Detailed Description
A protector includes: a protector body having one body side wall (first body side wall) and the other body side wall (second body side wall); a protector cover covering the opening of the protector body; a hinge connecting the protector body and the protector cover; a lock mechanism provided on the other body side wall; and a second locking mechanism provided at a position opposite to the locking mechanism. A main body side hinge-connecting portion that is connected to one end of a hinge is formed at an intermediate portion or a base end of one main body side wall. The protector cover includes: a cover main body; a cover side hinge connection part connected with the other end of the hinge; and a cover side wall provided between the cover side hinge connection part and the cover main body and facing the one main body side wall.
First embodiment
Hereinafter, the first embodiment will be described with reference to the drawings. Fig. 1 is an overall configuration diagram showing a protector, a protector wire overflow detecting structure, and a protector module according to an embodiment of the present invention. Fig. 2 is an enlarged view showing a portion indicated by an arrow a in fig. 1. Fig. 3 is an enlarged view illustrating the protector shown in fig. 2. Fig. 4 is a view showing a state in which the protector cover is opened as compared with the state in fig. 3. Fig. 5 is a view seen from the direction of arrow B in fig. 3. Fig. 6 is a view seen from the direction of arrow B in fig. 4.
In fig. 1, a protector module 21 is provided for a battery pack (not shown) mounted on an electric vehicle or the like. The protector module 21 may be referred to as a "wire harness" and may be laid at a predetermined position of the vehicle. The protector module 21 may be used in the state shown in the drawings, or may be used as a constituent member of another module. The protector module 21 shown in the drawings comprises: a protector 22 formed of resin; a wire harness main body 23 accommodated and protected by the protector 22; a connector 24 provided at a distal end of the wire harness main body 23; a bellows 25 provided between the protector 22 and the connector 24; and a clamp 26. This configuration of the protector module 21 is merely an example. As can be seen from the drawings, the protector module 21 is formed in a long shape. First, the wire harness main body 23 will be described, and then the protector 22 according to the embodiment of the present invention will be described.
In fig. 1 and 2, the wire harness main body 23 includes a plurality of wire bundles 27. Each wire bundle 27 is formed by bundling a plurality of wires each including a conductor and an insulator covering the conductor. The conductor is a portion formed of a conductive metal such as copper, a copper alloy, aluminum, and an aluminum alloy. The conductor is formed in a state where, for example, strands are twisted. The conductor is formed to have a circular sectional shape. The insulator is an insulating portion formed of a resin such as a polyvinyl chloride resin, a polyethylene resin, and a polypropylene resin. The insulator is extruded around the conductor and has a cylindrical cross-sectional shape. The insulator is a member that covers the conductor and is formed to have a predetermined thickness. A part of the wire harness main body 23 as described above is accommodated in the protector 22 and protected from the outside.
In fig. 1, the protector 22 is a resin molded article using an insulating resin material. The protector 22 includes: a protector main body 28; a protector cover 30 covering an opening portion 29 (see fig. 4) of the protector main body 28; a pair of hinges 31 connecting the protector main body 28 and the protector cover 30; a first locking mechanism 32 (locking mechanism) and a second locking mechanism 33. The protector 22 is formed in such a manner that the entire protector 22 is formed as one component. When the protector needs to be formed longer than the shape shown in the drawings, a plurality of protectors having the features of the protector 22 to be described later may be employed, and for example, these protectors may be connected. Here, the protector end 34 indicated by the arrow a in fig. 1 is taken as a representative example, and the structure of this portion will be described in detail (the structure of the portion other than the protector end 34 indicated by the arrow a has substantially the same structure).
In fig. 2 to 6, the protector main body 28 in the protector end portion 34 is formed in a groove shape. That is, the protector body 28 includes a body bottom wall 35, a body side wall 36, and a body side wall 37, and is formed in a shape formed inside as a groove shape shown in the drawings. Reference numeral 38 denotes a harness extraction opening in the protector body 28. Arrow P indicates the up-down direction, arrow Q indicates the left-right direction, and arrow R indicates the axial direction of the protector 22 (protector axial direction). These directions are merely examples, and here, the up-down direction of the drawing is substantially aligned with the arrow P. The harness exit 38 is formed with a scratch-proof portion (tapered or curved surface) for the wire harness 27 of the harness main body 23, and the reference numeral of the scratch-proof portion is omitted.
The main body bottom wall 35 is a wall positioned at the bottom of the groove, and both the inner surface and the outer surface of the main body bottom wall 35 are formed as flat surfaces. The width of the main body bottom wall 35 is formed to be equal to or larger than the diameter of the wire harness main body 23 (the wire harness 27). The body side walls 36 and 37 are formed as walls rising from the left and right side portions of the body bottom wall 35. The body side wall 36 and the body side wall 37 are connected to the body bottom wall 35 so as to rise at right angles. The height of the body side wall 36 is higher than the height of the body side wall 37 (due to the structure of the first locking mechanism 32). The height of the main body side wall 36 and the height of the main body side wall 37 are set to be equal to or larger than the diameter of the wire harness main body 23 (wire harness 27). In other words, the main body side wall 36 and the main body side wall 37 are formed to have a height equal to or larger than the diameter of the wire harness main body 23 (the wire harness 27). The inner and outer surfaces of the body side wall 36 and the body side wall 37 are also formed as flat surfaces.
A pair of main body side hinge connections 39 are formed on the outer surface of the main body side wall 36. Specifically, a pair of main body side hinge links 39 are formed at the base ends of the main body side walls 36. The pair of main body side hinge links 39 are formed as tab portions that project short from the base ends of the main body side walls 36. The pair of main body side hinge connections 39 are formed to protrude with the thickness of a cover side wall 43 to be described later. The pair of main body side hinge connecting portions 39 are formed as portions connected to respective end portions of the pair of hinges 31. Although in the present embodiment, the pair of main body side hinge links 39 are formed at the base end of the main body side wall 36, the pair of main body side hinge links is not limited thereto. That is, a pair of main body side hinge links 39 may be formed at the intermediate portion of the main body side wall 36 as in a second embodiment to be described later (see fig. 8).
The body end portions 40 and 41 located in the ascending direction (the upward direction of the arrow P) of the body side walls 36 and 37 face the left and right side portions of the body bottom wall 35 and are parallel to the left and right side portions of the body bottom wall 35. Body end 40 and body end 41 are also parallel to each other. The opening 29 is formed between the body end 40 and the body end 41. A body end 40 and a body end 41 are formed at the ends of the flat surface.
In fig. 2 to 6, the protector cover 30 is formed as a cover-like portion that covers the opening 29 of the protector main body 28 so as to straddle the opening 29. Alternatively, the protector cover 30 may be formed to cover a portion of the entire opening portion 29. The protector cover 30 includes a top wall 42 (cover main body), a cover side wall 43, and a cover side wall 44, and is formed in a shape shown in the drawings. The top wall 42 is formed in a wall shape according to the width of the opening 29 of the protector main body 28. When the top wall 42 covers the opening portion 29, the top wall 42 is disposed to face the main body bottom wall 35 of the protector main body 28 (disposed parallel to the main body bottom wall 35). The inner and outer surfaces of the top wall 42 are formed as flat surfaces. Locking indicia 45 are formed on the outer surface of the top wall 42. The lock mark 45 is formed as a portion for indicating the position of the first locking mechanism 32.
In fig. 2 to 6, the lid side wall 43 and the lid side wall 44 are formed as wall portions extending straight downward from the left side portion and the right side portion of the top wall 42, respectively. The cover side wall 43 is formed long in a downwardly extending manner. On the other hand, the cover side wall 44 is formed short in a manner extending downward. The lid side wall 43 and the top wall 42 are arranged to form an L-shape. The cover side wall 43 is formed such that the inner surface of the cover side wall 43 faces the outer surface of the main body side wall 36 of the protector main body 28. The cover side wall 43 is formed as a portion for detecting wire overflow, which will be described later. A pair of cover-side hinge coupling portions 46 are formed on the outer surface of the end portions of the cover side walls 43 formed in the above-described manner. The pair of cover-side hinge coupling portions 46 are respectively formed as portions that are continuous with the other end of each of the pair of hinges 31. The lid side walls 43 are disposed between a pair of lid side hinge connections 46 and the top wall 42.
In fig. 2 to 6, the pair of hinges 31 are portions for connecting the protector main body 28 and the protector cover 30, and are formed as thin walls that can be repeatedly bent into a U shape. Since the pair of hinges 31 are portions that join the protector main body 28 and the protector cover 30, the pair of hinges 31 can be used to prevent the protector cover 30 from falling off during operation. One end of each of the pair of hinges 31 is connected to each of a pair of main body side hinge links 39 protruding from the base end of the main body side wall 36. Since the pair of hinges 31 are connected at such a position, the second locking mechanism 33 can be formed. Since the second locking mechanism 33 is formed in this manner, even if the pair of hinges 31 is broken, the protector cover 30 can be prevented from falling off.
In fig. 2 to 6, the first locking mechanism 32 is a "locking mechanism" and is provided to hold a state in which the protector cover 30 covers the opening portion 29 of the protector main body 28 so as to straddle the opening portion 29. The first locking mechanism 32 includes: a female locking portion 47 formed on the main body side wall 37 of the protector main body 28; and a male locking portion 48 formed on the cover side wall 44 of the protector cover 30. The first locking mechanism 32 is formed as a mechanism in which the female locking portion 47 and the male locking portion 48 are engaged with each other. The female locking portion 47 is formed as a frame-shaped portion. The female locking portion 47 is provided according to the position of the body end 41 on the body side wall 37. Since the female locking portions 47 are provided as described above (i.e., since the female locking portions 47 are provided at the high positions), even when the electric wires overflow to the main body side walls 37 side, the electric wires can be brought into a state of being lifted up on the female locking portions 47. When the operator sees that the electric wire is lifted up on the female locking portion 47, the overflow of the electric wire can be detected. On the other hand, the male locking portions 48 are formed as male locking portions. The male locking portion 48 includes a male locking portion body 49 and a locking protrusion 50 formed on the male locking portion body 49, and is formed in a shape shown in the drawings. The male locking portion 48 is a portion formed in the following manner: when the male locking portion body 49 is inserted into the female locking portion 47, the locking protrusion 50 is hooked.
In fig. 2 to 6, the second locking mechanism 33 is a locking mechanism provided at a position opposite to the first locking mechanism 32. The second locking mechanism 33 includes: a locking projection 51 formed on the main body side wall 36 of the protector main body 28; and a locking hole 52 formed in the protector cover 30. The second lock mechanism 33 is provided to maintain the following state: even when the pair of hinges 31 is broken, the protector cover 30 covers the opening 29 of the protector body 28 so as to straddle the opening 29. The locking projection 51 has a main body side locking surface 53. The body-side locking surface 53 is formed in a protruding shape such that the body-side locking surface 53 is located at a downward position at the outer surface side of the body-side wall 36. The locking projection 51 is formed so as to project from the body end 40. Since the locking projection 51 is formed in the projection shape as described above, the locking projection 51 is formed as a functional portion that makes it less likely that the electric wire overflows even when the electric wire tends to overflow to the main body side wall 36 side. The locking hole 52 is formed as a portion: which is located at a connection portion between the top wall 42 as the cap main body and the cap side wall 43 and is opened to have a hole shape. The locking hole 52 is formed to be locked to a portion of the locking protrusion 51. The locking hole 52 is formed with a cover side locking surface 54 which is locked to the main body side locking surface 53 by a hook. In this way, the second locking mechanism 33 is disposed at a position aligned with the first locking mechanism 32 when viewed from a direction orthogonal to the protector axis. Since the two lock mechanisms are provided in the direction orthogonal to the protector axis, the locking is stable, and the holding state of the protector cover 30 can be enhanced. Instead of being arranged in a position aligned with the first locking means 32, said second locking means 33 may also be arranged in an alternative position axially offset from the protector.
In fig. 2 to 6, the protector 22 has a structure in which the hinge 31 is continuous with the base end of the main body side wall 36 of the protector main body 28, the notch portion 18 as shown in fig. 10A is not formed on the main body side wall 36 even when the hinge 31 is provided at the base end of the main body side wall 36, and further, the protector cover 30 has a cover side wall 43 facing the main body side wall 36. Therefore, even when the electric wires overflow to the outside of the main body side wall 36, the overflowing electric wires are interposed between the main body side wall 36 and the cover side wall 43, and the operation of covering the opening portion 29 with the protector cover 30 cannot be completed. Therefore, the protector 22 can detect the overflow of the electric wire by the above-described structure. According to the protector 22, even when the electric wire overflows and the operation of covering the opening portion 29 with the protector cover 30 is performed without noticing the overflowing electric wire, since the electric wire is interposed between the body side wall 36 and the cover side wall 43, the positions of the male locking portion 48 and the female locking portion 47 of the first locking mechanism 32 are deviated from the correct engagement positions at which the male locking portion 48 and the female locking portion 47 are engaged with each other, and the locking of the electric wire by the first locking mechanism 32 (locking mechanism) cannot be completed. Therefore, when the locking cannot be completed, the overflow of the electric wire can be detected.
According to the protector 22, since the ceiling wall 42 (cover main body) covering the opening portion 29 and the cover side wall 43 facing the main body side wall 36 are arranged in the L shape, when the electric wires overflow to the outside and the overflowing electric wires are interposed between the main body side wall 36 and the cover side wall 43, the ceiling wall 42 can also be brought into a state of being lifted relative to the opening portion 29 under the L-shaped arrangement. Thus, when the top wall 42 is raised, the protector 22 is also able to detect the spilling of the cord.
Since the locking projection 51 and the locking hole 52 are provided on the side where the hinge 31 is provided, the protector 22 may have a structure in which the second locking mechanism 33 can be provided on the side opposite to the first locking mechanism 32 (locking mechanism). Therefore, when the electric wires overflow to the outside, the overflowing electric wires are interposed between the body side wall 36 and the cover side wall 43, and the locking of the electric wires by the second locking mechanism 33 (the locking protrusion 51 and the locking hole 52) cannot be completed. Therefore, the protector 22 can also detect the overflow of the electric wire when the locking of the electric wire by the second locking mechanism 33 (the locking projection 51 and the locking hole 52) cannot be completed.
As described above with reference to fig. 1 to 6, the protector 22 according to the embodiment of the present invention is capable of detecting the overflow of the electric wire. Therefore, it is possible to prevent the operation without noticing the overflow of the electric wire before the opening portion 29 is covered by the protector cover 30. In addition, since the wire overflow detecting structure and the protector module 21 according to the embodiment of the present invention include the above-described protector 22, a better wire overflow detecting structure and a better protector module 21 can be provided.
Second embodiment
Hereinafter, the second embodiment will be described with reference to the drawings. Fig. 7 is an enlarged view showing a protector according to another embodiment. Fig. 8 is an enlarged view showing a protector according to another embodiment. The same components as those in the first embodiment described above are denoted by the same reference numerals, and the description thereof will be omitted.
In fig. 7, a protector 22' according to another embodiment is not provided with the second locking mechanism 33 (the locking projection 51 and the locking hole 52) according to the first embodiment. The protector 22' is capable of detecting the overflow of the wire.
In fig. 8, a protector 22 "according to another embodiment differs from the protector 22 according to the first embodiment in the arrangement of the hinge 31. That is, the hinge 31 is formed so as to be continuous with an intermediate portion of the main body side wall 36 of the protector main body 28. The protector 22 "is capable of detecting the overflow of the wire.
Needless to say, various modifications can be made to the present invention without departing from the gist of the present invention.
Here, the above embodiments are summarized as follows.
According to a first aspect of the present invention there is provided a protector comprising:
a protector body having a body bottom wall, and a first body side wall and a second body side wall that rise in a rising direction from both side portions of the body bottom wall, respectively;
a protector cover configured to cover an opening portion between first and second body end portions at end portions of the first and second body side walls in the ascending direction;
a hinge joining the first body sidewall and the protector cover; and
a lock mechanism provided on the second main body side wall to maintain a state in which the protector cover covers the opening portion,
wherein a main body side hinge-connection part connected to one end of the hinge is formed at a middle part or a base end of the first main body side wall, and
wherein the protector cover has: a cover main body covering the opening; a cover side hinge connection part connected to the other end of the hinge; and a first cover side wall provided between the cover side hinge connection portion and the cover main body and facing the first main body side wall in a state where the protector cover covers the opening portion.
According to the present invention having the features of the first aspect, the protector has a structure in which the hinge is continuous with the intermediate portion or the base end of the first body side wall of the protector main body, the notch portion as shown in fig. 10A is not formed on the first body side wall even when the hinge is provided at the intermediate portion or the base end of the first body side wall, and further, the protector cover has the first cover side wall facing the first body side wall. Therefore, when the electric wire overflows to the outside of the first body side wall, the overflowing electric wire is interposed between the first body side wall and the first cover side wall, and the operation of covering the opening portion with the protector cover cannot be completed. Therefore, the present invention can detect the overflow of the electric wire by the above-described structure. According to the present invention, when the electric wire overflows to the outside and the operation of covering the opening portion with the protector cover is performed without noticing the overflowing electric wire, since the electric wire is interposed between the first body side wall and the first cover side wall, the positions of the female locking portion and the male locking portion are deviated from the correct fitting position, and the locking of the electric wire by the locking mechanism cannot be completed. Therefore, when the locking cannot be completed, the overflow of the electric wire can be detected.
The second aspect of the present invention provides that the protector cover is formed such that the cover main body and the first cover side wall are arranged in an L-shape.
According to the present invention having the features of the second aspect, since the cover main body covering the opening portion and the first cover side wall facing the first main body side wall are arranged in the L shape, when the electric wire overflows to the outside and the overflowing electric wire is interposed between the first main body side wall and the first cover side wall, in the L-shaped arrangement, the cover main body can be brought into a state of being lifted with respect to the opening portion. Therefore, the present invention can also detect the overflow of the electric wire when the cover main body is lifted.
A third aspect of the present invention provides that the protector cover is formed in a shape in which the cover main body covers the opening portion so as to straddle the opening portion.
According to the invention having the features of the third aspect, the protector cover can be provided in a better form. The present invention can be realized in a form in which the cover main body of the protector cover covers the entire opening portion of the protector main body.
A fourth aspect of the present invention provides that a locking protrusion having a body-side locking surface and having a protrusion shape is formed at the first body end on the first body side wall, wherein the body-side locking surface is positioned at an outer surface side of the first body side wall, the protector cover has a locking hole which is positioned at a connection portion between the cover body and the first cover side wall and is opened to have a hole shape, and the locking hole has a cover-side locking surface which is locked to the body-side locking surface by hooking.
According to the invention having the features of the fourth aspect, since the locking projection and the locking hole are formed at the side where the hinge is provided, the invention can have a structure in which the second locking mechanism can be provided at the side opposite to the locking mechanism. Therefore, when the electric wire overflows to the outside and the overflowing electric wire is interposed between the first body side wall and the first cover side wall, the locking of the electric wire by the second locking mechanism (the locking protrusion and the locking hole) cannot be completed. Therefore, the present invention can also detect the overflow of the electric wire when the locking of the electric wire by the second locking mechanism (the locking protrusion and the locking hole) cannot be completed. The second locking mechanism (locking projection and locking hole) is used to ensure the function of the protector cover even when the hinge is broken for some reason.
A fifth aspect of the present invention provides that the locking projection and the locking hole are provided at positions aligned with the locking mechanism when viewed in a direction orthogonal to the axis of the protector body.
According to the invention having the features of the fifth aspect, since the two lock mechanisms are provided in the direction orthogonal to the protector shaft, the locking is stable, and the holding state of the protector cover can be enhanced.
A sixth aspect of the present invention provides the lock mechanism including: a female locking portion provided at a side wall of the second body; and a male locking portion provided at a second cover side wall of the protector cover according to a position of the female locking portion, and the female locking portion is provided according to a position of the second body end.
According to the invention having the features of the sixth aspect, since the female locking portion of the locking mechanism is provided (i.e., at a high position) in accordance with the position of the second body end portion on the second body side wall of the protector body, the female locking portion can be brought into a lifted state when the electric wire overflows to the second body side wall side. Therefore, the overflow of the electric wire can be detected by the state in which the female lock portion is lifted.
According to a seventh aspect of the present invention, there is provided a protector wire overflow detecting structure comprising:
a protector body having a body bottom wall, and a first body side wall and a second body side wall that rise in a rising direction from both side portions of the body bottom wall, respectively;
a protector cover configured to cover an opening portion between first and second body end portions at end portions of the first and second body side walls in the ascending direction;
a hinge joining the first body sidewall and the protector cover; and
a lock mechanism provided on the second main body side wall to maintain a state in which the protector cover covers the opening portion,
wherein a main body side hinge-connection portion that is continuous with one end of the hinge is formed at a middle portion or a base end of the first main body side wall,
wherein the protector cover has: a cover main body covering the opening; a cover side hinge connection part connected to the other end of the hinge; and a first cover side wall provided between the cover side hinge joint and the cover main body and facing the first main body side wall in a state where the protector cover covers the opening portion, and
wherein when an electric wire to be accommodated in the protector body overflows from the protector body before the protector cover covers the opening portion, the electric wire is interposed between the first body side wall and the first cover side wall and restricts a locking operation of the locking mechanism.
According to the present invention having the features of the seventh aspect, since the electric wire overflow detecting structure includes the protector according to the first aspect, the overflow of the electric wire can be detected in a similar manner to the first aspect.
According to an eighth aspect of the present invention, there is provided a protector module comprising:
the protector according to any one of the first to sixth aspects; and
an electric wire housed in the protector.
According to the invention having the features of the eighth aspect, since the protector module includes the protector according to the first aspect, a better protector module can be provided. When the "protector module" is referred to as a "wire harness", it is apparent that the "protector module" is also applicable to the invention of the "wire harness".