Electricity: conductors and insulators – Conduits – cables or conductors – Insulated
Reexamination Certificate
2001-11-21
2003-03-04
Nguyen, Chau N. (Department: 2831)
Electricity: conductors and insulators
Conduits, cables or conductors
Insulated
Reexamination Certificate
active
06528731
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a flat shield harness having a function of shielding noise.
2. Description of the Related Art
A motor car that is a moving body includes a wire harness arranged to supply power from a power source such as a battery to electronic appliances such as various lamps and various motors mounted in the motor car, and feed a control signal to these appliances from a control device. The wire harness is composed of a plurality of electric wires. For example, a flat harness as shown in
FIGS. 19 and 20
has been used as the wire harness.
As seen from
FIGS. 19 and 20
, a flat harness
101
is composed of a plurality of electric wires
102
in parallel to one another, a single drain wire
103
, a metallic film
104
and a sheath
105
. The electric wires
102
each consists of a conductive core
110
and a cladding
111
that clads the core
110
. The core
110
is formed in a round shape in section, and made of copper or copper alloy. The cladding
111
is made of insulating synthetic resin. The plurality of electric wires
102
are arranged in parallel. Therefore, the cores
110
are also arranged in parallel.
The drain wire
103
is arranged in parallel to the plurality of electric wires. The drain wire
103
is formed in a round shape in section and made of conductive metal such as copper or copper alloy. The metallic film
104
is made of conductive metal such as copper or copper alloy, and formed as a thin film. The metallic film
104
covers the claddings
111
of all the electric wires
102
and is kept in contact with the drain wire
103
.
The sheath
105
is made of insulting synthetic resin and sheathes the electric wires
102
, drain wire
103
and metallic film
104
. The flat harness
101
is formed in a belt in a state where the electric wires
102
and drain wire
103
are sheathed by the sheath
105
.
In the flat harness
101
, when external noise is about to invade the core
110
of each electric wire
102
, it conducts to metallic film
104
. The noise is dissipated outside the flat harness
101
through the drain wire
103
. Thus, the metallic film
104
of the flat harness
101
can prevent the external noise from invading the core
110
of each electric wire
102
.
Where the wire harness is assembled using the flat harness
101
as described above, each electric wire
102
is a “cladded electric wire” in which the electric wire is composed of the core
110
and the cladding
111
, and the drain wire
103
is a “bare electric wire” which consists of only the core. Therefore, when the cladding
111
of the electric wire
102
is removed after the sheath
105
has been removed, the processing for the drain wire
103
is not required. Thus, when the cladding
111
of each electric wire
102
is removed, the drain wire
103
may be curved so that it does not become parallel to the core
110
of each electric wire
102
as seen from FIG.
19
.
The cores
110
of the electric wires
102
, which are parallel to each other, can be subjected to the processing in which they are equipped with a terminal metallic fitting as a single unit using a known crimping, caulking or inserting device and inserted into a connector housing. However, where the drain wire
103
is not parallel to the core
110
of each electric wire
102
, it is difficult to connect the drain wire
103
to the terminal metal fitting using the above device.
Therefore, traditionally, the drain wire
103
was manually connected to the metal fitting by an operator, and each metal fitting was inserted individually into a connector housing. In this way, the conventional flat harness
101
increases a required number of man-hours in assembling the wire harness, which results in an increase in the production cost.
Further, in the above conventional technique, in order to dissipate the noise being about to invade the cores
110
of the electric wires, the drain wire
103
is connected to the thin metallic film
104
so that the contact therebetween becomes unstable in most cases. This makes it difficult to dissipate the noise trying to invade the core
110
of each electric wire
102
outside the flat harness
100
.
SUMMARY OF THE INVENTION
A first object of this invention is to provide a flat shield harness which can surely dissipate externally the noise which is about to invade the core of an electric wire and suppress an increase in the cost in the wire harness to be assembled.
A second object of this invention is to provide a method for manufacturing such a flat shield harness.
In order to attain the first object, in accordance with the first aspect of this invention, there is provided a flat shield harness comprising:
a flat harness including a plurality of first conductive cores arranged in parallel and an insulating cladding which clads the first conductive cores;
a thin film sheet having a thin film conductive layer; and
an electric wire including a second conductive core and a second cladding which clads the second core,
wherein the thin film sheet is wound around the outer periphery of the flat harness with its ends superposed in a width direction of the flat harness, the electric wire is superposed on the ends, and the conductive layer at the ends of the thin film sheet at the ends is bonded to the second core.
In the above configuration, the thin film sheet is wound around the outer periphery of the flat harness with its ends superposed in a width direction of the flat harness, the electric wire is superposed on the ends, and the conductive layer at the ends of the thin film sheet at the ends is bonded to the second core. Therefore, the electric wire can be used as a drain wire.
Since the second core is bonded to the conductive layer of the thin film sheet, an electric connection can be made surely therebetween. Further, since the electric wire is superposed on the ends superposed on each other, the position where the ends are to be formed can be optionally selected.
In the above configuration, preferably, the thin film sheet has a thin insulating layer laminated to the thin conductive layer, and the insulating layer of the thin film sheet at the ends and the second cladding of the electric wire are welded to each other. This improves the mechanical strength of the bonding portion between the conductive layer and the second core.
In the configuration, the flat shield harness, further comprises a metallic plate interposed between and fixed to the ends of the thin film sheet, and the second core is bonded to the conductive layer and the metallic plate. This improves the mechanical strength of the bonding portion between the conductive layer and the second core.
In accordance with the second aspect of this invention, preferably, the thin film sheet is divided into a plurality of sub-sheets, ends of the sub-sheets are superposed on each other in a width direction of the flat harness, and the electric wire is superposed on one of the ends of the sub-sheets. In this configuration also, since the second core is bonded to the conductive layer of the sub-sheet, an electric connection can be made surely therebetween. Further, since the electric wire is superposed on the ends superposed on each other, the position where the ends are to be formed can be optionally selected.
In accordance with the first aspect to attain the second object, there is provided a method for manufacturing a flat shield harness comprising the steps of:
winding the thin film sheet around the outer periphery of the flat harness so that the conductive layer is located inside and the insulating layer is located outside and ends of the thin film sheet are superposed on each other;
superposing the electric wire on the ends of the conductor thin film; and
bonding the second core of the electric wire to the conductive layer of the thin film sheet by ultrasonic welding.
In this method, because the ultrasonic welding is performed, it is not necessary to remove a part of the second core of the electric core when the electric wire is attached to the thin film sheet.
Further, si
Baba Akira
Murakami Kazuhiro
Tsuchiya Kimio
Watanabe Kazuhiko
Nguyen Chau N.
Yazaki -Corporation
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