Abstract: A wire harness manufacturing method includes a first step of covering a periphery of the wire with a molded body (13) having a thermoplastic material, and heating the molded body (13) to a temperature at which plastic deformation by thermo plasticity is possible and pressuring the molded body (13) to have predetermined cross-sectional shape and size. The method also includes a second step of, after the first step, while the molded body (13) has the temperature at which plastic deformation by thermo plasticity is possible, molding the thermoplastic material to have a predetermined axial shape, and cooling the molded body (13) having the predetermined axial shape.

Abstract: A wire harness has an exterior component (11a) that covers a certain part of at least one wires (12). The exterior component (11a) has parts having different hardness, including a relatively hard first part (111a), a relatively soft second part (112a), and a third part (113a) having an intermediate hardness between that of the first parts (111a, 112a). The first part is formed on a surface of the exterior component and functions as a shape keeping member and a protector. The second and third parts (112a, 113a) surround the certain part of the at least one wire 12 and each functions as a cushioning material and a muffler/soundproofing material. The first part (111a), the second part (112a), and the third part (113a) are formed integrally from a non-woven fabric (2) with thermo plasticity.

Abstract: An electric wire protection structure has a structure in which a branch portion of an electric wire bundle is protected. In the electric wire protection structure, a protection portion covers the branch portion of the electric wire bundle, the protection portion being formed by heating and compressing a thermoplastic material in a state of covering at least the branch portion of the electric wire bundle.

Abstract: A wire harness has an exterior component (11a) that covers a certain part of at least one wires (12). The exterior component (11a) has parts having different hardness, including a relatively hard first part (111a), a relatively soft second part (112a), and a third part (113a) having an intermediate hardness between that of the first parts (111a, 112a). The first part is formed on a surface of the exterior component and functions as a shape keeping member and a protector. The second and third parts (112a, 113a) surround the certain part of the at least one wire 12 and each functions as a cushioning material and a muffler/soundproofing material. The first part (111a), the second part (112a), and the third part (113a) are formed integrally from a non-woven fabric (2) with thermo plasticity.

Abstract: It is an object of the present invention to provide a wire harness that has a simple structure, that can be easily manufactured, and that includes a protective member having an extra-length absorbing function. A wire harness (1) includes an electrical wire bundle (12) and a protective member (21). The protective member (21) is a member obtained by heat-molding a nonwoven fabric, covers a portion in the longitudinal direction of the electrical wire bundle (12), and has a spiral shape or helical shape in which a curved portion is formed with a continuous turn in the longitudinal direction or has a meander shape in which a plurality of curved portions are formed with intermittent turns in the longitudinal direction.

Abstract: A wire harness protection structure includes a bundle of electric wires, and a protector formed into a tubular body that extends in a longitudinal direction of the bundle of electric wires and having a portion of the bundle of electric wires provided in an inner space of the tubular body. The protector is formed of a protection material including a base material and a binder material having a melting point lower than that of the base material. A joint portion of the protector is joined by heating and melting and then cooling and solidifying the binder material. The binder material in an inner peripheral surface is heated and melted and then cooled and solidified such that the inner peripheral surface, which faces the inner space, is harder than an outer peripheral surface of the protector.

Abstract: A wire harness includes a bundle of electric wires and a protector protecting the bundle of electric wires by extending in a longitudinal direction of the bundle of electric wires and surrounding a portion thereof. The protector includes a base material and a binder material having a lower melting point than the base material, the protector being joined in a joint portion thereof by cooling and solidifying the melted binder material. In a case where a first side portion and a second side portion are each provided as a portion along the longitudinal direction in an outer peripheral surface of the protector and the second side portion is disposed opposite the first side portion with the bundle of electric wires therebetween, a portion of the binder material in each of the first side portion and the second side portion is melted, cooled, and solidified such that the second side portion is harder than the first side portion.

Abstract: A wire protector is provided that is lightweight, that has a simple structure, and that is capable of covering a circumference of wires along a length direction thereof and of preventing an occurrence of noise due to contact with the wires sheathed therein. The wire protector covers the circumference of the wires in the length direction thereof, is configured with a cylindrical member made of a hot press processed non-woven fabric, is formed such that an inner surface is more pliable than an outer surface hardened by the hot press process, and has a slit from the outer surface to the inner surface formed along the entire length direction.

Abstract: A connector protection structure includes a connector electrically connected to an electric wire and a protector protecting the connector by surrounding the connector. The protector is formed of a protection material that includes a base material and a binder material having a melting point lower than that of the base material, and is joined in a joint portion thereof by cooling and solidifying the melted binder material. The connector is accommodated in an inner space formed in an inner surface of the protector. The binder material in the inner surface and outer surface is melted, cooled, and solidified such that the inner surface of the protector is harder than the outer surface of the protector.