WO2012014548A1 - Netted protective material for wire harnesses and manufacturing method for same - Google Patents

Abstract

Provided is a netted protective material for wire harnesses that has protective qualities and noise-reduction qualities. The netted protective material is characterized by being a sheet or tube comprising two layers, the outer-surface material and inner-surface material both being netted, wherein the netting of the outer-surface material and inner-surface material is achieved by pressure hot-melt bonding the intersections of vertical strands and horizontal strands, both of which are formed by resin wires; the outer surface of the inner-surface material and the inner surface of the outer-surface material are adhered together; and the cut edges are fray-proofed.

Description

Net-like protective material for wire harness and manufacturing method

The present invention relates to a net-like protective material for a wire harness that is routed in a vehicle and a method for manufacturing the net-like protective material, and the net-like protective material is composed of a sheet or tube that is sheathed on the outer peripheral surface of a wire group of a wire harness. Is.

Conventionally, to bind and protect the wires in the wire harness that is routed to the vehicle, to prevent interference with external interference materials, and to buffer the wires, wrap adhesive tape around the wires, or wrap around a tube such as a corrugated tube or round tube. Through the wire group.
Conventionally, a vinyl chloride tape has been widely used as an exterior material composed of these tapes and tubes, and polypropylene or the like has been used as a corrugated tube, both of which are made of resin.
Further, a net tube made of a resin yarn proposed in Japanese Utility Model Laid-Open No. 4-21119 is also used.

Net tube uses less resin and can be reduced in weight, contributing to improved fuel efficiency. Also, it has excellent stretchability and flexibility, and has an advantage that the wire harness can be easily passed and the wire harness can be easily bent along the route.

On the other hand, the protection function of the net tube is reduced because the wire group is exposed in the hole of the net as compared with the case where the wire harness is inserted into the closed cross-sectional space in the corrugated tube or the cylindrical tube. In addition, since the thickness is relatively thin and relatively hard, the cushioning property is inferior at the time of contact with the interference member, noise is likely to occur, and there is room for improvement in wear resistance.
Further, the conventional net tube is formed in a net shape by knitting warp and weft to reverse adjacent intersections and warp and weft. Therefore, the bonding force between the warp and the weft at the intersection is weak. Therefore, there is a problem that when the tensile force or tearing force is applied to the intersection point, it is easy to be released from the cutting opening, and peeling at the intersection point, so-called breakage occurs, and the shape retention force is low.

ACT No.4-211119

The present invention has been made in view of the above problems, and is relatively thick and imparts cushioning properties to enhance the protective function and enhance the noise prevention effect. Further, fraying does not occur from the cutting opening and does not peel off at the intersection. An object of the present invention is to provide a net-like protective material composed of a wire harness sheet or a tube having increased bonding strength.

In order to solve the above-mentioned problems, the present invention comprises a two-layer tube or sheet composed of an inner surface material and an outer surface material each having a net shape,
The inner surface material and the outer surface material are formed into a net shape by pressurizing and fusing the intersections of the vertical and horizontal lines made of resin wires, respectively, and the outer surface of the inner surface material and the inner surface of the outer surface material are fused. A net-like protective material for a wire harness is provided, which is frayed at the cut end.

As described above, since the net-like protective material made of the sheet or tube of the present invention is composed of a flame-retardant resin wire, it can be externally mounted on a wire harness routed in the engine room of the vehicle. In addition, since the net-like inner surface material and the net-like outer surface material are laminated, the thickness can be increased, and the cushioning property and wear resistance can be improved as compared with a single-layer net material. it can.

It is preferable that the outer surface material and the inner surface material have different material, thickness, hardness, and / or mesh size of the resin wire material, and the inner surface material and the outer surface material are different types of net materials.
Thus, by changing the physical properties of the outer surface material and the inner surface material, it is possible to easily obtain a net-shaped protective material having various characteristics, and to make an appropriate protective material according to the wiring conditions of the wire harness. it can.

The thickness of each vertical and horizontal line may be changed within a range of 0.4 to 0.8 mm, for example, so that the inner surface material is thin and the outer surface material is thick.
The shape of each hole surrounded by the vertical and horizontal lines is a square, rectangle, rhombus, hexagon, or a circle of any one of a perfect circle, an ellipse, and an ellipse. And the size may vary. The shape of the holes is adjusted according to the required stretchability and strength. For example, the inner surface material may have a small hole, and the outer surface material may have a large hole.

In particular, it is preferable that the outer surface material and the inner surface material are made of a thermoplastic material, and the outer surface material has a cushioning property than the inner surface material by including a foam material.

The flame retardant resin wire constituting the inner surface material and the outer surface material is made of polypropylene, polyester, polyethylene, polyethylene terephthalate, polyamide, polyphenylene ether, polybutylene terephthalate, polyphenylene sulfide, or a non-halogen selected from a mixture of two or more thereof. Flame retardant selected from bromine, phosphate ester, metal hydroxide, melamine is blended with one or more resin components, and
The vertical and horizontal lines made of the flame-retardant resin wire are overlapped up and down at intersections without knitting, and either or both of the vertical and horizontal lines are melted by 40% to 50% of the cross-sectional area. It is preferable that they are fused to each other in a state of being embedded in the counterpart fiber.

As described above, the outer peripheral surface is not welded by line contact at the intersection of the vertical and horizontal lines, and the vertical and horizontal lines have an elliptical cross section, and one or both of the wires are embedded in the counterpart wire. When they are fused together, they are firmly fixed. Therefore, even if a tensile force or tearing force is applied to the net-shaped protective material, the connection between the vertical and horizontal lines will not be peeled off at the intersections, no breakage will occur, the shape retention force is strong, and the reliability as a net-shaped protective material is high. It will be expensive.
As the resin component, polypropylene is most preferably used from the viewpoint of processability and cost.

The vertical and horizontal lines of the present invention are not knitted so that adjacent intersections are upside down, but formed into a net shape with a sizing machine described later, for example, the vertical lines are on the upper side, the horizontal lines are on the lower side, The intersections of the vertical and horizontal lines are brought into surface contact, and as described above, they are fused so as to be embedded in the mating wire.

As described above, the net-like protective material of the present invention is composed of a two-layer tube or sheet composed of an inner surface material and an outer surface material,
The sheet is bent in a cylindrical shape that wraps at both ends in the width direction, and
The tube is formed by heat-sealing the edges in the width direction of one sheet.

Furthermore, the present invention is a method for producing the net-like protective material,
The sizing machine is provided with an inner die forming die set and an outer die forming die set consisting of an out die and an in die,
The outer surface material forming die set is arranged as an upper stage, and the inner surface material forming die set is arranged coaxially as a lower stage,
A net-like outer surface material is formed from the vertical and horizontal lines spun from the upper outer surface material forming die set, and the inner surface of the outer surface material is spun from the lower inner surface material forming die set. A method for producing a net-like protective material for a wire harness in which a net-like inner surface material is formed by the vertical line and the horizontal line, and the outer surface of the inner surface material is brought into contact with the inner surface of the outer surface material on the outer periphery and fused. providing.

The inner surface material and outer surface material spun from the die set are net-like continuous sheets,
The net-like sheet is cut into a required length, and both ends of the cut net-like sheet in the width direction are wrapped so as to have a cylindrical shape.

The net-like protective material of the present invention is wound around the outer circumference of the wire group of the wire harness, and is fixed to the wire group by winding an adhesive tape around both ends in the length direction.

As described above, the net-like protective material made of the sheet or tube for the wire harness of the present invention has a shape in which a net-like inner surface material and a net-like outer surface material are laminated, so that the thickness is increased. Cushioning can be improved. In addition, because the vertical and horizontal lines made of flame-retardant resin wire are fused at the intersection, it can be used as an exterior material for wire harnesses that are required to be flame-retardant in the vehicle engine room. Even when a tensile force or a tearing force is applied to the shape protective material, the connection between the vertical and horizontal lines is not peeled off at the intersection, and no breakage occurs, and a net-shaped protective material having a strong shape retention force can be obtained.
Furthermore, by using the net shape, the weight can be reduced to ½ or less as compared with a conventional resin round tube.

It is a perspective view which shows the lamination | stacking net sheet of 1st Embodiment of this invention. (A) is a plan view of the inner surface material, (B) is a plan view of the outer surface material, and (C) is a cross-sectional view in a laminated state. (A) is a perspective view showing a flame-retardant resin wire that becomes a vertical line and a horizontal line, (B) is a perspective view showing a state in which the vertical line and the horizontal line are overlapped, (C) is an enlarged view of the intersection of the vertical and horizontal lines is there. (A) is an overall schematic diagram of a sizing machine, (B) is a perspective view of an outer surface material forming die set, and (C) is a perspective view of an inner surface material forming die set. It is an enlarged view of a die set part. It is drawing which each shows the process of shaping a net-like sheet | seat in circular arc shape. (A) (B) (C) is drawing which shows embodiment of the net-shaped tube of 2nd Embodiment.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
The net-like protective material of the first embodiment shown in FIG.
The laminated net sheet 1 is a laminate of a net-like inner surface material 2 and a net-like outer surface material 3 and is heat-sealed. The inner surface material 2 and the outer surface material 3 are each a net-like shape in which a vertical line and a horizontal line made of a flame-retardant resin wire 10 are pressed and heat-sealed at the intersection, and a rhomboid hole surrounded by the vertical and horizontal lines is provided. It is said.

As shown in FIG. 2A, the inner surface material 2 is formed in a net shape in which a vertical line 20 and a horizontal line 21 are heat-bonded at an intersection 22 and a rhomboid hole 25 surrounded by the vertical and horizontal lines is provided. Yes. As shown in FIG. 2 (B), the outer surface material 3 is also a net in which a vertical line 30 and a horizontal line 31 are pressurized and heat-sealed at an intersection 32 to provide a rhomboid hole 35 surrounded by the vertical and horizontal lines. It is in the shape.

While the vertical and horizontal lines 20 and 21 of the inner surface material 2 are molded from a resin having a relatively high hardness mainly composed of polypropylene, the vertical and horizontal lines 30 and 31 of the outer surface material 3 are resin materials obtained by blending an elastic resin such as urethane with polypropylene. Molded with.
Moreover, the vertical and horizontal lines 20 and 21 of the inner surface material 2 have a small diameter, and the thickness of the inner surface material is reduced. On the other hand, the vertical and horizontal lines 30 and 31 of the outer surface material 3 have a large diameter and a large thickness. And the void | hole 25 of the inner surface material 2 is made small, and the void | hole 35 of the outer surface material 3 is enlarged. The holes 25 and 35 may be the same size.
As described above, the inner surface material 2 and the outer surface material 3 that are laminated and fixed inside and outside have different physical properties and shapes depending on their functions.

As shown in FIG. 3A, the resin wire 10 constituting the vertical and horizontal lines 20, 21, 30, 31 of the inner surface material 2 and the outer surface material 3 has an elliptical cross section. These vertical and horizontal lines may be formed of a flame retardant resin wire, and are not limited to the above-mentioned polypropylene. Polyester, polyethylene, polyethylene terephthalate, polyamide, polyphenylene ether, polybutylene terephthalate, polyphenylene sulfide, a mixture of two or more of these A flame retardant selected from bromine-based, phosphate ester, metal hydroxide, and melamine is blended with one or more non-halogen resin components selected from
The flame retardant is blended in an amount of 0.5 to 100 parts by mass with respect to 100 parts by mass of the resin component. Furthermore, 0 to 50 parts by mass of a filler composed of magnesium oxide and / or calcium carbonate is blended with 100 parts by mass of the resin component as required.
As described above, in this embodiment, polypropylene (PP) is used as a resin component, and a brominated flame retardant composed of “tetraprobisphenol” is used as a flame retardant.

The vertical and horizontal lines 20 and 21, 30 and 31 of the inner surface material 2 and the outer surface material 3 are not knitted. As shown in FIGS. 2 and 3, the vertical lines 20 and 30 are on the upper side, and the horizontal lines 21 and 31 are on the lower side. They are arranged and fused at the intersections 22 and 32 so as to overlap each other.
At the intersections 22 and 32, as shown in FIG. 3C, the vertical line 20 and the horizontal lines 21, 30 and 31 having upper and lower elliptical cross sections are in surface contact, and the cross-sectional area of the lower horizontal line is 40. It is fused in a state where ˜50% of the portion enters the upper vertical line.

The laminated net sheet 1 to which the inner surface material 2 and the outer surface material are fixed is bent by a method described later so that both end sides in the width direction perpendicular to the axial direction of the length wrap around each other as shown in FIG. And is shaped in advance so as to have a cylindrical shape.
In the step of attaching the laminated net sheet 1 to the wire harness 5, the inner surface material 2 of the laminated net sheet 1 along the length direction of the electric wire group of the wire harness 5, and with the curl in this state, is attached to the electric wire group. Winding while closely contacting the outer peripheral surface. In this state, the both end sides in the width direction can be wrapped to completely cover the entire outer peripheral surface of the electric wire group. Thereafter, the adhesive tape T is wound around and fixed to both ends of the laminated net sheet 1 in the length direction and the electric wire group drawn from the laminated net sheet 1.

Below, the manufacturing method of the lamination | stacking net sheet 1 is demonstrated.
The laminated net sheet 1 is formed by a sizing machine 40 shown in FIGS. 4 (A) to (C). In detail, a flame retardant, a stabilizer, etc. are put into the hopper 41 in the resin component, and the hopper 41 is stirred and mixed, and the stirred and mixed mixture is conveyed to the die set 45 while being kneaded by the screw conveyor 42 and kneaded. The object is molded as a net-like sheet made of a flame-retardant resin wire with a die set 45.

In the die set 45, an outer face material die set 52 composed of an out die 50 and an in die 51 for forming the outer face material 3 shown in FIG. 4B is arranged in the upper stage, and the inner face material shown in FIG. 4C. A die set 55 for an inner surface material made up of the forming out die 53 and the in die 54 of No. 2 is arranged in the lower stage. The outer material die set 52 and the inner material die set 55 are arranged on the same rotational axis of the motor 57.

The out die 50 and the in die 51 of the outer material die set 52 are reversely rotated by a motor 57. As a result, an intersection (intersection) 32 where the vertical line 30 and the horizontal line 31 overlap is formed at the portion where the hole 50a of the out die 50 and the hole 51a of the in die 51 overlap, and the hole of the out die 50 and the hole of the in die 51 are formed. By separating, a lattice shape (in this embodiment, a rhombus) is formed.
Similarly, the out die 53 and the in die 54 of the inner surface material die set 55 are also reversely rotated by the motor 57 to form the lattice-shaped inner surface material 2 by the vertical lines 20 and the horizontal lines 21.

When extrusion molding is performed from the outer surface material die set 52 and the inner surface material die set 55, the vertical lines 20 and the horizontal lines 21, 30 and 31 are heated and pressurized, and the vertical and horizontal lines 20 and 21, 30 and 31 are Welds. In addition, since the points 22 and 32 of the vertical and horizontal lines 20 and 21 and 30 and 31 are heated under pressure, the vertical and horizontal lines are heat-sealed in the state where the vertical and horizontal lines have entered the counterpart fiber.

As described above, the outer surface material die set 52 is arranged on the upper stage, the inner surface material die set 55 is arranged on the lower stage, and the large-diameter guide disk 56 is interposed between the outer surface material die set 52 and the inner surface material die set 55. The outer surface material 3 formed by the upper outer surface material die set 52 is expanded in diameter.
Further, a small-diameter guide plate 57 is disposed below the inner surface material die set 55, and the inner surface material 2 formed by the lower inner surface material die set 55 is expanded and the outer surface formed by the outer surface material die set 52. The laminated sheet 4 is formed by inducing the inner surface of the material 3 to come into contact with the outer periphery of the inner surface material 2 formed by the inner surface material die set 55 and heating and heat-sealing.
In this way, by configuring the die set 45 to include the outer surface material die set 52 and the inner surface material die set 55 in the upper and lower stages, the net-shaped outer surface material 3 is stacked on the net-shaped inner surface material 2, The laminated sheet 4 is formed by heat fusion.

Next, the laminated sheet 4 is stretched by stretching rollers 62A and 62B. Subsequently, the outer surface material 3 is foamed by being conveyed to the foaming heating furnace 63, further stretched by the stretching roller 62 </ b> C, and then transported to the tank 64. Thereafter, the laminated sheet 4 is wound as a coil.

In the step shown in FIG. 6, the laminated sheet 4 is bent so that both side ends in the width direction wrap around each other to become a cylindrical shape.
A forming machine 70 having a conical cylindrical shape is used, and pulling rolls 71A and 71B are arranged upstream and downstream of the forming machine 70. The laminated sheet 4 is passed from the roll 71A through the molding machine 70, and is bent in an arc shape inside the molding machine 70, so that the end portion in the width direction wraps at the final small diameter portion. In this state, it is pulled out by the roll 71B, and the continuous laminated net sheet 1 is manufactured. The laminated net sheet 1 is cut to a required length by a cutting machine 73 according to use conditions.

Since the laminated net sheet 1 having the above-described structure is a laminated material of the inner surface material 2 and the outer surface material 3, the thickness is increased, and the vertical and horizontal lines of the outer surface material 3 are formed of a resin wire mixed with urethane. Therefore, the cushioning property is excellent, and the protection function of the wire harness can be enhanced. Further, by providing cushioning properties, it is possible to reduce and prevent abnormal noise generated when the wire harness contacts the panel.

Further, as shown in FIG. 3 (A), both the inner surface material 2 and the outer surface material 3 are heat-sealed in a state where the vertical and horizontal lines are deformed into an elliptical cross section and enter each other in the mating direction. Has been. Therefore, it becomes difficult to peel as compared with the case where only the outer peripheral surfaces of the vertical and horizontal lines are welded, and has the above-described tensile strength and tear strength, and does not cause breakage and is highly reliable.
Moreover, since the vertical and horizontal lines 20 and 21, 30 and 31 of the inner surface material 2 and the outer surface material 3 are made of flame retardant resin wires, the laminated net sheet 1 has flame resistance and is routed in the engine room. Since it can be used as an exterior material of a wire harness and the vertical and horizontal lines are firmly fixed to each other, the vertical and horizontal lines of the inner surface material 2 and the outer surface material 3 do not fray at the cut end. Moreover, since it is in a net shape, the weight can be halved compared to a round tube. In particular, when it is used as an exterior material for a large number of wire harnesses routed in an automobile, it can contribute to reducing the weight of the automobile and improve fuel efficiency.

FIG. 7 shows a laminated net tube 1-B of the second embodiment.
The laminated net sheet 1 of the first embodiment is formed into an arc shape and is formed so that both ends in the width direction are wrapped. In the second embodiment, the wrapped both ends are heat-sealed. Thus, the laminated net tube 1-B is obtained.
As shown in FIG. 7B, the laminated net tube 1-B is contracted and inserted through the wire harness 5, and after being inserted, is stretched as shown in FIG. It is fixed with tape T.

1 Laminated Net Sheet 1-B Laminated Net Tube 2 Inner Material 3 Outer Material 10 Resin Wire 20, 30 Vertical Line 21, 31 Horizontal Line 22, 32 Intersection 25, 35 Hole

Claims (5)

Each consists of a two-layer tube or sheet consisting of a net-like inner and outer material,
The inner surface material and the outer surface material are formed into a net shape by pressurizing and fusing the intersections of the vertical and horizontal lines made of resin wires, respectively, and the outer surface of the inner surface material and the inner surface of the outer surface material are fused. A net-like protective material for a wire harness characterized by being frayed at the cut end. The net shape for a wire harness according to claim 1, wherein the outer surface material and the inner surface material are different in material, thickness, hardness, hole size, and / or hole shape of the resin wire. Protective layer. 3. The net-like protective material for a wire harness according to claim 1 or 2, wherein the outer surface material and the inner surface material are made of a thermoplastic material, and the outer surface material includes a foam material and has a cushioning property than the inner surface material. The sheet is bent in a cylindrical shape that wraps at both ends in the width direction, and
The net-like protective material for a wire harness according to any one of claims 1 to 3, wherein the tube is formed by heat-sealing edges in the width direction of one sheet to each other. It is a manufacturing method of the net-like protective material according to any one of claims 1 to 4,
The sizing machine is provided with an inner die forming die set and an outer die forming die set consisting of an out die and an in die,
The outer surface material forming die set is arranged as an upper stage, and the inner surface material forming die set is arranged coaxially as a lower stage,
A net-like outer surface material is formed from the vertical and horizontal lines spun from the upper outer surface material forming die set, and the inner surface of the outer surface material is spun from the lower inner surface material forming die set. A method of manufacturing a net-like protective material for a wire harness, in which a net-like inner surface material is formed by the vertical lines and the horizontal lines, and the outer surface of the inner surface material is brought into contact with the inner surface of the outer surface material on the outer periphery.

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