CN114155996A

CN114155996A - Cable with sensor

Info

Publication number: CN114155996A
Application number: CN202111044828.3A
Authority: CN
Inventors: 冨田和彦
Original assignee: Hitachi Metals Ltd
Current assignee: Proterial Ltd
Priority date: 2020-09-08
Filing date: 2021-09-07
Publication date: 2022-03-08
Also published as: JP7456335B2; JP2022045059A

Abstract

The invention provides a cable with a sensor, which can improve the resistance to combustion and can inhibit poor welding. As a solution, a cable with a sensor has a first core wire, a sheath, a second core wire, and a covering member. The first core includes a first lead wire to which a terminal of the sensor is bonded by resistance welding, and a first insulating film covering the periphery of the first lead wire. The sheath covers the first core wire and is formed of a material having higher resistance to combustion than the first insulating film. The second core wire has a second conductive wire connected to the first conductive wire in a conductive manner, and a second insulating film covering the periphery of the second conductive wire and formed of a material having higher resistance to combustion than the first insulating film. The covering member covers at least the first insulating film exposed from the sheath and is formed of a material having higher resistance to combustion than the first insulating film.

Description

Cable with sensor

Technical Field

The present invention relates to a cable with a sensor used for a wire harness for a vehicle.

Background

Conventionally, a cable with a sensor used in a wire harness for a vehicle or the like includes a sensor and a lead wire that is electrically connected to a terminal of the sensor. In such a cable with a sensor, one end of a lead wire is electrically connected to a terminal of the sensor, and the other end of the lead wire is connected to a predetermined device or the like, whereby an electric signal or the like obtained by the sensor is transmitted to the predetermined device or the like (for example, see patent document 1).

[ Prior art documents ]

[ patent document ]

[ patent document 1] Japanese patent laid-open publication No. 2013-237428

Disclosure of Invention

Problems to be solved by the invention

When a cable with a sensor is manufactured, a terminal provided in the sensor and a lead wire connected to the terminal are connected by soldering.

When the sensor-equipped cable is used for a wire harness for a vehicle or the like, a material having high resistance to combustion may be used as a sheath of the cable or an insulating coating of a lead wire.

Here, a material having high resistance to combustion may contain a flame retardant. Therefore, the material is often brittle as compared with a material containing no flame retardant. As a result, for example, when the insulating film using the material containing the flame retardant is peeled off from the lead, the insulating film is separated from the surface of the lead, and a part of the separated insulating film is likely to remain in a state of being adhered to the surface of the lead.

As a result, a part of the insulating film remaining when the insulating film is peeled off from the lead wire is interposed between the terminal of the sensor and the surface of the lead wire or between the surface of the lead wire and the welding electrode, which causes a welding failure when the sensor terminal is welded to the lead wire.

An object of one aspect of the present disclosure is to provide a sensor-equipped cable capable of improving resistance to combustion and suppressing welding defects.

Means for solving the problems

One embodiment of the present disclosure is a sensor-equipped cable including a first core wire, a sheath, a second core wire, and a covering member. The first core includes a first lead wire to which a terminal of the sensor is bonded by resistance welding, and a first insulating film covering the periphery of the first lead wire. The sheath covers the first core wire and is formed of a material having higher resistance to combustion than the first insulating film. The second core wire has: a second conductive line connected to the first conductive line in a conductive manner; and a second insulating film covering the periphery of the second lead and formed of a material having higher resistance to combustion than the first insulating film. The covering member covers at least the first insulating film exposed from the sheath, and is formed of a material having higher resistance to combustion than the first insulating film.

With this configuration, the terminal of the sensor and the first lead wire of the first core wire are welded by resistance welding. Further, since the first insulating film of the first lead wire is not formed of a material having a resistance to combustion higher than a predetermined standard, it is possible to suppress adhesion of the insulating film after separation to the surface of the lead wire, which is caused by using the material for the insulating film, and which causes a welding failure.

In the first core, the circumferential surface of the first insulating film using a material having a lower resistance to combustion than a predetermined reference is covered with the sheath having a higher resistance to combustion than a predetermined reference, and therefore the cable has a higher resistance to combustion than a predetermined reference.

According to the above, the resistance to combustion is higher than a predetermined reference and welding can be easily performed for the cable with a sensor.

Drawings

Fig. 1 is a side view showing a configuration of a cable with a sensor in the embodiment.

Fig. 2 is a plan view showing a connection portion of the sensor with the first core wire in the embodiment.

Fig. 3 is a sectional view showing an a-a' section of the first core wire in fig. 1.

Fig. 4 is a sectional view showing a B-B' section of the second core wire in a state where the connector in fig. 1 is removed.

Fig. 5 is a plan view showing the inside of the sheathing member in the embodiment.

Fig. 6 is a plan view showing the inside of the sheathing member in another embodiment.

Fig. 7 is a plan view showing a positional relationship of the sheathing member with the first sheath and the second sheath in other embodiments.

Fig. 8 is a side view showing the structure of the cable with a sensor in the comparative example.

[ description of symbols ]

1, 2, 3, 100 … sensor-equipped cables, 10, 110 … sensors, 11 … sensor housings, 11a … through holes, 13 … sensor ICs, 15 … sensor terminals, 15a … first ends, 15b … second ends, 20 … cables, 21 … first core wires, 21a … first lead wires, 21b … first insulating films, 23 … second core wires, 23a … second lead wires, 23b … second insulating films, 25 … connectors, 27, 40, 127 … sheaths, 29, 69, 129 … sheaths, 30 … connectors, 50 … insulating members, 160 … core wires.

Detailed Description

[1. constitution ]

The sensor-equipped cable 1 according to the present embodiment will be described with reference to fig. 1 to 5. The sensor-equipped cable 1 is used for a wire harness for a vehicle such as an automobile. The cable with sensor 1 is used as an ABS cable or an EPB cable, for example. Here, ABS is an abbreviation of Antilock Brake System (Antilock Brake System), and EPB is an abbreviation of Electric Parking Brake (Electric Parking Brake).

Fig. 1 is a side view showing the structure of a sensor-equipped cable 1 according to the embodiment.

In the present embodiment, the positional relationship will be described using x, y, and z axes orthogonal to each other for the arrangement of each configuration. Note that the xy plane is a horizontal plane in real space, and the z axis is a height direction in real space orthogonal to the xy plane. The positive x-axis direction is designated as the right direction, the negative x-axis direction is designated as the left direction, the negative y-axis direction is designated as the near-front direction, the positive y-axis direction is designated as the depth direction, the positive z-axis direction is designated as the up direction, and the negative z-axis direction is designated as the down direction. The description will be made with the xz plane as a side surface.

As shown in fig. 1, the sensor-equipped cable 1 has a sensor 10 and a cable 20. The sensor-equipped cable 1 may further include a connector 30. In the present embodiment, an example including the connector 30 is described.

The sensor 10, the cable 20, and the connector 30 are arranged in this order from the negative side toward the positive side along the x-axis direction.

The sensor 10 uses an ABS sensor in the case where the cable 1 with a sensor is an ABS cable. The ABS sensor mentioned herein is a sensor for measuring the speed of the wheel of the vehicle to which the sensor-equipped cable 1 is attached, and is also referred to as a wheel speed sensor. The sensor 10 is not limited to the ABS sensor, and may be various sensors.

The cable 20 transmits the signals taken from the sensor 10. The cable 20 is formed in an elongated shape. The cable 20 is formed of a material capable of bending deformation. In the present embodiment, an example in which the longitudinal direction of the elongated shape of the cable 20 is located along the x-axis direction will be described.

The x-axis negative side end of the cable 20 is connected to the sensor 10. The x-axis positive end of the cable 20 is connected to the connector 30.

The connector 30 is configured to enable connection of the cable 20 to other components or devices. In the connector 30, for example, terminals may be arranged on the x-axis positive side and the x-axis negative side with respect to the connector 30 main body.

The terminal on the x-axis positive side of the connector 30 is formed so as to be connectable to other components or devices. The shape of the terminal on the x-axis positive side of the connector 30 may be specifically formed into a shape that satisfies a specification capable of connecting with a predetermined component or device.

The x-axis negative terminal of the connector 30 is configured to be connectable to the cable 20.

As the material of the connector 30, a flame retardant material described later can be used.

Fig. 2 is a plan view showing a connection portion of the sensor 10 and the first core wire 21. In other words, the respective configurations of the sensor 10 and the configuration of the portion connected to the first core wire 21 are shown from the z-axis positive side toward the z-axis negative side. The internal structure of the sensor 10 is shown by the sensor housing 11.

As shown in fig. 2, the sensor 10 includes a sensor housing 11, a sensor IC 13, and a sensor terminal 15.

The sensor housing 11 forms an internal space, and the sensor IC 13 and the sensor terminal 15 are disposed in the internal space. The sensor frame body 11 may be formed of a resin molded product. That is, as a material of the sensor housing 11, a resin material molded into a predetermined shape by injection molding can be used.

A through hole 11a is formed in at least a part of a boundary surface between an internal space formed by the sensor housing 11 and the outside. The through hole 11a is formed in the sensor housing 11 on the x-axis positive side with respect to the center of the sensor housing 11.

The sensor housing 11 may be divided into an upper portion and a lower portion, for example, so that the divided portions are fitted to each other to form an internal space.

As the material of the sensor housing 11, a flame retardant material described later can be used.

The sensor IC 13 is, for example, an electronic component that acquires a predetermined physical quantity, converts the physical quantity into an electric signal, and outputs the electric signal. For example, when the sensor 10 is a wheel speed sensor, the sensor IC 13 may acquire a physical quantity (magnetic flux density change) corresponding to a wheel speed of the vehicle, convert the physical quantity into an electric signal, and output the electric signal. Further, the type of physical quantity processed by the sensor IC 13 may be variously changed according to the physical quantity acquired by the sensor 10.

The sensor terminal 15 is a terminal for outputting an output from the sensor IC 13 to the outside of the sensor 10. The sensor terminal 15 is formed of a conductor such as a metal. The sensor terminal 15 is formed in a long shape, and is disposed so that the longitudinal direction thereof is the x-axis direction.

Hereinafter, the x-axis negative side end of the both ends of the sensor terminal 15 is also referred to as a first end 15a, and the x-axis positive side end of the both ends of the sensor terminal 15 is also referred to as a second end 15 b.

The first end portion 15a is connected to the sensor IC 13. The second end portion 15b is disposed so as to extend from the sensor IC 13 toward the through hole 11a formed in the sensor housing 11.

As shown in fig. 1, the cable 20 includes a first core wire 21, a second core wire 23, a connection portion 25, a sheath 27, and a covering member 29. In the present embodiment, an example in which the cable 20 includes two first cores 21 and two second cores 23, and two connection portions 25 are provided corresponding to the number of the first cores 21 and the second cores 23 will be described. The number of the first and

second core wires

21 and 23 included in the cable 20 is not limited to two, and may be less than two or more than two. The number of the connection portions 25 provided in the cable 20 is not limited to two, and may be less than two or more than two.

The first core 21, the second core 23, and the connection portion 25 of the cable 20 may be the same in number.

The two first core wires 21 are formed in an elongated shape. The two first core wires 21 are arranged such that the longitudinal direction thereof is along the x-axis direction.

The two first core wires 21 are provided with a first lead wire 21a and a first insulating film 21b, respectively.

The first wire 21a is a long metal wire. The first lead 21a is disposed so that the longitudinal direction thereof is oriented in the x-axis direction. The first insulating film 21b covers the peripheral surface of the first lead 21 a.

Fig. 3 shows a cross section taken along a yz plane (a-a' cross section in fig. 1) orthogonal to the x-axis of the two first core wires 21. As shown in fig. 3, the two first core wires 21 may be arranged adjacent to each other in the y-axis direction. The first lead 21a may be formed in a substantially circular shape in yz cross section, and the first insulating film 21b may be disposed along a circumferential direction of the substantially circular shape.

As a material of the first conductive line 21a, for example, copper is used. The first conductive line 21a may be a copper alloy line or a soft copper line. The material of the first conductive line 21a is not limited to copper. As a material of the first lead wire 21a, a material having conductivity and capable of being welded to another metal material by resistance welding may be used. The material of the first wire 21a may be a material used as a conductor of a general wire.

As shown in fig. 2, the x-axis negative side tip portion of the first core wire 21 may be inserted into the internal space of the sensor housing 11 only by a predetermined length. In the distal end portion inserted into the internal space of the sensor housing 11, the first lead wire 21a may be exposed from the first insulating film 21b by a predetermined length from the distal end on the x-axis negative side. That is, the first insulating film 21b may be peeled off from the first lead 21 a. Further, the first lead wire 21a exposed from the first insulating film 21b is welded to the second end 15b of the sensor terminal 15 by resistance welding. The position of the sensor terminal 15 to which the first lead wire 21a is welded is not limited to the second end portion 15b, and may be other positions as long as the sensor terminal 15 is electrically connected. Further, the method of welding the first lead wire 21a to the second end 15b of the sensor terminal 15 may be TIG (Tungsten Inert Gas) welding.

The material of the first insulating film 21b may be any material that suppresses adhesion of a part of the first insulating film 21b to the peripheral surface of the first conductive wire 21a when the first insulating film 21b is peeled off from the first conductive wire 21 a. As a material of the first insulating film 21b, a material not containing a flame retardant or a crosslinking assistant is used. The first insulating film 21b is made of a material having a lower resistance to combustion than a predetermined standard. Specifically, as a material of the first insulating film 21b, crosslinked polyethylene can be used.

The predetermined criterion relating to the resistance to combustion may correspond to a standard specified by JASO, for example. JASO is an abbreviation for Japanese automobile Standards Organization (Japan automatic Standards Organization). In addition, JASO is also known as the japan automobile technical society standard.

The predetermined reference relating to the resistance to combustion can be determined by a flame retardancy test performed by the following method.

The sample is horizontally supported so that the tip of the reducing flame of the burner is in contact with the sample from the lower side of the center portion of the sample within 30 seconds until the insulator burns. Next, the determination may be made by measuring the time from when the reducing flame of the burner is quietly removed until the combustion flame is extinguished. Here, the criterion is determined to be satisfied when the time from when the reducing flame of the burner is quietly removed until the combustion flame is extinguished is within 15 seconds, and the criterion is determined not to be satisfied when the time is longer than 15 seconds. The combustion flame as used herein refers to a flame generated when a reducing flame is ignited to a sample and the sample is burned.

When the reduction flame of the burner is brought into contact with the sample for 30 seconds, the sample is not combusted, and it can be determined that the reference is satisfied.

The sample used in the flame retardancy test may be a sample having a length of about 300mm taken from an electric wire. In the present embodiment, the first insulating film 21b having a length of about 300mm taken from the first core wire 21 may be used. The first insulating film 21b may be any insulating film that is determined to be not satisfactory as a standard by the flame retardancy test.

Hereinafter, the resistance to combustion is also referred to as flame retardancy. Materials having a higher resistance to combustion than a predetermined standard are also referred to as flame retardant materials or materials having flame retardancy, and materials having a lower resistance to combustion than a predetermined standard are also referred to as non-flame retardant materials or non-flame retardant materials. The material of the first insulating film 21b is a non-flame retardant material.

The two second core wires 23 are formed in an elongated shape. The two second core wires 23 are arranged such that the longitudinal direction thereof is substantially along the x-axis direction. The two second core wires 23 may be arranged to be inclined in the z-axis direction.

The two second core wires 23 are provided with a second conductive wire 23a and a second insulating film 23b, respectively. The second conductive line 23a may be of the same configuration as the first conductive line 21 a. In other words, the first core wire 21 and the second core wire 23 may have the same configuration except that the material for the first insulating film 21b and the material for the second insulating film 23b are different.

The second wire 23a is an elongated metal wire. The second lead 23a is disposed so that the longitudinal direction thereof is oriented in the x-axis direction. The second insulating film 23b covers the circumferential surface of the second lead 23 a.

Fig. 4 shows a cross section taken along a yz plane (a B-B' cross section in fig. 1) orthogonal to the x-axis of the two second core wires 23 as viewed along the x-axis direction. As shown in fig. 4, the second lead 23a is formed into a substantially circular shape in yz cross section, and the second insulating film 23b is disposed along the circumferential direction of the substantially circular shape.

As a material of the second wire 23a, for example, copper is used. The second conductive line 23a may be a copper alloy line or a soft copper line. The material of the second conductive line 23a is not limited to copper. As a material of the second lead 23a, a material having conductivity may be used. The material of the second wire 23a may be a material used as a conductor of a general wire.

The second insulating film 23b is formed of a material having higher resistance to combustion than a predetermined standard. The predetermined criterion here is the same as the criterion for setting the first insulating film 21b to be not satisfied. That is, in the present embodiment, the second insulating film 23b having a length of about 300mm taken from the second core wire 23 may be used. The second insulating film 23b may be any insulating film that satisfies the criterion in the flame retardancy test. The second insulating film 23b may be made of a flame retardant material. The second insulating film 23b may be made of, for example, polyethylene as a base material, and a flame retardant may be contained in the polyethylene base material. The flame retardant contained in the base material may be a halogen-based flame retardant or a halogen-free flame retardant. The halogen-based flame retardant used herein is a flame retardant using a compound containing a halogen such as bromine or chlorine. As the halogen-based flame retardant, for example, decabromodiphenylethane as a bromine-based flame retardant can be used. When a halogen-based flame retardant is used as the flame retardant, it is preferable to use a material containing 20 to 25 parts by mass of the halogen-based flame retardant per 100 parts by mass of polyethylene as the base material for the second insulating film 23 b.

The halogen-free flame retardant is a flame retardant using a compound containing no halogen such as bromine or chlorine. As the halogen-free flame retardant, phosphorus-based, nitrogen-based, silicon-based flame retardants and the like can be used. When a halogen-free flame retardant is used as the flame retardant, the second insulating film 23b is preferably made of a material containing 20 to 60 parts by mass of the halogen-free flame retardant per 100 parts by mass of polyethylene as the base material.

The x-axis positive end of the first core wire 21 and the x-axis negative end of the second core wire 23 are disposed close to each other.

In the following description, the x-axis negative end of the second core wire 23 is also referred to as a connection end, and the x-axis positive end of the second core wire 23 is also referred to as a connector-side end.

The two connection portions 25 are fixed in a state where the first conductive wires 21a of the two first core wires 21 and the second conductive wires 23a of the two second core wires 23 are respectively conducted. The two connection portions 25 are disposed between the x-axis positive-side end portion of the first conductive wire 21a and the x-axis negative-side end portion of the second conductive wire 23 a.

The connection portion 25 is made of metal, and the first core wire 21 and the second core wire 23 are fixed by applying pressure to the connection portion 25. As the connection portion 25, for example, a joint (スプライス) is used. The combination of the first core wire 21 and the second core wire 23 may be joined with the connecting portion 25 as a joint. Specifically, the connection portion 25, which is a bent plate-shaped metal member, may cover the circumferential surfaces of the first and

second lead wires

21a and 23a, and the circumferential surfaces of the first and

second lead wires

21a and 23a may be pressed in a state of being covered by the plate-shaped surface, thereby joining the first and

second lead wires

21a and 23 a.

The connection portion 25 may be any member that joins the first lead wire 21a and the second lead wire 23a, and for example, the connection portion 25 itself may not contact the first lead wire 21a and the second lead wire 23 a. That is, for example, a caulking material that holds the first lead wire 21a and the second lead wire 23a by fixing the first insulating film 21b covering the first lead wire 21a and the second insulating film 23b covering the second lead wire 23a in a state where the first lead wire 21a and the second lead wire 23a are joined to each other may be used for the connection portion 25.

The two connection portions 25 are disposed at different positions along the x-axis direction.

In other words, the connection portions 25 are arranged at mutually different positions along the line direction of the first core wire 21 and the second core wire 23.

That is, the lengths of the two first wires 21a may be different from each other, and the length of the second wire 23a may be a length corresponding to the length. Specifically, if one of the two first wires 21a is formed shorter than the other, the length of the second wire 23a connected to the shorter first wire 21a may be formed longer to be longer by an amount corresponding to the shorter one, in other words, formed longer to complement the short length. The connection portion 25 is configured to join the first wires 21a and the second wires 23a having different lengths, respectively.

The sheath 27 is disposed so as to cover the outside of the first insulating film 21b of the first core wire 21 in the x-axis direction. The outer side here means the opposite side across each member when the space between the two first cores 21 is defined as the inner side. In other words, the two first wires 21 are disposed inside the sheath 27.

The sensor 10 side end of the sheath 27, that is, the x-axis negative side end of the sheath 27 is disposed at a position to enter the internal space of the sensor housing 11. In other words, the end of the first insulating film 21b on the sensor 10 side is covered with at least one of the sheath 27 and the internal space of the sensor housing 11. That is, the end of the first insulating film 21b on the sensor 10 side is disposed so as not to be exposed to the outside from both the sheath 27 and the internal space of the sensor housing 11.

The sheath 27 is formed of a material having higher resistance to combustion than a predetermined reference, that is, a flame retardant material. In addition, the sheath 27 may be made of a material to which a flame retardant is added, such as thermoplastic polyurethane.

The covering member 29 is disposed so as to cover the outer side of the first core wire 21. The range in which the sheathing member 29 covers the first core wire 21 is configured to contain an end portion of the sheath 27 on the side opposite to the sensor 10 side and at least a part of each of the two connection portions 25 in the axial direction of the first core wire 21. In other words, the end of the cover member 29 on the sensor 10 side is located on the sensor 10 side of the end of the sheath 27 on the side opposite to the sensor 10 side, and the end of the cover member 29 on the side opposite to the sensor 10 side is located on the side opposite to the sensor 10 side of each of the ends of the two connection portions 25 on the sensor 10 side. That is, by covering the first core wire 21 with the covering member 29, the first insulating film 21b is disposed so as not to be exposed from the covering member 29. The covering member 29 is formed of a material having higher resistance to combustion than a predetermined reference, that is, a flame retardant material.

As the covering member 29, for example, a resin molded article or a heat shrinkable tube can be used. That is, as the material of the cover member 29, a resin material molded into a predetermined shape by injection molding may be used.

The heat-shrinkable tube used for the sheathing member 29 is a tube having a cylindrical shape that shrinks when heated to a predetermined temperature or higher, and may be a tube filled with a thermoplastic sealing agent.

In addition, the covering member 29 may expose the second core wire 23 from the end portion on the x-axis positive side. In the case where the second core 23 is exposed with respect to the covering member 29, the bending of the second core 23 is not hindered by the covering member 29, and therefore the second core 23 can be flexibly bent. Further, since the second insulating film 23b of the second core wire 23 is made of a material having a higher resistance to combustion than a predetermined standard, the resistance to combustion can be improved in the portion exposed from the covering member 29.

As described above, the second insulating film 23b, the sheath 27, and the covering member 29 are formed of a flame retardant material. The sensor housing 11 and the connector 30 may be made of a flame retardant material. However, the flame retardancy, in other words, the resistance to combustion, of each member may be the same or different.

[2. Effect ]

< method for manufacturing Cable with sensor >

A method of manufacturing the sensor-equipped cable 1 will be described.

The sheath 27 and the first insulating film 21b are peeled off by a predetermined length from the x-axis negative-side end portion of the cable 20, and the first lead wire 21a is exposed. Here, when the first insulating film 21b is peeled off from the first lead wire 21a, the first insulating film 21b is soft because it does not contain an additive such as a flame retardant. Therefore, a part of the first insulating film 21b remaining at the time of peeling can be suppressed from remaining in a state of adhering to the surface of the first lead 21 a.

The welding is performed by resistance welding in a state where the tip end portion of the first lead wire 21a is in contact with the second end portion 15b of the sensor terminal 15. The first lead wire 21a and the sensor terminal 15 may be sandwiched between electrodes, and welding may be performed by joule heat generated by contact resistance at the welding portion by applying a current while applying a pressure.

Thereby, the sensor terminal 15 is electrically connected to the first lead wire 21a, and the sensor IC 13 is electrically connected to the first lead wire 21 a.

Next, the sensor housing 11 is formed around the sensor terminal 15 and the first lead wire 21a connected by welding. In the case where the sensor housing 11 is formed of a resin molded product, it may be formed by injection molding in such a manner that the sensor housing 11 covers the sensor terminal 15 and the periphery of the first lead wire 21 a. That is, the sensor housing 11 is formed, for example, as follows: a mold is disposed around the sensor terminal 15 and the first lead wire 21a, and a synthetic resin, which is a material of a resin molded product constituting the sensor housing 11, is heated and flowed into the mold, and is cooled and solidified. In this case, the through hole 11a is formed not by penetrating a part of the sensor housing 11 but by being located at a position where the first lead 21a and the first insulating film 21b are located by the injection molding, and is formed by solidifying a resin material around the first insulating film 21 b.

Next, the x-axis positive-side ends of the two second wires 23a, that is, the connector-side ends, are electrically connected to the terminals on the cable 20 side of the connector 30, in other words, the x-axis negative-side terminals of the connector 30, respectively. A method of electrically connecting the two second wires 23a to the terminal on the x-axis negative side of the connector 30 is not particularly limited. Further, the connection of the two second wires 23a to the terminal on the x-axis negative side of the connector 30 may also be connected before the sensor 10 and the cable 20 are resistance-welded.

Next, the two first conductive wires 21a exposed from the x-axis positive end of the sheath 27 are joined to the two second conductive wires 23a by the connection portion 25.

The joining by the two connecting portions 25 may be performed by a joint, but is not limited to such a joining method, and may be performed by various methods. That is, the bonding method is not particularly limited as long as the first lead wire 21a and the second lead wire 23a are fixed in a conductive state.

Then, the circumferential surface of the first core wire 21 is covered with the covering member 29. Here, in the case where the covering member 29 is a heat shrinkable tube, the first conductive wire 21a and the second conductive wire 23a may be joined by the connection portion 25 after the first core wire 21 is inserted into the inside of the cylinder of the heat shrinkable tube.

In the case of the heat shrinkable tube, the heat shrinkable tube may be arranged so as to cover the first lead wires 21a and the connection portions 25, and the heat shrinkable tube may be shrunk by heating to bring the inner surface of the heat shrinkable tube into close contact with the first core wires 21 and the connection portions 25.

The above-described production method is merely an example, and the steps are not particularly limited.

[3. Effect ]

(1) The sensor-equipped cable 1 of the present embodiment includes a first core wire 21, a sheath 27, a second core wire 23, and a covering member 29. The first core wire 21 has: a first lead wire 21a to which a sensor terminal 15 of a predetermined sensor 10 is welded by resistance welding; and a first insulating film 21b which covers the periphery of the first lead wire 21a and is formed of a material having a lower resistance to combustion than a predetermined reference. The jacket 27 further covers the circumferential surface of the first insulating film 21b of the first core wire 21, and is formed of a material having higher resistance to combustion than the standard. The second core wire 23 has: a second lead wire 23a connected to be electrically connected to the first lead wire 21a as a lead wire of the first core wire 21; and a second insulating film 23b which covers the periphery of the second conductive wire 23a and is formed of a material having higher resistance to combustion than a standard. The covering member 29 covers at least the first insulating film 21b of the first core wire 21 exposed from the sheath 27, and is formed of a material having higher resistance to combustion than a standard.

With this configuration, the sensor terminal 15, which is a terminal included in the sensor 10, and the first lead wire 21a included in the first core wire 21 are welded by resistance welding. Further, since the first insulating film 21b, which is the insulating film of the first conductive wire 21a of the first core wire 21, is not formed of a material having a higher resistance to combustion than a predetermined reference, it is possible to suppress adhesion of the first insulating film 21b, which is separated, to the surface of the first conductive wire 21a and causes a welding failure due to the use of the material for the first insulating film 21 b.

In the first core 21, the circumferential surface of the first insulating film 21b using a material having a lower resistance to combustion than a predetermined reference is covered with the sheath 27 having a higher resistance to combustion than a predetermined reference, and therefore the cable 20 has a higher resistance to combustion than a predetermined reference.

According to the above, the resistance to combustion is higher than the predetermined reference and welding can be easily performed for the sensor-equipped cable 1.

(2) For comparison, fig. 8 shows an example of the structure of a sensor-equipped cable different from the sensor-equipped cable 1. Here, in the sensor-equipped cable 100 of the comparative example shown in fig. 8, the structures corresponding to the sensor 10, the sheath 27, and the covering member 29 of the sensor-equipped cable 1 are denoted as a sensor 110, a sheath 127, and a covering member 129, respectively.

From the viewpoint of improving resistance to combustion, it is desirable that the insulating film of the core wire 160 included in the region a exposed from the covering member 129 is formed of a material having higher resistance to combustion than a standard. However, the insulating film of the core wire 160 uniformly covers the conductive wire of the core wire 160. Therefore, the insulating film of the core wire 160 covers the lead wire up to the end on the opposite side to the exposed side, i.e., the x-axis negative side in the drawing. At the end portion on the x-axis negative side of the core wire 160, the insulating film of the core wire 160 is peeled off from the lead portion of the core wire 160 for resistance welding with the terminal of the sensor 110. In this case, when the insulating film of the core wire 160 is formed of a material having higher resistance to combustion than a standard, the insulating film becomes brittle by containing a flame retardant or the like. As a result, when the brittle insulating film is peeled off from the lead wire, the insulating film adheres to the surface of the lead wire, and causes a welding failure in resistance welding of the lead wire between the terminal of the sensor 110 and the core wire 160.

On the other hand, in the sensor-equipped cable 1 of the present embodiment, since the first lead wire 21a resistance-welded to the sensor terminal 15 of the sensor 10 is covered with the first insulating film 21b containing no flame retardant, it is possible to suppress adhesion of a part of the first insulating film 21b to the surface of the first lead wire 21a at the time of peeling.

The second insulating film 23b of the second core 23 exposed from the covering member 29 is formed of a material having higher resistance to combustion than a standard. For the cable 1 with a sensor, the resistance to combustion is higher than a predetermined reference, and welding can be easily performed.

(3) In the sensor-equipped cable 1 of the present embodiment, a material containing a halogen-based flame retardant or a halogen-free flame retardant is used for the second insulating film 23b included in the second core wire 23.

With such a configuration, the second insulating film 23b of the second core wire 23 can have higher resistance to combustion than a predetermined standard by containing a halogen-based flame retardant or a halogen-free flame retardant.

(4) In the sensor-equipped cable 1 of the present embodiment, the second insulating film 23b of the second core wire 23 may be formed of polyethylene containing a halogen-based flame retardant. The halogen flame retardant may be contained in an amount of 20 to 25 parts by mass with respect to 100 parts by mass of the polyethylene of the second insulating film 23b of the second core wire 23.

According to such a configuration, the second insulating film 23b of the second core wire 23 can have higher resistance to combustion than the standard by containing the halogen flame retardant in an amount of 20 parts by mass or more and 60 parts by mass or less with respect to 100 parts by mass of polyethylene.

(5) In the sensor-equipped cable 1 according to the present embodiment, the second insulating film 23b included in the second core wire 23 may be formed of polyethylene containing a halogen-free flame retardant. The halogen-free flame retardant may be contained in an amount of 20 parts by mass or more and 25 parts by mass or less with respect to 100 parts by mass of the polyethylene of the second insulating film 23b included in the second core wire 23.

According to such a configuration, the insulating film of the second core wire 23 can have higher resistance to combustion than the standard by containing the halogen-free flame retardant in an amount of 20 parts by mass or more and 60 parts by mass or less with respect to 100 parts by mass of the polyethylene.

(6) The sensor-equipped cable 1 of the present embodiment includes a metal connection portion 25 connecting the second core wire 23 and the first core wire 21, and the covering member 29 is configured to cover the circumferential surface of the connection portion 25.

With this configuration, the second core 23 can be connected to the first core 21 by the metal connection portion 25. Further, the circumferential surface of the connection portion 25 can be insulated by the covering member 29.

(7) The sensor-equipped cable 1 of the present embodiment includes a plurality of first core wires 21, a plurality of second core wires 23, and a plurality of connection portions 25, and the plurality of connection portions 25 are arranged at different positions along the longitudinal direction of the first core wires 21 and the second core wires 23, in other words, along the x-axis direction.

With this configuration, the plurality of connection portions 25 can be prevented from contacting each other and conducting.

(8) In the sensor-equipped cable 1 of the present embodiment, a connection end portion as one end portion of the second core wire 23 is connected to the first core wire 21, and a connector 30 configured to be connectable to another member is connected to a connector-side end portion as the other end portion.

According to such a configuration, by connecting another member or device to the connector 30, the other member or device can be electrically connected to the second core wire 23 of the cable 20, the first core wire 21, the sensor IC 13 of the sensor 10, and the sensor terminal 15 via the connector 30.

(9) The sensor-equipped cable 1 of the present embodiment includes a sensor housing 11 in the sensor 10, and the sensor housing 11 satisfies a standard for resistance to combustion.

With such a configuration, the sensor 10 can be protected by a member whose resistance to combustion satisfies a standard.

(10) The sensor-equipped cable 1 of the present embodiment satisfies the standard for flame resistance when the sensor-equipped cable is used as a wire harness for a vehicle of an automobile.

With such a configuration, when the cable is used as a cable with a sensor provided in a wire harness for a vehicle of an automobile, the standard of flame resistance to be satisfied can be satisfied.

[4 ] other embodiments ]

While the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments, and can be implemented in various modifications.

(1) In the sensor-equipped cable 1 of the above embodiment, the two connection portions 25 are arranged so that the positions along the x-axis direction are different from each other, and thus the connection portions 25, which are metal members, are prevented from contacting each other by the movement of the connection portions 25 along the yz plane. This suppresses the connection portions 25 from being electrically connected to each other, and even the first and second

conductive wires

21a and 23a electrically connected to the connection portions 25 from being electrically connected to each other.

However, the configuration for suppressing conduction due to contact between the connection portions 25 is not limited to this configuration. Fig. 6 shows a diagram illustrating a configuration of a connection portion in another embodiment. As shown in fig. 6, the insulating member 50 may be disposed between the two connection portions 25 of the sensor-equipped cable 2.

According to such a configuration, since it is not necessary to arrange the positions of the connection portions 25 at positions different from each other in the x-axis direction, the range in which the two connection portions 25 are arranged in the x-axis direction can be reduced as compared with the case where the connection portions 25 are arranged at positions different from each other.

As a result, the length of the covering member 29 covering the outside of the two connecting portions 25 along the x-axis direction can be shortened.

The insulating member 50 may have insulation properties to such an extent that the connection portions 25 are not electrically connected to each other through the insulating member 50 while suppressing contact between the connection portions 25.

The insulating member 50 may be fixed between the connection portions 25 by covering the outside of the two connection portions 25 with the covering member 29 after being disposed between the connection portions 25.

In addition, a thermoplastic material such as ethylene vinyl acetate may be used for the insulating member 50. According to such a configuration, after the outer sides of the two connection portions 25 are covered with the covering member 29, the insulating member 50 can be softened or melted by applying heat and molded. Here, in the case of using a heat-shrinkable tube as the sheathing member 29, the temperature to be heated may be set to the shrinkage temperature of the heat-shrinkable tube.

Fig. 6 shows an example in which the two connecting portions 25 are disposed at the same position in the x-axis direction, and the insulating member 50 is disposed therebetween. However, the arrangement of the insulating member 50 is not limited to the arrangement of the two connecting portions 25 at the same position as each other. For example, as described in the above embodiment, the two connection portions 25 may be disposed at different positions from each other along the x axis, and the insulating member 50 may be disposed between the two connection portions 25.

According to such a configuration, by disposing the two connection portions 25 at different positions from each other along the x-axis, conduction due to movement and contact of the connection portions 25 with each other can be suppressed, and by interposing the insulating member 50 between the two connection portions 25, conduction due to contact of the connection portions 25 with each other can be further suppressed.

(2) In the sensor-equipped cable 1 of the above embodiment, the two second core wires 23 connected to the terminals of the connector 30 are exposed from the covering member 29, but the configuration in which the second core wires 23 are exposed from the covering member 29 is not limited.

Fig. 7 shows a configuration in which the outer sides of the two second core wires 23 are covered with the sheath 40. As shown in fig. 7, for example, the sheath 40 may cover the outer sides of the two second core wires 23. As with the jacket 27, the jacket 40 may be made of a material having higher resistance to combustion than the standard.

In the following, in the sensor-equipped cable 3 in which the sheath 40 is disposed, the sheath 27 is also referred to as a first sheath, and the sheath 40 is also referred to as a second sheath.

Here, in the configuration including both the sheath 27 as the first sheath and the sheath 40 as the second sheath, the covering member 69 of the sensor-equipped cable 3 corresponding to the covering member 29 in the sensor-equipped cable 1 of the above embodiment may include an end portion on the x-axis positive side of the sheath 27 and an end portion on the x-axis negative side of the sheath 40. In other words, the end portions of the first sheath and the second sheath that are close to each other may be included in the range covered by the covering member 69.

With such a configuration, the second core 23 can be protected by the sheath 40 as the second sheath. In addition, the second core 23 can be further protected by the covering member 69.

(3) In the sensor-equipped cable 1 of the present embodiment, the second core wire 23 is exposed between the connector 30 and the covering member 29. In order to ensure the resistance of the exposed second core 23 to combustion, the second insulating coating 23b of the second core 23 is configured to have a resistance to combustion higher than a predetermined reference. However, if the second core 23 is not exposed from the connector 30 and the covering member 29, the second insulating coating 23b of the second core 23 may have a lower resistance to combustion than a predetermined standard.

(4) The plurality of functions of 1 component in the above embodiment may be realized by a plurality of components, or 1 function of 1 component may be realized by a plurality of components. Further, a plurality of functions provided by a plurality of components may be realized by 1 component, or 1 function realized by a plurality of components may be realized by 1 component. In addition, a part of the configuration of the above embodiment may be omitted. At least a part of the configuration of the above embodiment may be added to or replaced with the configuration of another embodiment.

Claims

1. A cable with a sensor, comprising:

a first core wire having a first lead wire connected to a terminal of the sensor and a first insulating film covering the periphery of the first lead wire,

a sheath that covers the first core wire and is formed of a material having higher resistance to combustion than the first insulating film,

a second core wire having a second conductive wire and a second insulating film, the second conductive wire being connected to the first conductive wire so as to be electrically connected to the first conductive wire, the second insulating film covering the periphery of the second conductive wire and being formed of a material having higher resistance to combustion than the first insulating film, and

and a covering member that covers at least the first insulating film exposed from the sheath and is formed of a material having higher resistance to combustion than the first insulating film.

2. The sensor-equipped cable according to claim 1, wherein a material containing a halogen-based flame retardant or a halogen-free flame retardant is used for the second insulating film of the second core wire.

3. The sensor-equipped cable according to claim 1, wherein the second insulating film of the second core wire is formed of polyethylene containing a halogen-based flame retardant,

the halogen-based flame retardant is contained in an amount of 20 to 60 parts by mass with respect to 100 parts by mass of the polyethylene of the insulating film of the second core wire.

4. The sensor-equipped cable according to claim 1, wherein the second insulating film of the second core wire is formed of polyethylene containing a halogen-free flame retardant,

the halogen-free flame retardant is contained in an amount of 20 to 25 parts by mass with respect to 100 parts by mass of the polyethylene of the insulating film of the second core wire.

5. The sensor-equipped cable according to any one of claims 1 to 4, which has a metal connecting portion that connects the second core wire and the first core wire,

the covering member is configured to cover a circumferential surface of the connecting portion.

6. The sensored cable according to claim 5 having a plurality of the first core wires, the second core wires, and the connecting portion,

the plurality of connecting portions are arranged at different positions along the line direction.

7. The sensored cable according to claim 5 having a plurality of the first core wires, the second core wires, and the connecting portion,

an insulating member is disposed between the plurality of connecting portions.

8. The sensored cable of claim 7, the insulating member being comprised of a thermoplastic.

9. The sensor-equipped cable according to any one of claims 1 to 8, wherein a connection end portion as one end portion of the second core is connected to the first core, and a connector is connected to a connector-side end portion as the other end portion, the connector being configured to be connectable to another member.

10. The sensor-equipped cable according to claim 9, comprising:

the sheath covering the first core wire as a first sheath, and

a second sheath covering the second core wire and formed of a material having higher resistance to combustion than the first insulating film,

the range covered by the covering member includes the end portions of the first sheath and the second sheath that are close to each other.

11. The sensor-equipped cable according to any one of claims 1 to 10, the covering member being formed of a heat-shrinkable tube or a resin molded article.

12. The sensor-equipped cable according to any one of claims 1 to 11, the sensor having a frame body whose resistance to combustion satisfies a standard.