Patent ID: 8752286

Claim:
A method of manufacturing a wire harness comprising a plurality of wires and a connector with a housing for holding end portions of the plurality of wires, the method comprising: arranging the plurality of wires in an insertion hole of an airtight block of the housing to have a gap between the plurality of wires and an inner surface of the insertion hole, the insertion hole being formed in the airtight block for inserting the plurality of wires therethrough; supplying a molten resin having a fluidity into the gap through a flow channel in communication with the gap; and solidifying the molten resin inside a space to resin-seal the gap between the insertion hole and the plurality of wires, wherein the supplying of the molten resin is conducted such that a tool for melting a solid resin member is attached to the airtight block, the resin member is melted by applying an ultrasonic vibration while being pressed against the tool, and the molten resin obtained by the melting is poured into the flow channel, wherein the tool comprises a holding hole for holding a shaft-shaped resin member so as to be movable in an axis direction thereof, a lead-out path for guiding the molten resin to an outside of the tool, and a melting zone provided between the holding hole and the lead-out path to melt the resin member, and wherein the melting zone comprises a receiving surface against which the resin member is pressed so as to be melted by frictional heat generated by friction between the resin member and the receiving surface.