JP2010135203A - Flat cable, and manufacturing method of flat cable - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve heat dissipation of conductors, and to connect a general terminal to its end part, as to a flat cable equipped with a plurality of conductors. <P>SOLUTION: The flat cable is provided with a plurality of conductors 12 each with a plurality of strands 14 arrayed in parallel in contact with each other, and the plurality of conductors 12 are covered with a coating 20 in a state arrayed in parallel with an interval. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a flat cable having a plurality of conductor portions and a method for manufacturing the flat cable.

  Conventionally, there exists a thing disclosed in patent document 1 or patent document 2 as a flat cable provided with the multiple conductor part.

  Patent Document 1 discloses a flat cable in which a plurality of conductors having a substantially circular cross-sectional shape are arranged in parallel at a predetermined interval.

  Patent Document 2 discloses a flat cable having a plurality of flat conductors arranged in parallel.

Japanese Patent Laid-Open No. 2001-238221 JP 2002-343141 A

  However, the flat cable disclosed in Patent Document 1 has a problem that since the cross section of each conductor is substantially circular, the surface area is small and heat dissipation is poor. For this reason, the heat generated by the current flowing through the conductor cannot be efficiently dissipated, and as a result, the allowable current of each conductor is reduced.

  Moreover, since the flat cable disclosed in Patent Document 2 uses a flat conductor, when connecting the flat conductor to other electrical components at the end of the flat cable, a crimp terminal dedicated to the flat conductor is required. End up.

  Accordingly, an object of the present invention is to improve heat dissipation of a conductor portion in a flat cable having a plurality of conductor portions, and to connect a general terminal to an end portion of the conductor portion. To do.

  In order to solve the above-described problem, the flat cable according to the first aspect includes a plurality of conductor portions arranged in parallel in a state where a plurality of strands are in contact with each other, and the plurality of conductor portions spaced apart from each other. And a covering portion covering in a parallel state.

  A 2nd aspect is a flat cable which concerns on a 1st aspect, Comprising: The space | interval dimension between the said each conductor parts is set to 0.1 mm-4.0 mm.

  A 3rd aspect is a flat cable which concerns on a 1st or 2nd aspect, Comprising: The edge part of the said conductor part is exposed from the said coating | coated part, and the crimping | crimped part of a crimp terminal is crimp-connected to the exposed edge part. It is a thing.

  A fourth aspect is a flat cable according to any one of the first to third aspects, wherein a pitch dimension of the plurality of conductor portions is a maximum width portion of a crimp terminal crimped to each conductor portion. It is set larger than the width dimension.

  A fifth aspect is a flat cable according to any one of the first to fourth aspects, wherein a pitch terminal connected to an end of each conductor part is inserted into the pitch dimension of the plurality of conductor parts. It is set within ± 10% with respect to the pitch dimension of the plurality of cavities of the connector.

  A 6th aspect is a flat cable which concerns on any one 1st-5th aspect, Comprising: The surface of the said coating | coated part is formed in uneven | corrugated shape.

  The flat cable manufacturing method according to the seventh aspect includes a step of winding and housing a plurality of strands in one reel, and a plurality of strands supplied from the reels in parallel with each other in a state of mutual contact. Forming a covering portion on the outer periphery.

  According to the flat cable which concerns on a 1st aspect, since each conductor part is set as the structure arranged in parallel in the state in which the some strand was mutually contacted, a surface area can be made comparatively large and heat dissipation is improved. Can be achieved. Moreover, since each conductor part is comprised by the some strand, a general terminal can be connected by bundling a some strand at the edge part of a conductor part.

  According to the second aspect, by making the interval dimension between the conductor parts 0.1 mm or more, it is possible to effectively prevent the dielectric breakdown between the conductor parts, and by making the same interval dimension 4.0 mm or less. The use amount of the covering portion can be suppressed to achieve weight reduction and flame retardancy.

  According to the third aspect, since the conductor portion has a configuration in which a plurality of strands are brought into contact with each other and arranged in parallel, the end portion of the conductor portion is exposed and the plurality of strands are bundled to form the conductor portion. The crimping part of the crimping terminal can be crimped and connected to the end part.

  According to the fourth aspect, in a state where a plurality of crimp terminals are arranged in parallel on substantially the same plane, the end portions of the plurality of conductor portions can be walked together and continuously crimped to the corresponding crimp terminals. It is possible to perform terminal crimping quickly.

  According to the 5th aspect, it is easy to insert the crimp terminal connected to the edge part of a some conductor part simultaneously into a some cavity.

  According to the 6th aspect, since the surface of the coating | coated part is formed in uneven | corrugated shape, a surface area becomes large and can improve heat dissipation.

  According to the seventh aspect, since a plurality of strands are supplied from one reel, it is possible to simplify the manufacturing equipment.

  Hereinafter, the flat cable according to the embodiment will be described. FIG. 1 is a cross-sectional view showing a flat cable 10 according to this embodiment.

  The flat cable 10 includes a plurality of conductor portions 12 and a covering portion 20, and has a flat shape in which the conductor portions 12 are arranged in parallel with a space therebetween.

Each conductor portion 12 has a plurality (9 in FIG. 1) of strands 14. Each strand 14 is formed of a metal wire such as copper or a copper alloy, and is formed in a linear shape having a substantially circular cross section. In addition, the plurality of strands 14 are arranged in parallel on substantially the same plane in a state where they are in electrical contact with each other, and the plurality of strands 14 as a whole is a single linear conductor. A certain conductor portion 12 is configured. In addition, the diameter of the strand 14 does not need to be the same between the strands 14 which comprise each conductor part 12. FIG. The material, diameter, and the like of each strand 14 can be appropriately set according to required electrical characteristics, etc., and the diameter of the strand 14 is preferably 0.5 mm or less, for example, a diameter of 0.185 mm Things can be used. Moreover, the number of the strands 14 in each conductor part 12 can also be set suitably according to the electrical property etc. which are required, and it is preferable that it is three or more. Moreover, it is preferable that the total cross-sectional area of the conductor part 12 is 0.2 mm < ² > or more. Moreover, each conductor part 12 does not need to be the same structure, Each may be comprised with the strand of a different material, the strand of a different diameter, and a different number of strands, Furthermore, these differ in combination. It may be a configuration.

  The covering portion 20 is formed of an insulating material such as a resin, and is formed so as to cover the plurality of conductor portions 12 in a state where the conductor portions 12 are arranged in parallel with a space between each other. More specifically, the covering portion 20 covers the plurality of conductor portions 12 in a state in which the respective flat directions are aligned on the same plane and are arranged in parallel on the substantially same plane with a space between each other. The covering portion 20 may be formed by extruding and coating a resin around the plurality of conductor portions 12, or formed by sandwiching the plurality of conductor portions 12 between a pair of insulating films. It may be what was done. In short, the covering portion 20 only needs to have a configuration capable of achieving insulation protection from the outside while maintaining the plurality of conductor portions 12 in a predetermined form.

  The flat cable 10 is formed in a flat cable shape that is flat in the parallel arrangement direction of the plurality of conductor portions 12 (the flat direction of the conductor portions 12).

  The number of the conductor portions 12 is appropriately set according to the required number of wirings. Moreover, the space | interval dimension between the some conductor parts 12 and the pitch dimension of the some conductor parts 12 can be set to arbitrary values, The preferable example is demonstrated later.

  According to the flat cable 10 configured as described above, each conductor portion 12 is configured in parallel with a plurality of strands 14 in contact with each other, so that the surface area of each conductor portion 12 is increased. It is possible to improve heat dissipation. Moreover, as a result of being able to improve heat dissipation, the conductor cross-sectional area can be suppressed, and further, the weight of the flat cable 10 can be reduced. In addition, since each conductor portion 12 is composed of a plurality of strands 14, when connecting a crimp terminal to the end portion of the conductor portion 12, the plurality of strands 14 are connected to the end portion of the conductor portion 12. It can be bundled to have the same form as the end of a general twisted core wire. Thereby, the crimp terminal for general twisted core wires can be crimped and connected to the end portion of the conductor portion 12, and the cost of the wiring member using the flat cable 10 can be reduced. In addition, when bundling the several strand 14, it is preferable to twist together. Moreover, since the flat conductor rolled by another process or the strand 1 etc. twisted by another process are not used as a conductor part, the flat cable 10 can be manufactured comparatively cheaply.

  A preferred dimension setting example of the flat cable 10 will be described.

  First, it is preferable that the space | interval dimension D of each conductor part 12 which adjoins at intervals is 0.1 mm-4.0 mm.

  The dielectric breakdown voltage of a general insulating resin used in the flat cable 10 or the like is 10 kV / mm or more. By setting the distance dimension D between the conductor parts 12 to 0.1 mm or more, the conductor voltage between the conductor parts 12 can be reduced. This is because sufficient dielectric breakdown characteristics that can withstand a voltage of 1000 V can be obtained. In addition, by setting the distance dimension D between the conductor portions 12 to 4.0 mm or less, it is possible to suppress the amount of resin used to reduce the weight and improve the flame retardancy.

  FIG. 2 is a plan view showing a state where the crimp terminal 30 is crimped and connected to the end 12a of the conductor portion 12, and FIG. 3 is a side view showing the same state.

  The crimp terminal 30 has a crimp part 32 and a terminal part 34. The crimping portion 32 has a substantially U-shaped cross-sectional shape before crimping, and can be crimped to a conductor having a substantially circular cross section, that is, a general twisted core wire obtained by twisting a plurality of strands. It is configured. The terminal portion 34 is a portion that can be terminal-connected to the counterpart terminal, and is formed in a female terminal portion shape having a substantially rectangular tube shape in this case. A tongue piece 34a that can elastically contact the tab portion of the male terminal portion is formed. But the terminal part 34 may be comprised by the elongate plate shape or the pin-shaped male terminal part shape.

  And the edge part of the conductor part 12 is exposed from the said coating | coated part 20, The exposed edge part 12a is twisted together and bundled, and the crimping | compression-bonding part 32 of the crimp terminal 30 is crimp-connected to the said edge part 12a. Has been.

  Considering the crimp connection workability when connecting the crimp terminals 30 to the plurality of conductor portions 12 as described above, the pitch dimension P1 of the plurality of conductor portions 12 is larger than the width dimension W of the maximum width portion of the crimp terminals 30. Larger is preferred. Here, the pitch dimension P1 of the plurality of conductor portions 12 is an interval at which the conductor portions 12 are repeatedly arranged in the parallel direction of the plurality of conductor portions 12 (width direction of the flat cable 10). Is defined as the distance between one side of the same and one side of the same side of the adjacent conductor 12. Moreover, the maximum width part of the crimp terminal 30 is a part where the width dimension becomes the largest in the crimp terminal 30 before crimping. In the crimp terminal 30 as the female terminal assumed in the present embodiment, the upper holder portion 34U facing the tongue piece 34a of the terminal portion 34 of the crimp terminal 30 is the maximum width portion. Therefore, the upper holder portion 34U The width dimension is the maximum width W. In addition, in the form before crimping, when the crimped portion of the crimp terminal is the maximum width portion, the width of the crimped portion is the width of the maximum width portion.

  Thus, when the pitch dimension P1 of the plurality of conductor portions 12 is set to be larger than the width dimension W of the maximum width portion of the crimp terminal 30, the plurality of crimp terminals 30 are arranged in parallel on substantially the same plane. Thus, the end portions 12a of the plurality of conductor portions 12 can be respectively disposed on the corresponding crimping portions 32 so that the crimping operation can be performed collectively or continuously, and rapid terminal crimping can be performed.

  FIG. 4 is a plan view showing a state where a plurality of crimp terminals 30 attached to the end of the flat cable 10 are inserted into the cavities 42 of the connector 40.

  The connector 40 is formed of a resin or the like, and a through hole cavity 42 into which the crimp terminal 30 can be inserted and disposed is formed in parallel. Further, the cavities 42 are partitioned by a partition wall.

  In relation to the connector 40, the pitch dimension P1 of the plurality of conductor portions 12 is preferably set within ± 10% with respect to the pitch dimension P2 of the plurality of cavities 42. Here, the pitch dimension P2 of the plurality of cavities 42 is an interval at which the cavities 42 are repeatedly arranged in the parallel direction of the plurality of cavities 42 (width direction of the connector 40). It is defined as the distance from one side of the same side of the adjacent cavity 42.

  As described above, when the pitch dimension P1 of the plurality of conductor portions 12 is set within ± 10% with respect to the pitch dimension P2 of the plurality of cavities 42, the end portions of the plurality of conductor portions 12 are crimped and connected. The crimp terminals 30 and the corresponding cavities 42 can be disposed to face each other simultaneously. Therefore, there is an advantage that the crimp terminals 30 crimp-connected to the end portions of the plurality of conductor portions 12 can be easily inserted into the plurality of cavities 42 at once.

  FIG. 5 is a cross-sectional view showing a flat cable 110 according to a modification of the first embodiment. In FIG. 5, the same components as those in the first embodiment are denoted by the same reference numerals as above.

  In this modification, a recess 122 a is formed on the surface of the covering portion 120. Here, a substantially triangular groove-shaped recess 122 a along the longitudinal direction of the flat cable 110 is formed at a position corresponding to each conductor portion 12. Thereby, the surface area of the coating | coated part 120 can be enlarged and the heat which generate | occur | produced in the conductor part 12 can be spread | diffused outside more efficiently. Moreover, since the recessed part 122a is formed in the position between the conductor parts 12 according to the arrangement | positioning aspect of the conductor part 12, heat dissipation is as mentioned above, aligning the thickness dimension of the insulating member with respect to the conductor part 12 substantially the same. Can be improved.

  But the position and shape of the recessed part 122a are not restricted to the said example. The surface of the covering portion may be formed in an uneven shape with various shapes. This is because the surface area of the covering portion can be increased to improve heat dissipation.

  Next, a flat cable manufacturing method applied to the flat cable 10 will be described. FIG. 6 is a process diagram showing a manufacturing method, and FIGS. 7 and 8 are explanatory views showing a manufacturing apparatus that can be applied to the manufacturing method.

  This manufacturing method is a state in which a plurality of drawn wires 14 are wound and accommodated in one reel 52, and a plurality of the wires 14 supplied from the reel 52 are in contact with each other. And an extrusion step S2 for forming the covering portion 20 on the outer periphery.

  FIG. 7 is a diagram showing a wire drawing device 60 used in the wire drawing step S1. The wire drawing device 60 includes a plurality of wire supply units 62 for supplying a wire that is the source of the wire 14, a wire drawing unit 64 for drawing the wire, and a plurality of wire 14 that has been drawn into a single reel 52. And a winding part 66 that winds around. The wire rod supply unit 62 is configured to be able to continuously supply the wire rod. Moreover, the wire drawing part 64 is comprised so that the wire drawing process may be performed with respect to the said wire by giving tension | tensile_strength to the said wire in the state which heated and softened the wire. The winding unit 66 is configured to be able to set one reel 52 for winding, and is configured to rotationally drive the reel 52 so as to wind and receive the wire 14 that has passed through the wire drawing unit 64. Yes. A plurality of the wires 14 drawn by the wire drawing portion 64 are wound and accommodated on one reel 52 through a guide member 68 in which guide holes are formed. In this step S1, a plurality of reels 52 each having a plurality of strands wound and accommodated are prepared.

  In the present embodiment, the wire drawing process is performed in the wire drawing step S <b> 1, but the wire 14 that has been separately drawn may be wound and accommodated on one reel 52.

  FIG. 8 is a view showing an extrusion coating apparatus 50 used in the extrusion step S2. The extrusion coating apparatus 50 includes a plurality of strand supply parts 51, a preheater 53, an extruder 54, a cooling water tank 55, a take-up capstan 56a, an accumulator 56b, a measuring instrument 57, and a cable winding part 58. It has.

  The reels 52 can be set in each of the plurality of strand supply parts 51. A plurality of strands 14 can be continuously supplied from each strand supply section 51. The strand 14 supplied from the strand supply section 51 is preheated by the preheater 53 and then supplied to the extruder 54.

  The extruder 54 has a cross head 54a capable of guiding the wire 14 in the form shown in FIG. Then, by the extruder 54, the plurality of strands 14 supplied from the reels 52 are arranged in parallel with each other, and the resin is extruded and coated on the strands 14 arranged in the form. .

  The flat cable 10 in which the covering portion 20 is extrusion-coated around the strand 14 by the extruder 54 is cooled through the cooling water tank 55, and then passed through the take-up capstan 56 a and the accumulator 56 b, and then measured by a measuring instrument 57. After the inspection, the cable winder 58 is wound and accommodated.

  In addition, it is good also as a process of inserting the strand 14 arrange | positioned with the said form with a pair of resin film instead of extrusion process S2. In short, this step S2 may be any step in which the plurality of strands 14 supplied from the reel 52 are arranged in parallel with each other and the covering portion is formed on the outer periphery.

  According to the method of manufacturing the flat cable 10, the plurality of strands 14 are wound and accommodated on one reel 52, and the plurality of strands 14 are collectively supplied from the reel 52 to form one conductor portion 12. Since the flat cable 10 is manufactured, the number of the strand supply units 51 can be reduced, and the manufacturing process and the manufacturing equipment can be simplified.

  When the allowable current was tested with respect to the flat cable 10 described in the above embodiment, Examples 1 to 6 shown in FIG. 9 were obtained.

  The allowable current was determined as follows. In other words, a thermocouple is attached to the conductor part at the center of a 1m long sample, current is passed through the conductor in an atmosphere of 40 ° C, and the current value when the conductor surface temperature reaches 80 ° C is calculated as the allowable current of the cable. It was.

The conditions of Examples 1-6 are as follows. First, as a common condition, a round element wire made of annealed copper and having a substantially circular conductor was used as the element wire 14. Moreover, the insulator material of the coating | coated part 20 was polyolefin, and the insulator thickness was made to be 0.15 mm. And about the structure of the conductor part 12, the diameter and the number of the strand 14 were changed as follows. That is, in Example 1, seven strands 14 having a diameter of 0.20 m are arranged in parallel and having a cross-sectional area of 0.22 mm ^2, and in Example 2, 14 strands 14 having a diameter of 0.20 m are used. parallel arrangement, with those cross-sectional area 0.44 mm ^2, in example 3, the strand 14 having a diameter of 0.20m and 21 present in parallel arrangement, with those cross-sectional area 0.66 mm ^2, example In Example 4, six strands 14 having a diameter of 0.35 m are arranged in parallel and the cross-sectional area is 0.57 mm ^{2. In} Example 5, nine strands 14 having a diameter of 0.35 m are arranged in parallel, A cross-sectional area of 0.85 mm ² was used, and in Example 6, 14 strands 14 having a diameter of 0.35 m were arranged in parallel to obtain a cross-sectional area of 1.32 mm ² .

  As a result of the experiment, the allowable current is 10.0 A in Example 1, the allowable current is 14.5 A in Example 2, the allowable current is 19.5 A in Example 3, and the allowable current is 15.5 A in Example 4. In Example 5, the allowable current was 19.0 A, and in Example 6, the allowable current was 27.5 A.

  As comparative examples, Comparative Examples 1 to 6 and Comparative Examples 7 and 8 were tested. In Comparative Examples 1 to 6, allowable currents were measured in the same manner as described above for flat cables using a flat conductor (flat conductor), and in Comparative Examples 7 and 8, flat cables using a round conductor.

In Comparative Examples 1 to 6, the thickness dimension and the width dimension of the conductor were changed as follows. That is, in Comparative Example 1, a conductor thickness dimension of 0.15 mm and a conductor width dimension of 1.50 mm and a cross-sectional area of 0.22 mm ² was used. In Comparative Example 2, a conductor thickness dimension of 0.15 mm and a conductor width dimension of 2.50 mm were used. A cross-sectional area of 0.38 mm ² was used. In Comparative Example 3, a conductor thickness dimension of 0.15 mm, a conductor width dimension of 4.0 mm, and a cross-sectional area of 0.61 mm ² were used. In Comparative Example 4, a conductor thickness dimension of 0 .30 mm, conductor width dimension 1.50 mm and cross-sectional area 0.45 mm ² were used, and in Comparative Example 5, conductor thickness dimension 0.30 mm, conductor width dimension 2.50 mm and cross-sectional area 0.75 mm ² In Comparative Example 6, a conductor having a thickness of 0.30 mm and a conductor width of 4.00 mm and a cross-sectional area of 1.20 mm ² was used. The conditions regarding the conductor material, the insulator material, and the insulator thickness are the same as those in the above embodiment.

In Comparative Examples 7 and 8, the conductor diameter was changed. That is, in Comparative Example 7, a round conductor having a diameter of 0.67 mm and a cross-sectional area of 0.35 mm ² was used, and in Comparative Example 8, a round conductor having a diameter of 0.98 mm and a cross-sectional area of 0.35 mm ² was used. . The conditions regarding the conductor material and the insulator material are the same as described above. However, the insulator thickness is set to 0.20 mm.

  In this case, the allowable current is 9.5 A in Comparative Example 1, the allowable current is 12.5 A in Comparative Example 2, the allowable current is 18.0 A in Comparative Example 3, and the allowable current is 14.0 A in Comparative Example 4. Then, the allowable current was 17.5 A, the allowable current was 25.0 A in Comparative Example 6, the allowable current was 10.5 A in Comparative Example 7, and the allowable current was 16.0 A in Comparative Example 8.

  These experimental results are shown in FIG. 11 as a graph with the conductor cross-sectional area on the horizontal axis and the allowable current on the vertical axis. In FIG. 11, black circles indicate Examples 1 to 3, black triangles indicate Examples 4 to 6, white circles indicate Comparative Examples 1 to 3, white triangles indicate Comparative Examples 4 to 6, and black squares indicate Comparative Examples 7 and 8.

  From these experimental results, in Examples 1 to 6 according to the present embodiment, the allowable current is clearly larger than Comparative Examples 7 and 8 using a round conductor, and Comparative Examples 1 to 6 using a flat conductor and It was found that the allowable current was equivalent or larger than that.

It is sectional drawing which shows the flat cable which concerns on embodiment. It is a top view which shows the state which crimp-connected the crimp terminal to the edge part of a conductor part. It is a side view which shows a state same as the above. It is a top view which shows the state which inserted the several crimp terminal attached to the edge part of a flat cable in the cavity of a connector. It is sectional drawing which shows the flat cable which concerns on a modification. It is process drawing which shows one manufacturing method of a flat cable. It is explanatory drawing which shows a wire drawing apparatus. It is explanatory drawing which shows an extrusion coating apparatus. It is a figure which shows the experimental condition and experimental result which concern on Examples 1-6. It is a figure which shows the experimental condition and experimental result which concern on Comparative Examples 1-8. It is a figure which shows the experimental result which concerns on Examples 1-6 and Comparative Examples 1-8 in the relationship between a cross-sectional area and an allowable current.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10,110 Flat cable 12,120 Conductor part 12a End part of conductor part 14 Wire 20 Covering part 30 Crimp terminal 32 Crimp part 34 Terminal part 40 Connector 42 Cavity 50 Extrusion coating apparatus 52 Reel 60 Wire drawing apparatus 122a Recessed part D Spacing P1 Pitch dimension of conductor part P2 Pitch dimension of cavity W Width dimension of maximum width part of crimp terminal S1 Wire drawing process S2 Extrusion process

Claims (7)

A plurality of conductor portions arranged in parallel in a state where a plurality of strands are in contact with each other;
A covering portion that covers the plurality of conductor portions in a state where the conductor portions are arranged in parallel with a space between each other;
Flat cable with The flat cable according to claim 1,
A flat cable in which a distance between the conductor portions is set to 0.1 mm to 4.0 mm. The flat cable according to claim 1 or 2,
A flat cable in which an end portion of the conductor portion is exposed from the covering portion, and a crimp portion of a crimp terminal is crimped and connected to the exposed end portion. The flat cable according to any one of claims 1 to 3,
A flat cable in which a pitch dimension of the plurality of conductor portions is set to be larger than a width dimension of a maximum width portion of a crimp terminal crimped to each conductor portion. The flat cable according to any one of claims 1 to 4,
The flat cable in which the pitch dimension of the plurality of conductor portions is set within ± 10% with respect to the pitch dimension of the plurality of cavities of the connector into which the crimp terminal connected to the end of each conductor portion is inserted. . The flat cable according to any one of claims 1 to 5,
The flat cable which formed the surface of the said coating | coated part in uneven | corrugated shape. A step of winding and accommodating a plurality of strands on one reel;
A plurality of strands supplied from the reel are arranged in parallel with each other in contact with each other, and a covering portion is formed on the outer periphery; and
A flat cable manufacturing method comprising:

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