JP2013020750A - Method for manufacturing flat cable, and flat cable - Google Patents

Abstract

PROBLEM TO BE SOLVED: To maintain a form of a flat cable while suppressing heating of a core wire.SOLUTION: A method for manufacturing a flat cable 10 in which a plurality of core wires 22 as twisted wires are covered with an insulating material 32, includes: (a) delivering the plurality of core wires 22 through respective core wire passage openings 62, in a core wire guide part 60 in which the plurality of core wire passage openings 62 circularly opened with the same diameter as a circumscribed circle of the core wire 22 are set so that the interval between central axes of the openings is equal to the diameter of the circumscribed circle of the core wire 22, and arranged side by side in one direction so that internal spaces of the openings are communicated with each other; and (b) extruding the insulating material 32 in a form covering an outer periphery of the plurality of core wires 22 delivered at the step (a).

Description

  The present invention relates to flat cable extrusion technology.

  In a hybrid electric vehicle, an electric vehicle, or the like, a flat cable in which a plurality of core wires are arranged in parallel may be used as a power supply cable.

  In Patent Document 1, a conductor composed of a bundle of stranded wires in which a plurality of stranded wires are arranged in the width direction is formed, and insulation is performed so as to cover the outer periphery of the conductor by extruding an insulating material on the outer periphery of the conductor. A flat cable manufactured by forming a body is disclosed.

  Here, when manufacturing a power supply cable, if a plurality of core wires are separated in the width direction (hereinafter referred to as a parallel direction), current flowing in the plurality of core wires is biased and heat generation in some core wires is increased. There is a risk of doing. That is, it is preferable that a plurality of core wires arranged in parallel are electrically connected. Therefore, a flat cable may be manufactured by arranging a plurality of core wires in contact with each other in a parallel direction and covering the arranged core wires with an insulating material.

JP 2011-14449 A

  However, when the insulating material is molded in a state where the plurality of core wires are in contact with each other in the parallel direction, a covering is formed in a state where the insulating material does not enter between the plurality of core wires. According to this configuration, when a force is applied to the covering from the outside (particularly from the longitudinal direction in the cross-sectional view), the cores are separated from the form in which the core wires are arranged in parallel within the covering and overlap in the thickness direction. As a result, the shape of the flat cable may be destroyed.

  Then, an object of this invention is to maintain the shape of a flat cable, suppressing the heat_generation | fever of a core wire.

  A first aspect is a flat cable manufacturing method for forming a flat cable in which a plurality of core wires that are stranded wires are covered with an insulating material, and (a) a circular opening having the same diameter as a circumscribed circle of the core wire. A plurality of core wire passage openings, each having a center axis interval set to be equal to the diameter of the circumscribed circle of the core wire, and the core wire guide portion provided in a line in one direction with the internal space communicating with each other, A step of delivering the plurality of core wires through the mouth portion; and (b) a step of extruding the insulating material in a form covering the outer periphery of the plurality of core wires delivered in the step (a).

  A 2nd aspect is provided with the conductor part comprised by arranging the several core wire which is a strand wire in parallel along one direction, and the coating | coated part which coat | covers the outer periphery of the said conductor part, The said conductor part In the extending direction, the adjacent core wires are in partial contact with each other and are not in contact with each other, and the covering portion is a portion in which the adjacent core wires in the conductor portion are not in contact with each other. It is interposed between the core wires.

  A 3rd aspect is a flat cable which concerns on a 2nd aspect, Comprising: The said adjacent core wire in the said conductor part is contacting in parts far from a center axis | shaft among outer peripheral parts.

  According to the flat cable manufacturing method according to the first aspect, the plurality of core wire passage openings that open in a circle with the same diameter as the circumscribed circle of the core wire are set so that the interval between the central axes is the same as the diameter of the circumscribed circle of the core wire. In addition, in the core wire guide portions that are arranged in one direction with the internal space communicating, a plurality of core wires are sent out through the respective core wire passage openings, and the insulating material is pressed in a form that covers the outer periphery of the plurality of core wires to be sent out. A flat cable is manufactured by taking out. For this reason, in the extending direction of the plurality of core wires, in the portion where the adjacent core wires are arranged so that the direction connecting the central axis of the core wires and the portion far from the central axis of the outer peripheral portion is along the direction in which the plurality of core wires are arranged, Adjacent core wires are in contact with each other, and adjacent core wires are not in contact with each other. Then, in the extending direction of the plurality of core wires, an insulating material enters and is interposed between the adjacent core wires at a portion where the adjacent core wires are not in contact with each other. As a result, adjacent core wires are partially contacted and electrically connected in the extending direction, and a plurality of core wires are connected in the thickness direction at other non-contact portions. Therefore, the shape of the flat cable can be maintained while suppressing the heat generation of the core wire.

  According to the flat cable which concerns on a 2nd aspect, it is provided with the conductor part comprised by arranging the several core wire which is a strand wire in parallel along one direction, and the coating | coated part which coat | covers the outer periphery of a several core wire. The adjacent core wires in the conductor part are in partial contact with each other in the extending direction and are not in contact with each other part. The covering part is a part in which the adjacent core wire in the conductor part is not in contact with each other. Is intervening. For this reason, a form can be maintained, suppressing the heat_generation | fever of a core wire.

  According to the flat cable which concerns on a 3rd aspect, the some core wire in a conductor part is contacting in parts far from a center axis | shaft among outer peripheral parts. For this reason, a form can be maintained, suppressing the heat_generation | fever of a core wire.

It is a schematic perspective view of a flat cable. It is sectional drawing of a core wire. It is sectional drawing of a flat cable. It is other sectional drawing of a flat cable. It is sectional drawing of an extruder. It is a front view of an extrusion port part.

  Hereinafter, the flat cable 10 and its manufacturing method according to the embodiment will be described (see FIG. 1). The flat cable 10 is used as a power supply cable for a hybrid electric vehicle (HEV), an electric vehicle (EV) or the like. The flat cable 10 is formed in a flat shape so that it can be routed in a gap or the like between peripheral members.

<Flat cable>
The flat cable 10 includes a conductor portion 20 having a plurality of core wires 22 and a covering portion 30 (see FIG. 1). Hereinafter, the flat cable 10 may be described with the longitudinal direction in the cross-sectional view as the width direction and the short direction as the thickness direction.

  Each of the core wires 22 is a stranded wire in which a plurality of strands 24 are bundled and twisted (see FIG. 2). The strand 24 is made of, for example, copper, a copper alloy, aluminum, an aluminum alloy, or the like. The wire 24 may be plated with metal such as tin or nickel.

  The core wires 22 are bundled in parallel in a form inscribed in the non-circular virtual frame so as to form a shape along a non-circular shape such as a polygon or an ellipse as a whole in a cross-sectional view orthogonal to the extending direction. , Is formed by twisting. Here, a form in which a bundle of a plurality of strands 24 is inscribed in a non-circular virtual frame means that a non-circular virtual frame is formed on the outer peripheral portion of the strands 24 positioned on the outer peripheral portion of the bundled strands 24. It is a form that passes through a part in the circumferential direction. Here, the plurality of strands 24 are bundled and twisted in a form inscribed in a regular hexagonal virtual frame (see FIG. 2). More specifically, in the core wire 22, six strands 24 are arranged in parallel around one strand 24, and further, 12, 18,... The strands 24 are arranged by a predetermined number of turns, and a bundle of the strands 24 is twisted to form a stranded wire along a regular hexagon in cross section. FIG. 2 illustrates the core wire 22 formed by bundling and twisting the 19 strands 24 as described above. Hereinafter, the core wire 22 inscribed in a virtual hexagonal frame in cross-sectional view will be described as a hexagonal core wire 22 in cross-sectional view.

  But the core wire 22 should just be a thing in which the distance from the central axis in one direction of the radial directions with respect to a central axis to an outer peripheral part changes in an extending direction, ie, a twisted wire. That is, the core wire 22 may be a twisted wire in which a plurality of strands 24 are bundled and twisted in a form inscribed in a virtual frame having a shape other than a hexagon in cross section, such as a polygon or an ellipse. Even if the bundle of strands 24 is inscribed in a circular virtual frame, the outer peripheral portion has a different distance from the central axis along the outer peripheral portion of the strand 24 in the circumferential direction (and has a large number of corners). Therefore, if the bundle of strands 24 is twisted, this core wire has a distance from the central axis to the outer peripheral portion in one of the radial directions with respect to the central axis. It can be said that the shape changes in the extending direction.

  The core wire 22 is located at a position corresponding to the apex of the hexagon, and the distance from the central axis to the outer peripheral portion is long, and the other outer peripheral portions are closer to it. In particular, the distance from the central axis to the outer peripheral portion is closer at a position corresponding to the middle portion of the side of the hexagon.

  The conductor part 20 is configured by arranging a plurality of core wires 22 in parallel along one direction. That is, the plurality of core wires 22 in the conductor portion 20 are arranged in the width direction in the flat cable 10. More specifically, the adjacent core wires 22 are in partial contact with each other in the extending direction, are not in contact with each other, and are positioned with a gap between the adjacent core wires 22. The plurality of core wires 22 are arranged such that the distance between the central axes is the same as the diameter of the circumscribed circle of the core wire 22. The circumscribed circle of the core wire 22 will be described in the description regarding the core wire passage port portion 62 of the core wire guide portion 60 in the extruder 50 described later. However, the form in which the plurality of core wires 22 are arranged may be slightly shifted due to the disorder of alignment, but the plurality of core wires 22 may be arranged in parallel along one direction as a whole. Hereinafter, the direction in which the plurality of core wires 22 are arranged will be described as the parallel direction. In the drawing, the flat cable 10 configured by arranging four core wires 22 is illustrated.

  Adjacent core wires 22 are in contact with each other at the portions of the outer peripheral portion far from the central axis. Here, the adjacent core wires 22 are in contact with each other at portions corresponding to the vertices of the hexagonal sectional view (more specifically, the strands 24 arranged at positions corresponding to the vertices). The portion where the adjacent core wires 22 are in contact with each other in the extending direction is a portion where the direction connecting the central axis of the core wire 22 and the strands 24 arranged at the positions corresponding to the hexagonal apexes is along the parallel direction. However, along the parallel direction is not limited to a state in which the direction connecting the central axis of the core wire 22 and the strand 24 arranged at the position corresponding to the vertex of the hexagon is strictly parallel to the parallel direction. . Further, the core wires 22 may be in contact with each other even in a portion slightly inclined from the above state (see FIG. 4).

  The covering portion 30 is a portion that is formed of an insulating material 32 and covers the outer periphery of the plurality of core wires 22. As the insulating material 32, for example, a synthetic resin material such as polyolefin resin or vinyl chloride resin is used.

  This coating | coated part 30 coat | covers the outer periphery of the some core wire 22 arrange | positioned in parallel, and maintains the state in which this some core wire 22 was located in a line. Further, the covering portion 30 is not interposed between the core wires 22 at the portion where the adjacent core wires 22 are in contact with each other in the extending direction of the plurality of core wires 22 and is adjacent at the portion where the adjacent core wires 22 are not in contact with each other. It is interposed between the core wires 22. That is, the covering portion 30 is formed in a shape in which both side portions sandwiching the plurality of core wires 22 are connected at portions interposed between adjacent core wires 22 in the thickness direction of the flat cable 10.

  The covering portion 30 is formed in a flat and substantially oval shape in a cross-sectional view orthogonal to the extending direction of the flat cable 10. Here, the cross-sectional shape of the covering portion 30 is set to a shape in which a pair of arcs are connected by a pair of straight lines. Further, the thickness dimension of the covering portion 30 (the dimension from the outer peripheral portion of the conductor portion 20 to the outer peripheral portion of the covering portion 30) may be determined in consideration of protection performance, bending performance, and the like.

<Flat cable manufacturing method>
Next, a flat cable manufacturing method for manufacturing the flat cable 10 will be described.

  The flat cable 10 sends out a plurality of core wires 22 (step (a)) and extrudes the insulating material 32 in a form covering the outer periphery of the plurality of core wires 22 sent out in the step (a) (step (b)). Manufactured by. This flat cable 10 is manufactured using the extruder 50 (refer FIG. 5, FIG. 6). The extruder 50 is a device that guides a plurality of core wires 22 to be delivered and coats the outer periphery of the core wires 22 with an insulating material 32. The extruder 50 includes a core wire guide part 60, a covering extrusion part 70, a stirring mechanism part not shown, and the like.

  The core wire guide portion 60 is a mold called a nipple, a point jig or the like, and is a portion that guides the plurality of core wires 22 through. The core wire guide portion 60 has a plurality of core wire passage opening portions 62 that are circularly opened with the same diameter as the circumscribed circle of the core wire 22, and the interval between the central axes is set to be the same as the diameter of the circumscribed circle of the core wire 22. It is formed in a shape that is communicated and arranged in one direction (see FIG. 6). Here, the circumscribed circle of the core wire 22 is two or more portions far from the central axis in the outer periphery of the core wire 22 (here, the outer periphery of each strand 24 arranged at a position corresponding to the hexagonal vertex) It is a circle that passes through the surface) (the portion farthest from the central axis of the core wire 22). Also, the core wire passage port portion 62 has the same diameter as the circumscribed circle of the core wire 22 means that the core wire 22 passed through the core wire passage port portion 62 does not get caught on the inner peripheral portion of the core wire passage port portion 62. And the diameter set so that it can pass without rattling shall be said.

  Moreover, the opening width of the communication part of the adjacent core wire passage opening portions 62 is such that the strands 24 arranged at positions corresponding to the vertices of the hexagons in a sectional view of the core wires 22 passed through the respective core wire passage opening portions 62 are arranged. It is good to set it large to such an extent that it can contact through this communicating part.

  The covering extrusion part 70 is a die and is a part that extrudes the insulating material 32 in a preset shape through an extrusion port part 72 formed at the tip. The extrusion port portion 72 has a shape corresponding to the outer shape in a cross-sectional view of the covering portion 30 of the flat cable 10 in front view, here an oval shape (more specifically, a pair of arcs are connected by a pair of straight lines. It is formed so as to open in a flat shape (see FIG. 6). And the extrusion port part 72 passes the inner side through the several core wire 22 of the arranged state sent through the core wire guide part 60 with the clearance gap of the thickness dimension of the coating | coated part 30 set beforehand with respect to the outer surface. It is set to a size that can be allowed.

  The covering extruding part 70 is arranged with a gap on the outer peripheral side of the core wire guide part 60 (see FIG. 5). Further, the position of the extrusion port portion 72 of the covering extrusion portion 70 is such that the plurality of core wire passage port portions 62 are positioned in front of the plurality of core wire passage port portions 62 of the core wire guide portion 60 and in the front view. It is set (see FIG. 6).

  The insulating material 32 melted and stirred by the stirring mechanism portion in the extruder 50 is sent out through the gap between the core wire guide portion 60 and the coating push portion 70, and is guided by the core wire guide portion 60 and sent out. Extruded through the extrusion port 72 together with the plurality of core wires 22 so as to cover the outer periphery of the wire 22.

  More specifically, among the plurality of core wires 22 sent out through the plurality of core wire passage opening portions 62 of the core wire guide portion 60, the adjacent core wires 22 that pass through the adjacent core wire passage opening portions 62 that communicate with the internal space are: It is delivered in a form of partial contact in the extending direction. That is, as described above, the plurality of core wire passage opening portions 62 have an opening edge portion opened to the same diameter as the diameter of the circumscribed circle of the core wire 22, and the distance between the central axes of adjacent inner spaces is the circumscribed circle of the core wire 22. It is set to be the same as the diameter. For this reason, the adjacent core wires 22 that are twisted and extend in a spiral shape are arranged at the portion corresponding to the apex of the hexagon in a cross-sectional view in the extending direction through the communicating portion of the adjacent core wire passage opening portions 62 (disposed at this position). Contact with each other at the portion where the strands 24) are in contact with each other. On the other hand, in the adjacent core wires 22 where the portions corresponding to the apexes are not abutted with each other through the communicating portion of the adjacent core wire passage port portion 62, the adjacent core wires 22 exist with a gap therebetween and are in a non-contact state. Sent out.

  However, the adjacent core wires 22 may be in a contact or non-contact state at a location different from the above location due to disorder of alignment or the like.

  The insulating material 32 pushed out so as to cover the outer circumferences of the plurality of core wires 22 thus fed also enters between the core wires 22 so as to partially or entirely cover the outer circumferences of the individual core wires 22. And in the part which adjacent core wires 22 contact, the insulating material 32 is dammed up by the contact part, and it pushes out through the extrusion opening part 72 in the state which the insulating material 32 is not connected through the contact part. On the other hand, in the portion where the adjacent core wires 22 are not in contact with each other, the insulating material 32 is extruded between the adjacent core wires 22 through the extrusion port portion 72 while being connected in a direction perpendicular to the parallel direction in the cross-sectional view of the core wires 22. It is.

  Among the plurality of core wires 22 extruded through the extrusion port portion 72 and the insulating material 32 covering the outer periphery thereof, the plurality of core wires 22 constitute the conductor portion 20, and the insulating material 32 lowers the temperature and solidifies the covering portion 30. Configure. Note that the insulating material 32 covering the extruded plurality of core wires 22 may be cooled by passing underwater downstream of the extruder 50 or the like. Thereby, the flat cable 10 is manufactured.

  According to the flat cable 10 and the manufacturing method thereof according to the above embodiment, in the extending direction of the plurality of core wires 22, the direction connecting the central axis of the core wire 22 and the portion far from the central axis is along the parallel direction. The adjacent core wires 22 are in contact with each other at the portion where the adjacent core wires 22 are arranged, and the adjacent core wires 22 are not in contact with each other at other portions. In the extending direction of the plurality of core wires 22, the insulating material 32 enters and is interposed between the adjacent core wires 22 at a portion where the adjacent core wires 22 are not in contact with each other. Thereby, the flat cable 10 provided with the conductor part 20 comprised by the several core wire 22 arrange | positioned in parallel along one direction, and the coating | coated part 30 which coat | covers the outer periphery of the conductor part 20 is formed. That is, the adjacent core wires 22 in the conductor portion 20 are partially in contact with each other and electrically connected in the extending direction, and between the adjacent core wires 22 in which the covering portion 30 is adjacent in other non-contact portions. Therefore, the flat cable 10 can be maintained in a form while suppressing the heat generation of the core 22.

  Further, since the plurality of core wires 22 in the conductor portion 20 are each formed in a substantially hexagonal shape in a cross-sectional view orthogonal to the extending direction and are partially in contact with each other at the apexes in the extending direction, Adjacent core wires 22 come into contact with each other at intervals of a twist pitch that makes a round in the present direction, and the form can be maintained while suppressing the heat generation of the core wires 22.

DESCRIPTION OF SYMBOLS 10 Flat cable 20 Conductor part 22 Core wire 30 Coating | coated part 32 Insulating material 60 Core wire guide part 62 Core wire passage opening part

Claims (3)

A flat cable manufacturing method for forming a flat cable in which a plurality of core wires that are stranded wires are covered with an insulating material,
(A) A plurality of core wire passage openings that open in a circle with the same diameter as the circumscribed circle of the core wire are set so that the interval between the central axes is set to be the same as the diameter of the circumscribed circle of the core wire, and the internal space is communicated. In the core wire guide portion provided side by side in the direction, the step of sending the plurality of core wires through each of the core wire passage openings,
(B) extruding the insulating material in a form covering the outer periphery of the plurality of core wires sent out in the step (a);
A flat cable manufacturing method comprising: A conductor portion configured by arranging a plurality of core wires which are stranded wires in parallel along one direction; and
A covering portion covering the outer periphery of the conductor portion;
With
The adjacent core wires in the conductor portion are in partial contact in the extending direction and non-contact in other portions,
The said covering part is a flat cable which is interposed between the said adjacent core wires in the part which the said adjacent core wires in the said conductor part becomes non-contact. The flat cable according to claim 2,
The said adjacent core wire in the said conductor part is a flat cable which is contacting in parts far from a center axis | shaft among outer peripheral parts.

Images