigs  20  and  21  through the opening  20   a  and  21   a.  The predetermined connectors are attached to the ends of each of the main and branch flat harnesses  6  and  7 , respectively, thus providing the desired wire harness  5 .  
         [0080]    The suitable output of the laser beam oscillator  36  for effecting the welding is 20 to 50 [J].  
         [0081]    In the above operation process, the operation for mounting the conductors  11   a  and  11   b  one by one in the jigs can be omitted, and besides the conductors  11   a  and  11   b  to be connected together can be automatically connected together by welding.  
         [0082]    The thus prepared wire harness  5  is fixed to the one side face  4   a  of the web  4  of the reinforce  2  by the clips (not shown). Then, the electrical equipments  18 , a center brace and so on are mounted respectively on predetermined portions of the reinforce  2 , thereby forming a sub-assembly.  
         [0083]    Then, the reinforce  2  is mounted on the instrument panel body having meter-indicating portions and switch-indicating portions mounted thereon. In this manner, the instrument panel module is formed.  
         [0084]    The junction box brackets  10 , serving also as the mounting portions for mounting on the vehicle body, are beforehand fixedly secured to this vehicle body by welding or by screws. The junction box brackets  10  have grooves for fitting on the opposite end portions of the flange portions  2   a  and  2   b  of the reinforce  2 .  
         [0085]    The instrument panel module is fitted in these grooves, and by doing so, this module is mounted on the vehicle body.  
         [0086]    The multi-pole connectors  9   d  ( 9   e ), provided respectively at the opposite ends of each main flat harness  6 , are connected to the wire harnesses, installed on the vehicle body, at the electric junction box brackets  10  in a one-touch manner by self-fitting connection.  
         [0087]    As described above, the wire harness  5  is incorporated in the reinforce  2  forming the vehicle module assembly, and by doing so, the electric wiring in the vehicle module assembly can be provided in a labor-saving manner, and the efficiency of the operation can be enhanced.  
         [0088]    Although the present invention has been shown and described with reference to specific preferred embodiments, various changes and modifications will be apparent to those skilled in the art from the teachings herein. Such changes and modifications as are obvious are deemed to come within the spirit, scope and contemplation of the invention as defined in the appended claims.