Branch wire tie band, binding structure, and method of binding a wiring harness

Abstract

A branch wire tie band including a strap portion on which ratchet grooves are formed, the strap portion extending from a head portion within which a strap locking channel is formed. A curved attachment coil, which is preformed as an integral portion of the strap portion, is placed around the branched portion of a wire harness after which the strap portion is inserted and locked into the band locking channel. The tie band may includes two tie band strap portions extending from respective head portions and an anchor plate within which left and right through holes are formed. The two tie band straps may be inserted through the left and right through holes in the anchor plate from where they extend diagonally, their tip portions crossing, and their head portions prevented from passing through the through holes.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a tie band to tie branch wires of a wire harness, and a method of easily cross wrapping the branch wires using the tie band.

2. Description of Background Information

In the prior art, a wire harness installed in a vehicle includes branch wires that lead away from the trunk wires at multiple locations. Tape is wound around the electrical wires at the branch-off points in order to secure the position of the branch wires with respect to the trunk wires. As shown in FIG. 8, the branch wires are to be tied at the point where wire bundle ‘W’ is supported by a branch jig which is mounted on wire harness assembly stand 1. Adhesive tape ‘T’ is wound around the group of wires at this location in order to bind the wires together. However, at the point where branch wires W2 separate from trunk wires W1, wire bundle ‘W’ runs between the arms of support yoke 2b′, which extends from the top of main shaft 2a′ of wrapping jig 2′, and thus support yoke 2b′ interferes with the wrapping of adhesive tape ‘T’ around bundle ‘W’. As a result, wiring jig 2′ must be lowered so that wire bundle ‘W’ may separate from support yoke 2b′ to allow adhesive tape ‘T’ to be wrapped around the wires.

The tape wrapping operation at the wire branch point is, as shown in FIG. 9, executed by first wrapping adhesive tape ‘T’ around the X-side of trunk wires W1, then diagonally toward the Y-side of branch wires W2, then from trunk wires W1 in a diagonal direction to the X-side of branch wires W2, and then around the Y-side of trunk wires W1 in a configuration that forms tape ‘T’ into an X-shaped pattern.

There are problems associated with this operation. For example, training and skill are required to perform the tape wrapping operation at the branch locations, the quality of the tape wrap may vary due to differences in the skill of the people wrapping the wires, and excessive time is required to perform the tape wrapping operation due to the many locations where wires branch off of the main harness. Of special concern is the need to remove the wires from the wiring jig in order to wrap the branched portion. This can lead to a change in the taping location where the wires branch off, and thus reduce the positioning precision of the branched portion. This demonstrates that there is room for improvement in the branch wire wrapping operation in the wire harness assembly process.

Japanese (Laid Open) Utility Patents H6-84736 and H6-65682 have proposed the use of a tie band, instead of the previously described tape wrap, that can be attached by the assembly technician without the need for training. FIGS. 10A and 10B illustrate band 3 which is described in JP H6-84736. Band 3 includes plate-shaped arm 4 in the middle of which are formed a pair of lock channels 4a. In addition to lock channels 4a, band 3 includes base part 4c, and clamp pin 4b that extends from base part 4c with the purpose of attaching band 3 to the vehicle body. Straps 5A and 5B are able to insert, slide through, and lock into each channel 4a. As shown in FIG. 10B, straps 5A and 5B of band 3 wrap around trunk wires W1 on the X and Y sides of branch wires W2, and mutually cross before being secured within band lock channels 4a.

As shown in FIGS. 11A and 11B, band 6, which is described in JP H6-65682, includes base part 7 within which a pair of lock channels 7a are formed, and wide band 8 which extends from base part 7 and then separates into a pair of branch straps 8a. As shown in the FIG. 11B view of band 6, branch straps 8a mutually separate to wrap around each side of branch wires W2 respectively, and then are inserted and secured within lock channels 7a located on trunk wires W1.

Bands 3 and 6, which are described in JP H6-84736 and JP H6-65682, respectively, use two straps that extend from trunk wires W1, wrap around branch wires W2, and pass into and through separate lock channels.

Moreover, in regard to band 3 described in JP H6-84736, branch wires W2 may incline in relation to the specified branch-off direction if straps 5A and 5B are tightened unevenly. Also, any movement of strap 5A or 5B toward base part 4c, in relation to arm 4, will reduce tightening pressure and possibly change the position where the wires branch off. Band 6, which is described in JP H6-65682, includes wide band 8 which separates into a pair of straps 8a. In the case where the bundle of branch wires W2 is of a large diameter, however, straps 8a must wrap around the wires at a wider angle than that formed between straps 8a at the time of their manufacture. Straps 8a must then be brought together again from that wider angle for insertion into their respective lock channels. This makes it difficult for straps 8a to follow the contour of the wire bundle as they wrap around it, allows the formation of a gap between the bands and wires, and reduces binding pressure which can result in the problem of the branch wires branching off from the trunk wires at an imprecise location. There is an additional problem in that band 8 is formed as a single structure that includes the head part and two lock channels formed therein. It thus becomes expensive to fabricate the dies needed to manufacture tie band 6 in different configurations.

SUMMARY OF THE INVENTION

Taking the above-noted shortcomings into consideration, the present invention provides, inter alia, a branch wire tie band that is able to wrap around a wire bundle in a cross pattern at a wire branch point, closely follow the contour of the wire bundle, and be easily tightened. The present invention also provides a method of using the branch wire tie band, and a tie band binding structure. Further, the present invention provides a simple and economical wire branch tie band structure that combines tie bands with a flat anchor plate to wrap a bundle of wires at a branch location.

In order to resolve at least the above described shortcomings, an embodiment of the present invention provides a branch wire tie band for use on a wiring harness, the tie band including a synthetic resin strap portion, onto which ratchet grooves are formed, that extends from a head portion in which a band lock channel is formed. Further, a curved attachment coil is preformed on the strap portion which extends as a belt-like structure from the head portion. The attachment coil is placed around the region where branch wires separate from the wire bundle that forms the wire harness, and the tip of the strap portion is then inserted into the lock channel of the head portion and tightened in order to cross wrap and bind the region where the branch wires separate from the trunk wires.

The branch wire tie band described by a first embodiment of the present invention includes one strap that extends from a head portion within which a lock channel is formed. The single strap portion has been previously formed to include an attachment coil that can be attached to a wire branch point by wrapping around the trunk wires and the branch wires after which the strap portion is inserted and locked into the head portion lock channel. Due to the presence of the preformed attachment coil, the strap portion can be wrapped and bound around the trunk and branch wires, thus maintaining the positional precision of the branched portion, eliminating the need for the assembly technician to be skilled in the branch portion binding procedure, and providing the same level of binding quality at each branch wire location. Moreover, because the narrow strap portion is able to closely follow the contour of the wire bundle, and because the strap portion can be pulled under the wire bundle while the bundle is still supported by the wiring jig, the need to remove the wire bundle from the wiring jig in order to bind the branch portion is eliminated, thus increasing the positional accuracy of the wire branch locations.

The strap portion is first formed as a straight band that extends from the head portion after which the curved attachment coil is formed. The curved attachment coil may be formed, for example, by heating the strap portion to soften it, and then, for example, winding it around a mandrel. The strap portion is allowed to harden in this shape to form the curved attachment coil.

Further, a second embodiment of the present invention provides an attachment coil of the strap portion that is a curved spiral shape that extends from the head portion through two loops, the portion of the strap portion extending from the second loop being inserted into the lock channel of the head portion. By preforming an attachment coil on the strap portion, the strap portion is able to extend from the trunk wires to wrap around one side of the branch wires, and then continue to wrap around the other side of the branch wires where the tip of the strap portion is inserted into the head portion, thus forming a binding structure in which the strap portion is able to easily bind the branch region by wrapping around both the trunk wires and branch wires.

The attachment coil may also be formed in the middle of the strap portion by the strap portion curving in the lengthwise direction with the tip of the strap crossing the head portion. In this configuration, the attachment coil is placed beneath the branch wires, and both ends of the strap portion wrap around to the top of the trunk wires on both sides of the branch wires. The branching region can then be easily bound by the mutual securing of both ends of the strap portion over the branch wires.

Ratchet grooves are formed in a saw tooth pattern on the inner side of the strap portion that contacts the wire bundle. Also, it is preferable that slip-prevention spikes be formed on the inner side of the strap portion. By providing these spikes at intervals on the strap portion, it becomes possible to prevent the strap portion from moving on the wire bundle.

A clamping portion may be formed as an integral member of, or attachable member to the external surface of the band head in order to attach the tie band to the vehicle body.

Additionally, the present invention provides a wire harness branch wire binding structure utilizing the branch wire tie band whereby the tie band is cross wrapped and tightened around the trunk wires and branch wires of the wiring harness. By tightly binding the branching portion of the wire bundle in this manner, the position of the branching portion cannot change during the harness layout process, and the layout process is made more productive.

Further, the present invention provides a method of binding the branched wire portion of a wire harness, utilizing the branch wire tie band, whereby a bundle of wires is placed on a wiring jig provided on a wire harness assembly stand. Branch wires are separated from trunk wires by passing between multiple wire support posts extending upward from the topmost portion of the wiring jig main post. The attachment coil of the strap portion is first wrapped around the trunk wires and then continues around one side of the branch wires to face the lock channel of the head portion which is located on the other side of the branch wires. The strap portion returns to cross over the attachment coil after which it is inserted into and locked within the lock channel. The above described operations are conducted without removing the wire bundle from the wiring jig at the wire branching location.

Three or four evenly spaced wire support posts may be formed at the topmost portion of the wiring jig main post to respectively accommodate a T-shaped or X-shaped wire branch pattern. The branch wire tie band is used to bind the T-shaped or X-shaped wire branch location.

Because the strap portion is of narrow width and pre-curved so as to wrap around the wire bundle, it can be easily wrapped around the underside of the wire bundle without removing the wire bundle from the wiring jig. Compared to the conventional method in which the wire bundle must be removed from the jig and tape pulled out and wrapped around the wires, the present invention provides an easy method of binding the branch region while increasing its positional accuracy.

A third embodiment of the present invention is a wire harness branch wire tie band including two tie bands whose strap parts, onto which ratchet grooves are formed, extend from respective head portions within which lock channels are formed, and an anchor plate within which left and right through holes are formed. The two tie band straps are loosely inserted through the left and right through holes in the anchor plate from which they extend diagonally, their tip portions crossing, and their head portions being prevented from passing through the thru-holes. At the location where the branch wires are diverted from the trunk wires, the two tie band straps pass from the trunk wires along both sides of the branch wires, after which they wrap around and mutually cross over the wire bundle, each strap then being inserted into the lock channel of the other strap's head portion in order to bind the bundle of wires at the branching wire location.

The branch wire tie band of the present invention uses two multi-purpose electrical wire tie bands of the type on which a head portion, within which a lock channel is provided, is formed on one end, and a strap extends from the head portion. The tie bands are inserted into and pass through holes formed on the left and right sides of a long narrow anchor plate which is the only component of the tie band structure that requires special manufacture. The anchor plate can be used with trunk and branch wire bundles of various diameter. Because the tie band straps pass through the anchor plate holes with sufficient clearance, they are able to traverse diagonal paths through which they mutually cross, while remaining in contact with the wire bundle, after which each strap is inserted and secured in the lock channel of the other strap.

Moreover, after the straps are wrapped around the trunk and branch wires, they need only be inserted and locked into the lock channels. This is an operation that requires little skill, eliminates differences in the quality of the binding at each branching wire location, and increases the positional accuracy of the branching wire locations. Furthermore, after the anchor plate is placed on the trunk wires and the two straps wrapped between the wiring jig and wire bundle, the straps cross on the upper side of the trunk wires after which each is inserted into the lock channel of the other tie band, thus allowing the wire binding operation to be conducted with the wire bundle still supported by the wiring jig, and thereby increasing the positional accuracy of the branching wire location.

As described above, the anchor plate is a long, thin, flat member in which through holes are formed at the right and left ends, and in which a vehicle body attachment plug is integrally formed at the center portion thereon, or separately formed so as to be removably insertable into a hole provided in the anchor plate. In order to install the wire harness onto a common vehicle, the vehicle body attachment plugs can be provided between the through holes on the anchor plate, thus eliminating the need to install separate vehicle body attachment plugs and reducing the number of wire harness components and assembly processes. In addition, in cases where the wire harness attachment positions on the vehicle body differ from the locations of the wire branching locations on the wire harness, a flat T-shaped anchor plate may be employed to provide an offset attachment plug position. In this case, the through holes are formed at the left and right ends of the horizontal portion, and the vehicle body attachment plug is integrally formed at the end of the vertical portion which extends from the mid-portion of the horizontal portion, or separately formed so as to removably attach to an attachment hole provided in the vertical portion.

A fourth embodiment of the present invention is a wire harness branch wire binding structure that uses the branch wire tie band wherein the tie band straps wrap around and bind the trunk wires and branch wires. By using the tie band to tightly tie the wires at the branch locations beforehand, changes in branch positions can be prevented when laying out the wiring harness, and the productivity of the wire harness layout process can be improved.

A fifth embodiment of the present third invention is a wire harness branch wire binding method wherein a wire bundle is placed on a wiring jig on a wire harness assembly stand at the location where branch wires divert from trunk wires and are supported between multiple wire support posts that branch upward from the wiring jig main post. The tie band straps are wrapped around the trunk wires and branch wires after which they mutually cross and are each inserted and locked into the lock channel of the head portion of the other tie band, this operation being executed without removing the wire bundle from the wiring jig at the branching wire location.

The wiring jig used for a T-shaped wire branch has three uniformly spaced wire support posts extending upward from the wiring jig main post. The single bundle of branch wires at the T-intersection extend from the trunk wires which are supported by the wiring jig. As noted previously, the two tie band straps are wrapped around the trunk wires and branch wires after which they mutually cross on the trunk wires and are tightened in order to bind the wire bundle.

Moreover, the wiring jig used for an X-shaped wire branch has four uniformly spaced wire support posts extending upward from the wiring jig main post. The two branch wire bundles intersect with the trunk wires at right angles at the X-intersection. The anchor plate is placed in the center of the trunk wires, the two straps are wrapped around the trunk wires across both sides of the branch wires after which they mutually cross, and then each strap is inserted and secured in the lock channel of the other tie band. The tie band can thus be appropriately used for either a T-shaped or X-shaped branch wire pattern.

An aspect of the present invention provides a branch wire tie band for use on a wire harness, the tie band including a head portion having a lock channel formed therein; a strap portion extending from the head portion, the strap portion including ratchet teeth formed thereon; and a curved attachment coil provided as a portion of the strap portion; wherein the attachment coil is configured to be cross wrapped around a wire branch region on a wire bundle of a wire harness, and the strap portion is configured to be inserted into the lock channel of the head portion and tightened to bind the branching wire region. Further, the attachment coil of the strap portion is configured as a curved spiral shape including first and second curved loops, the attachment coil extending from the head portion to the tip of the strap portion, wherein the tip of the strap portion extends from the second curved loop and is configured to be inserted into the lock channel of the head portion. Further, the center portion of the strap portion curves in the lengthwise direction providing a curved portion followed by a tip portion that crosses the head portion to form the attachment coil. The branch wire tie band includes spikes which project from the inner wire-bundle-contacting surface of the strap portion to prevent displacement of the strap portion; and the tie band is formed of synthetic resin. Further, the strap portion may be cross wrapped around the trunk wires and branch wires of the wire harness and tightened.

A further aspect of the present invention provides a method of binding the branched wire portion of a wiring harness, the method including providing a branch wire tie band including a head portion having a lock channel formed therein; a strap portion extending from the head portion, the strap portion including ratchet teeth formed thereon; and a curved attachment coil formed as a portion of the strap portion; wherein the attachment coil is configured to be cross wrapped around a wire branch region on a wire bundle of a wire harness, and the strap portion is configured to be inserted into the lock channel of the head portion and tightened to bind the branching wire region; placing a bundle of wires on a wiring jig provided on a wire harness assembly stand; and separating branch wires from trunk wires by passing between multiple wire support posts extending upward from the topmost portion of the wiring jig main post, wherein the attachment coil of the strap portion extends from the trunk wires to wrap around one side of the branch wires, the strap portion continues to a position facing the lock channel of the head portion located on the other side of the branch wires, and returns to cross over the attachment coil and lock within the lock channel to bind the wire branch location with the cross wrapped tie band, wherein the method is performed without removing the wire bundle from the wiring jig at the wire branch location. Further, the wiring jig may include three uniformly spaced wire support posts formed at the topmost portion thereof to accommodate a T-shaped wire branch pattern, and the branch wire tie band is configured to bind the T-shaped wire branch location. Further, the wiring jig may include four uniformly spaced wire support posts formed at the topmost portion thereof to accommodate an X-shaped wire branch pattern, and the branch wire tie band is configured to bind the X-shaped wire branch location.

A further aspect of the present invention provides a wire harness branch wire tie band including two tie bands, each the tie band including strap portions having ratchet grooves formed thereon, each the strap portion extending from a respective head portion within which lock channels are formed; and an anchor plate including left and right through holes formed therein; wherein the two strap portions are configured to be loosely inserted through the left and right through holes in the anchor plate and extend diagonally therefrom, their tip portions mutually crossing, and their head portions prevented from passing through the through holes; and at the location where the branch wires divert from the trunk wires, the two strap portions pass along both sides of the branch wires, and wrap around and mutually cross over the wire bundle, each strap portion then projecting through the lock channel of the other strap to bind the bundle of wires at the branching wire location. Further, the anchor plate is configured as a long, thin, planar member including through holes formed therein at right and left extremities thereof, and further including a vehicle body attachment plug provided at a center portion of the anchor plate. The vehicle body attachment plug may be formed integrally and in one piece with the anchor plate. The vehicle body attachment plug may be configured to be removably inserted into a vehicle body attachment plug hole provided on the anchor plate. Further, the anchor plate is configured as a planar T-shaped member including through holes formed therein at left and right extremities of a horizontal portion thereof, and further including a vehicle body attachment plug provided at the end of a vertical portion extending from the midportion of the horizontal portion of the anchor plate. The vehicle body attachment plug may be formed integrally and in one piece with the end of the vertical portion of the anchor plate. The vehicle body attachment plug may be configured to be removably inserted into a vehicle body attachment plug hole provided on the end of the vertical portion of the anchor plate. The two strap portions may be cross wrapped around the trunk wires and branch wires and tightened.

A further aspect of the present invention provides a method of binding the branch wire portion of a wiring harness, the method including providing a branch wire tie band including two tie bands, each the tie band including strap portions having ratchet grooves formed thereon, each the strap portion extending from a respective head portion within which lock channels are formed; and an anchor plate including left and right through holes formed therein; placing a wire bundle on a wiring jig on a wire harness assembly stand at the location where branch wires divert from trunk wires, and supporting the wire bundle between multiple wire support posts that branch upward from a wiring jig main post, and wrapping the strap portions around the trunk wires at both sides of the branch wires after which they mutually cross, then inserting and locking each strap portion into the lock channel of the head portion of the other tie band without removing the wire bundle from the wiring jig at the branching wire location. The wiring jig may include three uniformly spaced wire support posts formed at the topmost portion thereof to accommodate a T-shaped wire branch pattern, and the branch wire tie band is configured to bind the T-shaped wire branch location. The wiring jig may include four uniformly spaced wire support posts formed at the topmost portion thereof to accommodate an X-shaped wire branch pattern, and the branch wire tie band is configured to bind the X-shaped wire branch location.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, and other objects, features and advantages of the present invention will be made apparent from the following description of the preferred embodiments, given as nonlimiting examples, with reference to the accompanying drawings in which:

FIG. 1A is a front perspective view of a branch wire tie band according to a first embodiment of the present invention;

FIG. 1B is side perspective view of the branch wire tie band of the embodiment of FIG. 1A;

FIG. 2 is a perspective view of a T-shaped wire branch supported by a wiring jig on a wire harness assembly stand according to the embodiment of FIG. 1A;

FIGS. 3A-3D are perspective views of the binding procedure applied to a T-shaped wire branch according to the embodiment of FIG. 1A;

FIGS. 4A-4C are perspective views of the binding procedure applied to an X-shaped wire branch according to the embodiment of FIG. 1A;

FIG. 5A is a perspective view of a branch wire tie band according to a modified form of the first embodiment of the present invention;

FIG. 5B is a perspective view of the branch wire tie band of the modified form of the first embodiment of FIG. 5A;

FIG. 6 is a perspective view of the branch wire tie band according to a second embodiment of the present invention;

FIGS. 7A-7C are perspective views of the binding method of the embodiment of FIG. 6;

FIG. 8 illustrates the conventional tape wrapping method used to secure a branched wire joint;

FIG. 9 illustrates a branched wire joint conventionally bound by tape;

FIGS. 10A and 10B illustrate an example of conventional tie bands;

FIGS. 11A and 11B illustrate a second example of conventional tie bands;

FIG. 12A is a front elevational view of a branch wire tie band according to a third embodiment of the present invention;

FIG. 12B is a perspective view of the anchor plate of the embodiment of FIG. 12A;

FIG. 13 is a perspective view of a T-shaped wire branch supported by the wiring jig on a wire harness assembly according to the embodiment of FIG. 12A;

FIGS. 14A and 14B are perspective views of the branch wire tie band attachment procedure according to the embodiment of FIG. 12A;

FIGS. 15A and 15B provide perspective views of the branch wire tie band attachment procedure for an X-shaped wire branch according to the embodiment of FIG. 12A;

FIG. 16 is a front elevational view of a branch wire tie band according to a fourth embodiment of the present invention;

FIG. 17A is a front elevational view of a branch wire tie band according to a fifth embodiment of the present invention;

FIG. 17B is perspective view of the anchor plate of the embodiment of FIG. 17A; and

FIG. 18 is a perspective view of the branch wire tie band of the embodiment of FIG. 17A installed onto the branching wire point.

DETAILED DESCRIPTION OF THE INVENTION

The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description is taken with the drawings making apparent to those skilled in the art how the forms of the present invention may be embodied in practice.

The following will explain embodiments of the invention with reference to the drawings. FIGS. 1 through 3 illustrate the first embodiment of the invention. FIG. 1 illustrates branch wire tie band 10 (hereafter referred to as tie band 10) which may be made of any suitable material such as, for example, a synthetic resin, and in the present embodiment the resin is polypropylene. Tie band 10 includes box-shaped head portion 11 from which extends strap 12. Lock pawl 11b protrudes into lock channel 11a which is formed within head portion 11. Strap 12, onto which ratchet teeth 12a are formed, is inserted into lock channel 11a and secured at a position therein through the engagement of any of ratchet teeth 12a against lock pawl 11b.

Strap 12 is a narrow belt-shaped strap that has been formed into a spiral shape extending from head portion 11 to the tip of the strap. Half-loop shaped first and second attachment coils 12b and 12c connect to form one complete loop from which head portion side 12d continues from one end and strap tip 12e from the other. The spiral shape may be formed by a suitable process such as, for example, heating the strap 12, wrapping the strap 12 around a mandrel in a softened state, and then allowing the strap 12 to cool.

As shown in FIG. 2, a wire bundle is placed on wire harness assembly stand 1 so that branch wires W2 separate from trunk wires W1 at wiring jig 2 to form a ‘T’ shape branching region at branch support portion WT. Wiring jig 2, which is used to establish the ‘T’ shaped branch, includes wire support posts 2b-1, 2b-2, and 2b-3 that extend upward from the top of main post 2a at 120-degree intervals. Trunk wires W1 are placed between wire support post 2b-1 and the two posts 2b-2 and 2b-3 in a linear configuration, and branch wires W2 are arranged between wire support posts 2b-2 and 2b-3.

T-shaped branch support portion WT is bound by tie band 10 through the procedure illustrated in FIGS. 3A-3D. As shown in FIG. 3A, the two regions at trunk wires W1 adjacent to branch wires W2 are designated as ‘X’ and ‘Y’ sides. First, strap 12 is extended, and head portion 11 pressed against the X-side of trunk wires W1. Strap 12 is then drawn past the Y-side of branch wires W2 and wrapped downward around trunk wires W1 on the Y-side. As strap 12 is pre-curved, releasing head portion 11, as shown in FIG. 3B, results in strap 12 wrapping downward around trunk wires W1 on the X-side, after which it can be pulled out from the X-side of branch wires W2. In this condition, first attachment coil 12b wraps around the lower perimeter of trunk wires W1 on the X-side of branch wires W2, and second attachment coil 12c wraps around the upper perimeter of trunk wires W1 on the Y-side of branch wires W2. Next, as shown in FIG. 3C, tip 12e of strap 12, tip 12e being positioned on the Y-side and curving toward the X-side where head portion 11 is located, crosses the previously attached coil and is pulled toward head portion 11 on the X-side. Strap 12 is then pulled through lock channel 11a in head portion 11 where lock pawl 11b locks against ratchet teeth 12a on strap 12 to form the structure shown in FIG. 3D. The wire bundle is now bound at the region where branch wires W2 lead away from trunk wires W1.

When wire bundle ‘W’ is bound by tie band 10, strap 12 does not pass under the lower perimeter of wire bundle ‘W’ at main post 2a of wiring jig 2. Wire bundle ‘W’ need not be removed from wiring jig 2 because strap 12 is wound around trunk wires W1 at the X- and Y-sides between wire support posts 2b-1 and 2b-2, and between 2b-1 and 2b-3 respectively. Moreover, strap 12 can be secured around the wires in a cross-wrapped pattern by simply inserting it through lock channel 11a in head portion 11 and pulling it tight. As a result, the wire binding operation can be executed without the need for training, the wire bundle can be bound with uniform pressure, there is no change in the position of the branch wires, and the locations where the branch wires are bound to the main harness can be maintained with sufficient precision.

FIG. 4 illustrates a method through which tie band 10 can be used to bind an X-shaped branch pattern. The wire bundle is supported by wiring jig 2 which has been configured for an X-shaped branch pattern to support branched portion WX. Four wire support posts 2b-1, 2b-2, 2b-3, and 2b-4 extend upward from the main post. Trunk wires W1 run between wire support posts 2b-1 and 2b-2, and between posts 2b-3 and 2b-4. Branch wires W2-1 and W2-2 branch off at right angles to wire bundle W1 between wire support posts 2b-2 and 2b-3, and between wire support posts 2b-3 and 2b-1 respectively.

In regard to the X-shaped pattern of branched portion WX, head portion 11 of tie band is located at the X-side of trunk wires W1. Strap 12 passes through the Y-side of branch wires W2-1 and is then pulled out to the Y-side of branch wires W2-2. As a result of the preformed curve in tie band 10, head portion 11 curves downward across the X-side of trunk wires W1, after which it is pulled out on the X-side of branch wires W2-1 as shown in FIG. 4B. In this configuration, head portion 11 (which is located at the X-side of branch wires W2-1) and the tip of strap 12 (which is located at the Y-side of branch wires W2-2) are pulled together on the upper perimeter of trunk wires W1 at the branching point. The tip of strap 12 is then inserted into lock channel 11a of head portion 11, tightened, and secured therein as shown in FIG. 4C. In this manner, tie band 10 can also be used to bind X-shaped branch pattern WX in a cross-wrapped configuration.

As illustrated in FIG. 5A, one large curve can be formed into strap 12′, and because strap 12′ maintains a preformed curve in the coiled direction, it can be easily attached and tightened around the branch location, as shown in FIG. 3, in a cross-wrapped configuration. Moreover, FIG. 5B illustrates spikes 12f′ that are formed adjacent to ratchet teeth 12a″ on the inner surface of strap 12″. Spikes 12f′ can be positioned in the gaps between the wires, and thus prevent the positional displacement of strap 12″ with respect to the wire bundle.

FIGS. 6 and 7 describe a second embodiment. In this second embodiment, tie band 20, similar to tie band 10 of the first embodiment, is a one-piece structure that includes a single strap 22 extending in a straight path from head portion 21, and attachment coil 22a formed as portion of strap 22.

Attachment coil 22a bends back toward head portion 21 in the lengthwise direction relative to strap 22. Strap end portions 22b and 22c, which form the ends of attachment coil 22a, cross each other, and end portion 22c, which is located toward the tip of the strap, faces end portion 22b which is connected to head portion 21.

FIG. 7A shows strap 22 with end portions 22b and 22c pulled apart to open the area where they cross. FIG. 7B shows how semi-loop shaped attachment coil 22a is positioned beneath the lower perimeter of branch wires W2, how end portions 22c and 22b are placed on the upper perimeter of trunk wires W1 at the respective X- and Y-sides, and pulled under the lower perimeter of trunk wires W1 on the X- and Y-sides of branch wires W2. FIG. 7C shows the tip of end portion 22c inserted into head portion 21, which is formed at the extremity of end portion 22b, so that end portions 22b and 22c bind branch wires W2.

Tie band 20 can be used to bind a T-shaped branch by winding and locking it around trunk wires W1 and branch wires W2 without removing the wire bundle from wiring jig 2. Moreover, as tie band 20 is preformed into a shape resembling the shape with which it attaches and winds around the wire bundle, tie band 20 can be wrapped around the wire bundle while maintaining contact with the wire bundle perimeter.

As previously noted, the present invention provides a branch wire tie band preformed into a curved shape conducive to binding branching electrical wires in a cross-wrapped pattern, thus eliminating the skill required to conventionally tape wrap the branch location and reducing the time needed to bind the location. Further, the present invention differs from those described in the prior art in that a single band may be tightened at a single location, thus increasing the positional precision of the bound branch portion, preventing variations in the quality of the branch bindings, and increasing the productivity of the wire harness assembly process.

The third embodiment of the present invention is shown in FIGS. 12 through 14. As illustrated in FIG. 12, branch wire tie band 110 (hereafter referred to as tie band 110) includes two bands in the form of first tie band 111 and second tie band 112, and anchor plate 13. Tie bands 111 and 112 are utilitarian tie bands of identical configuration.

Anchor plate 13 is a narrow, flat, planar member of any suitable material such as, for example, resin, into which two through holes 13a and 13b are formed at the right and left ends. Tie bands 111 and 112 include straps 111a and 112a that are loosely inserted into through holes 13a and 13b which are formed to a dimension large enough to allow the inclination of straps 111a and 112a therein, but small enough to prevent head portions 111c and 112c, which are part of tie bands 111 and 112 and contain lock channels 111b and 112b formed therein, from passing there through.

Lock pawls 111e and 112e project within lock channels 111b and 112b of first and second tie bands 111 and 112, respectively, and are thus able to lock against any of multiple ratchet grooves 111d and 112d which are formed on one surface of straps 111a and 112a.

As shown in FIG. 13, a wire bundle is placed on wire harness assembly stand 1 so that branch wires W2 separate from trunk wires W1 at wiring jig 2 to form a ‘T’ shape branching region at branch support part WT. Wiring jig 2, which is used to establish the ‘T’ shaped branch, includes wire support posts 2b-1, 2b-2, and 2b-3 that extend upward from the top of main post 2a at 120-degree intervals. Trunk wires W1 are placed between wire support post 2b-1 and the two posts 2b-2 and 2b-3 in a linear configuration, and branch wires W2 are arranged between wire support posts 2b-2 and 2b-3.

T-shaped branch point WT is bound by tie band 110 as illustrated in FIGS. 14A and 14B. ‘X’ and ‘Y’ indicate the two sides of trunk wires W1 that border branch wires W2. First, anchor plate 13 is placed on the side of trunk wires W1 opposite branch wires W2 with strap 111a of first tie band 111 oriented along branch wires W2 on the X-side of trunk wires W2, and strap 112a of second tie band 112 oriented along the Y-side. Strap 111a wraps around from under trunk wires W1, passes between wire support posts 2b-1 and 2b-2 on the X-side, and is then pulled over trunk wires W1 from the X-side of branch wires W2. Strap 112a wraps around from under trunk wires W1, passes between wire support posts 2b-1 and 2b-3, and is then pulled over the trunk wires from the Y-side of branch wires W2.

Straps 111a and 112a wrap around the top of trunk wires W1 where they mutually cross. Strap 112a of second tie band 112 and strap 111a of first tie band 111 are respectively inserted into lock channel 111b of first tie band 111 and lock channel 112b of second tie band 112 which have been pulled up from anchor plate 13. Straps 111a and 112a are secured by pulling them to the required tightness where they lock in position as a result of lock pawl 111e engaging ratchet grooves 112d, and lock pawl 112e engaging ratchet grooves 111d as shown in FIG. 14B. In this manner, straps 111a and 112a of tie band 110 cross-wrap around the wire bundle at T-shaped branch point WT from trunk wires W1 to branch wires W2. After the tie bands have been tightened, the excess pulled-out portions of the straps may be sheared off and discarded.

When tie band 110 is attached to the wiring harness wire bundle, straps 111a and 112a are wrapped around trunk wires W1 which are located between the wire support posts of wiring jig 2. The wire bundle need not be removed from wiring jig 2 because straps 111a and 112a mutually cross and are secured in the lock channels at the top side of trunk wires W1. Moreover, as a result of straps 111a and 112a being wrapped around the trunk wires W1 at both sides where trunk wires W1 border branch wires W2, mutually crossing, and being inserted and pulled through lock channels 112b and 111b to cross-wrap and secure the wire branch point, the wire harness assembly operation does not require a skilled assembly technician, differences in the quality of the branch bindings are eliminated along with positional variations, and the branch binding operation can be conducted with a high degree of precision.

FIGS. 15A and 15B illustrate a variation of the embodiment in which tie band 110 can be used to bind X-shaped wire branch WX. Wire support posts 2b-1, 2b-2, 2b-3, and 2b-4 extend from the top of the main post of wiring jig 2 at 90-degree intervals. Branch wires W2-1 and W2-2 intersect trunk wires W1 at right angles, and pass through wire support posts 2b-2 and 2b-3, and 2b-2 and 2b-4 respectively.

At the time tie band 110 is to be attached to the wiring harness, anchor plate 13 is positioned between the main post of wiring jig 2 and the lower side trunk wires W1 a shown in FIG. 15A. Strap 111a of first tie band 111, which has been placed in the through hole of anchor plate 13, is located on the X-side of branch wires W2-1 and W2-2, and strap 112a of second tie band 112 is located on the Y-side of branch wires W2-1 and W2-2. As shown in FIG. 15B, straps 111a and 112a cross at the upper side of trunk wires W1 with strap 111a pulled through and secured within lock channel 112b of second tie band 112, and strap 112a pulled through and secured within lock channel 111b of first tie band 111. Thus, tie band 110 can be used to bind X-shaped branch WX in this manner as illustrated in FIG. 15B.

FIG. 16 shows a fourth embodiment of the present invention in the form of tie band 110′. In this embodiment, anchor plate 13′ is configured differently from anchor plate 13 of the third embodiment in that anchor plate 13′ is longer and includes vehicle body attachment plug 13c that projects from anchor plate 13′ between right and left thru-holes 13a′ and 13b′. Attachment plug 13c includes post 13c-2 that extends from the upper surface of base portion 13c-1, and a pair of lock tabs 13c-3 that extend back from the tip of post 13c-2. Attachment plug 13c may be integrally formed with the anchor plate 13′. Alternatively, attachment plug 13c may be separately formed and installed through a hole provided in anchor plate 13, thus allowing plug 13c to be attached or removed as desired.

Because there are multiple locations where the wire harness attaches to the vehicle body, the pre-installation of vehicle body attachment plug 13c to anchor plate 13 eliminates the need to attach separate vehicle body attachment plugs to the wire harness, thus reducing the number of wiring harness components as well as assembly processes.

FIGS. 17A, 17B, and 18 illustrate tie ban 110″, a fifth embodiment of the present invention in which the position of the vehicle body attachment plug has been offset with respect to the branching wire location. As shown in FIG. 17B, anchor plate 23 is a flat, planar, T-shaped member in which through holes 23a and 23b are formed at the left and right ends of horizontal portion 23d, and plug hole 23c is formed at the tip of vertical part 23e that extends from the central portion of horizontal part 23d. Vehicle body attachment plug 33 inserts and locks into plug hole 23c. Straps 111a and 112a of first and second tie bands 111 and 112 pass through holes 23a and 23b in the same manner as described in the fourth embodiment.

The procedure through which tie band 110″ is attached and wrapped around T-shaped wire branch WT has been omitted as it is identical to the attachment procedure described in the fourth embodiment.

As noted previously, the present invention includes a wire branch tie band structure that includes an anchor plate in which a pair of through holes are formed, and a pair of utilitarian tie bands whose strap portions are inserted through the anchor plate through holes which are formed large enough to allow sufficient inclination of the straps therein. This structure offers a simple branch wire binding operation in which the tie bands are able to bind a branching wire location by wrapping around and mutually crossing over the trunk wires at each side of the branch wires, after which each strap is inserted and locked within the lock channel of the other tie band.

Moreover, as noted above, the procedure through which each strap is wrapped around the trunk wires at both sides of the branch wires, crossed over the other strap, and then inserted and tightened in the lock channel of the other tie band is a simple process that does not require a skilled assembly technician. Therefore, differences in the quality of the branch bindings are eliminated along with positional variations of the wire branches, and the branch binding operation can be conducted with a higher degree of precision. In addition, the wire branch can be bound without removing the wire bundle from the wiring jig as a result of the procedure through which the anchor plate is positioned on the trunk wires, the two straps wrapped around the wire bundle between the wire bundle and wiring jig and crossed over the trunk wires, and each strap inserted and locked into the lock channel of the other tie band. This structure provides the benefit of allowing the wire branch locations to be positioned with greater accuracy.

Further, because the vehicle body attachment plug can be integrally formed at the center of the anchor plate or at an offset position on a T-shaped anchor plate, or separately formed and attached to the anchor plates, separate vehicle body attachment plugs need not be installed onto the wiring harness, thus making it possible to reduce the number of assembly steps required to fabricate the wiring harness.

Although the invention has been described with reference to an exemplary embodiment, it is understood that the words that have been used are words of description and illustration, rather than words of limitation. Changes may be made within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the invention in its aspects. Although the invention has been described with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed. Rather, the invention extends to all functionally equivalent structures, methods, and uses such as are within the scope of the appended claims.

The present disclosure relates to subject matter contained in priority Japanese Application Nos. JP 2003-192114 and JP 2003-192143, both filed on Jul. 4, 2003, which are herein expressly incorporated by reference in their entireties.

Claims

1. A branch wire tie band for use on a wire harness, said tie band comprising:

a head portion having a lock channel formed therein;

a strap portion extending from said head portion, said strap portion including ratchet teeth formed thereon; and

a curved attachment coil provided as a portion of the strap portion;

wherein said attachment coil is configured to be cross wrapped around a wire branch region on a wire bundle of a wire harness, and said strap portion is configured to be inserted into said lock channel of said head portion and tightened to bind the branching wire region.

2. The branch wire tie band according to claim 1 wherein said attachment coil of said strap portion is configured as a curved spiral shape including first and second curved loops, said attachment coil extending from said head portion to the tip of said strap portion, wherein the tip of said strap portion extends from said second curved loop and is configured to be inserted into said lock channel of said head portion.

3. The branch wire tie band according to claim 1 wherein the center portion of said strap portion curves in the lengthwise direction providing a curved portion followed by a tip portion that crosses said head portion to form said attachment coil.

4. The branch wire tie band according to claim 1, further including spikes which project from the inner wire-bundle-contacting surface of said strap portion to prevent displacement of said strap portion.

5. The branch wire tie band according to claim 1, wherein said tie band is formed of synthetic resin.

6. A wire harness branch wire binding structure including the branch wire tie band according to claim 1, wherein said strap portion is cross wrapped around the trunk wires and branch wires of said wire harness and tightened.

7. A method of binding the branched wire portion of a wiring harness, said method comprising:

providing a branch wire tie band including: a head portion having a lock channel formed therein; a strap portion extending from said head portion, said strap portion including ratchet teeth formed thereon; and a curved attachment coil formed as a portion of the strap portion; wherein said attachment coil is configured to be cross wrapped around a wire branch region on a wire bundle of a wire harness, and said strap portion is configured to be inserted into the lock channel of the head portion and tightened to bind the branching wire region;

placing a bundle of wires on a wiring jig provided on a wire harness assembly stand; and

separating branch wires from trunk wires by passing between multiple wire support posts extending upward from the topmost portion of the wiring jig main post, wherein the attachment coil of the strap portion extends from the trunk wires to wrap around one side of the branch wires,

the strap portion continues to a position facing the lock channel of the head portion located on the other side of the branch wires, and returns to cross over the attachment coil and lock within the lock channel to bind the wire branch location with the cross wrapped tie band,

wherein said method is performed without removing the wire bundle from the wiring jig at the wire branch location.

8. The method of binding the branched wire portion of a wiring harness according to claim 7, wherein the wiring jig includes three uniformly spaced wire support posts formed at the topmost portion thereof to accommodate a T-shaped wire branch pattern, and

said branch wire tie band is configured to bind the T-shaped wire branch location.

9. The method of binding the branched wire portion of a wiring harness according to claim 7, wherein the wiring jig includes four uniformly spaced wire support posts formed at the topmost portion thereof to accommodate an X-shaped wire branch pattern, and

said branch wire tie band is configured to bind the X-shaped wire branch location.

10. A wire harness branch wire tie band comprising:

two tie bands, each said tie band including strap portions having ratchet grooves formed thereon, each said strap portion extending from a respective head portion within which lock channels are formed; and

an anchor plate including left and right through holes formed therein;

wherein said two strap portions are configured to be loosely inserted through the left and right through holes in said anchor plate and extend diagonally therefrom, their tip portions mutually crossing, and their head portions prevented from passing through said through holes; and

at the location where the branch wires divert from the trunk wires, said two strap portions pass along both sides of the branch wires, and wrap around and mutually cross over the wire bundle, each strap portion then projecting through the lock channel of the other strap to bind the bundle of wires at the branching wire location.

11. The wire harness branch wire tie band according to claim 10, wherein said anchor plate is configured as a long, thin, planar member including through holes formed therein at right and left extremities thereof, and further comprising:

a vehicle body attachment plug provided at a center portion of the anchor plate.

12. The wire harness branch wire tie band according to claim 11, wherein said vehicle body attachment plug is formed integrally and in one piece with said anchor plate.

13. The wire harness branch wire tie band according to claim 11, wherein said vehicle body attachment plug is configured to be removably inserted into a vehicle body attachment plug hole provided on said anchor plate.

14. The wire harness branch wire tie band according to claim 10, wherein said anchor plate is configured as a planar T-shaped member including through holes formed therein at left and right extremities of a horizontal portion thereof, and further comprising:

a vehicle body attachment plug provided at the end of a vertical portion extending from the midportion of said horizontal portion of said anchor plate.

15. The wire harness branch wire tie band according to claim 14, wherein said vehicle body attachment plug is formed integrally and in one piece with the end of the vertical portion of said anchor plate.

16. The wire harness branch wire tie band according to claim 14, wherein said vehicle body attachment plug is configured to be removably inserted into a vehicle body attachment plug hole provided on the end of the vertical portion of said anchor plate.

17. A wire harness branch wire binding structure including the branch wire tie band according to claim 10, wherein said two strap portions are cross wrapped around the trunk wires and branch wires and tightened.

18. A method of binding the branch wire portion of a wiring harness, said method comprising:

providing a branch wire tie band including: two tie bands, each said tie band including strap portions having ratchet grooves formed thereon, each said strap portion extending from a respective head portion within which lock channels are formed; and an anchor plate including left and right through holes formed therein;

placing a wire bundle on a wiring jig on a wire harness assembly stand at the location where branch wires divert from trunk wires, and supporting the wire bundle between multiple wire support posts that branch upward from a wiring jig main post, and

wrapping said strap portions around the trunk wires at both sides of the branch wires after which they mutually cross, then inserting and locking each strap portion into the lock channel of the head portion of the other tie band without removing the wire bundle from the wiring jig at the branching wire location.

19. The method of binding the branched wire portion of a wiring harness according to claim 18, wherein the wiring jig includes three uniformly spaced wire support posts formed at the topmost portion thereof to accommodate a T-shaped wire branch pattern, and

said branch wire tie band is configured to bind the T-shaped wire branch location.

20. The method of binding the branched wire portion of a wiring harness according to claim 18, wherein the wiring jig includes four uniformly spaced wire support posts formed at the topmost portion thereof to accommodate an X-shaped wire branch pattern, and

said branch wire tie band is configured to bind the X-shaped wire branch location.