JP2016081731A - Flat wire and flat wire production method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production method for a flat wire having an insulating coating having a substantially uniform thickness on a surface of a bus bar.SOLUTION: There is provided a flat wire 10 comprising a bus bar 11 having a substantially rectangular cross section and an insulating coating 13 made of resin covering an outer periphery of the bus bar 11. Both sides 11a and 11a of the bus bar 11 are formed curved in a substantially arc shape toward outside. Then, liquid insulating resin is partially applied to the bus bar 11 having both sides 11a and 11a curved in a substantially arc shape toward outside. Then, the liquid insulating resin is cured to form an insulating coating 13. The insulating coating 13 is configured such that an edge coverage being a rate obtained by dividing the thickness of the insulating coating 13 at the edge portion of the bus bar 11 by the thickness of the insulating coating 13 at the flat portion of the bus bar 11 is 60% or more.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a flat wire and a flat wire suitable for wiring as a high-voltage cable in a short path / narrow space such as between an electric motor and an inverter arranged close to each other in a hybrid vehicle or an electric vehicle. It is related with the manufacturing method of an electric wire.

  What is shown in FIG. 6 is known as a flat electric wire wired between this kind of short paths (for example, refer patent document 1).

  As shown in FIG. 6, the flat electric wire 1 includes a bus bar 2 having a substantially rectangular cross section, and a resin insulating coating 3 that partially covers the outer periphery of the bus bar 2. Both end portions of the bus bar 2 where the insulating coating 3 is not formed are mating connection portions 2a and 2a. That is, one connection part 2a of the bus bar 2 is a terminal part connected to an electric motor of a hybrid vehicle, for example, and the other connection part 2a is a terminal part connected to an inverter.

  Further, as shown in FIGS. 7A to 7C, for example, the flat electric wire 1 is formed by applying a bus bar continuous body 2A having a substantially rectangular cross section and continuously formed in the longitudinal direction by a pressing device (not shown). The resin 6 is applied by passing through the coating jig 5 and the opening 7a of the coating head passes through the rectangular base 7 so that the resin 6 has a substantially uniform thickness on the bus bar continuous body 2A. After the resin 6 is cured, the portions of the bus bar continuous body 2A where the insulating coating 3 is not formed (that is, the connecting portions 2a) are cut.

JP2014-107201A (FIG. 1) Japanese Patent Laying-Open No. 2013-4444 (FIG. 1)

  In the conventional rectangular electric wire 1, the bus bar continuous body 2A coated with the resin 6 passes through the opening 7a of the base 7 so that the resin 6 is coated on the bus bar continuous body 2A so as to have a substantially uniform thickness. However, since the opening 7a of the base 7 is rectangular, the resin is easily applied to the upper and lower surfaces of the finished bus bar 2 and the flat portions on both sides, and the resin at the edge portion (four corners). Therefore, it was difficult to form the insulation coating 3 having a uniform thickness on the surface of the bus bar 2.

  Accordingly, the present invention has been made to solve the above-described problems, and an object of the present invention is to provide a flat electric wire provided with an insulating coating having a substantially uniform thickness on the surface of a bus bar and a method for manufacturing the flat electric wire.

  The invention according to claim 1 is a flat electric wire comprising a bus bar having a substantially rectangular cross section and a resin insulating film covering an outer periphery of the bus bar, wherein both side surfaces of the bus bar are curved outward in a substantially arc shape. Insulation of the edge portion of the bus bar is formed by applying a liquid insulating resin to a bus bar having both sides curved in a substantially arc shape on the outside and then curing the liquid insulating resin. An edge cover ratio, which is a ratio obtained by dividing the thickness of the coating by the thickness of the insulating coating on the flat portion of the bus bar, is 60% or more.

  A second aspect of the present invention is the flat electric wire according to the first aspect, wherein a photocurable resin is used as the insulating resin.

  The invention according to claim 3 is a method of manufacturing a rectangular electric wire comprising a bus bar having a substantially rectangular cross section and a resin insulating film covering the outer periphery of the bus bar. A liquid insulating resin is applied at predetermined intervals to surrounding portions of the bus bar continuous body having insulation, and then the bus bar continuous body coated with the liquid insulating resin at predetermined intervals has openings. Covering the liquid insulating resin with a substantially uniform thickness at a peripheral portion where the insulation of the bus bar continuum is required to pass through an elliptical base, and then curing to form the insulating coating, Each portion of the bus bar continuum where the insulating coating is not formed is cut.

  As described above, according to the first aspect of the present invention, both side surfaces of the bus bar are formed to be curved outward in a substantially arc shape, and the bus bar having both side surfaces curved in a substantially arc shape on the outer side is liquid. An edge that is a ratio obtained by dividing the thickness of the insulating coating on the edge portion of the bus bar by the thickness of the insulating coating on the flat portion of the bus bar by forming an insulating coating by partially applying the insulating resin and then curing the insulating coating. By setting the cover ratio to 60% or more, an insulating film having a substantially uniform thickness can be formed on the surface of the bus bar, and stable electrical insulation can be ensured.

  According to the invention of claim 2, since the insulating coating can be cured in a shorter time by using the photocurable resin as the insulating resin, for example, a necessary amount of the material can be used at the site such as an assembly line. An electric wire can be manufactured in a short time and reliably at low cost.

  According to the invention of claim 3, the liquid insulating resin is applied at predetermined intervals to a peripheral portion where insulation of the bus bar continuous body having both side surfaces curved in a substantially arc shape on the outside is required, and then the liquid state The bus bar continuum coated with the insulating resin at regular intervals is passed through a base having an elliptical opening, and the liquid insulating resin is coated in a substantially uniform thickness around the area where the bus bar continuum needs to be insulated. And then curing to form an insulating coating, and then cutting each portion of the bus bar continuous body where the insulating coating is not formed, thereby forming a rectangular electric wire with an insulating coating having a substantially uniform thickness on the surface of the bus bar. Can be manufactured reliably at low cost in a short time.

It is a perspective view which shows the flat electric wire of one Embodiment of this invention. (A) is a side view of the said flat electric wire, (b) is sectional drawing which follows the AA line in the (a). It is a schematic diagram which shows the various apparatuses used with the manufacturing method of the said flat electric wire. (A) is a cross-sectional view of a coating jig of a resin supply device for manufacturing the flat electric wire, (b) is a cross-sectional view of a cap of a resin supply device for manufacturing the flat electric wire, and (c) is manufactured by each of the devices. It is sectional drawing of a flat rectangular electric wire. (A)-(c) is a schematic diagram which shows the manufacturing method of the said flat electric wire. It is a perspective view of the conventional flat electric wire. (A) is a sectional view of a coating jig of a conventional resin supply device for manufacturing a rectangular electric wire, (b) is a sectional view of a base of a resin supply device for manufacturing the rectangular electric wire, and (c) is manufactured by the same device. It is sectional drawing of the conventional conventional rectangular electric wire.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 is a perspective view showing a flat electric wire according to an embodiment of the present invention, FIG. 2A is a side view of the flat electric wire, and FIG. 2B is a cross section taken along the line AA in FIG. FIG. 3 is a schematic view showing various devices used in the method for producing the flat electric wire, FIG. 4A is a sectional view of a covering jig of a resin supply device for producing the flat electric wire, and FIG. 4B. FIG. 4C is a cross-sectional view of a flat electric wire manufactured by the apparatus, and FIGS. 5A to 5C are schematic views showing a method for manufacturing the flat electric wire.

  As shown in FIG. 1, the flat electric wire 10 includes a short bus bar 11 having a substantially rectangular cross section made of aluminum or an aluminum alloy, and a resin insulating film 13 that partially covers the outer periphery of the bus bar 11. I have.

  As shown in FIGS. 1 and 2 (a) and 2 (b), both side surfaces 11a and 11a of the bus bar 11 are formed as semicircular arc surfaces curved outward in a substantially circular arc shape, and upper and lower edge portions ( The corners are rounded. A urethane acrylate resin (photo-curing resin) as a liquid insulating resin is partially applied to a peripheral portion where insulation of the bus bar 11 having both side surfaces 11a and 11a that are curved in a substantially arc shape on the outside is required. Then, the insulating coating 13 is formed to have a substantially uniform thickness by curing. That is, the edge cover ratio, which is a ratio obtained by dividing the thickness of the insulating coating 13 on the upper and lower edge portions of the bus bar 11 by the thickness of the insulating coating 13 on the upper and lower surfaces 11b and 11c side of the bus bar 11, is 60%. That's it.

  Further, both end portions (exposed portions) of the bus bar 11 where the insulating coating 13 is not formed are connection portions 12 and 12 on the other side. That is, one connecting portion 12 of the bus bar 11 is, for example, a terminal portion connected to the electric motor of the hybrid vehicle, and the other connecting portion 12 is a terminal portion connected to the inverter. In addition, as a use of the flat electric wire 10, it is suitable for using as a connection bus bar between the battery batteries provided side by side.

  According to the flat electric wire 10 of the embodiment described above, the insulating coating 13 is formed by covering the peripheral portion of the bus bar 11 having both sides 11a, 11a that are curved in a substantially arc shape on the outside and requiring insulation with the urethane acrylate resin. And the insulating coating 13 of the substantially uniform thickness can be formed in the surface 11a-11c of the bus-bar 11 by the edge cover rate of this insulating coating 13 having been 60% or more. As a result, for example, when the connecting portions 12 and 12 on both ends where the insulating coating 13 of the bus bar 11 is not formed are connected to the electric motor and the inverter of the hybrid vehicle by bolt fastening or the like, stable electric insulation is ensured. can do.

  In addition, by using the short bus bar 11 having a substantially rectangular cross section, a flat voltage can be easily and reliably obtained even in a short path / narrow space such as a power circuit of a hybrid vehicle in which a relatively large voltage is applied and insulation is a problem. The electric wire 10 can be routed.

  Next, the manufacturing method of the flat electric wire 10 is demonstrated using FIGS.

  First, as shown in FIG. 3, a bus bar continuum 11A having both sides 11a, 11a that are formed in a substantially rectangular shape in a longitudinal direction and curved in a substantially arc shape on the outside by a press device (not shown). The guide 40 and the roller 41 guide the application head 50 as a resin supply device.

  When the bus bar continuum 11A passes through the coating jig (cartridge) 51 of the coating head 50, the urethane acrylate resin is supplied from the tank 61 in which the liquid urethane acrylate resin (photocurable resin) 60 is stored by the liquid feed pump 62. As shown in FIG. 4 (a), the urethane acrylate resin 60 is applied to the bus bar continuous body 11A at predetermined intervals (so-called intermittently) by feeding 60 to the coating jig 51 of the application head 50 at predetermined intervals. Is done. Then, as shown in FIG. 4B, the bus bar continuum 11A coated with the urethane acrylate resin 60 passes through the flat elliptical base 52 with the opening 52a of the coating head 50, thereby providing a continuous bus bar. The urethane acrylate resin 60 having a substantially uniform thickness is coated on a peripheral portion where the body 11A needs to be insulated. That is, the opening 52a of the base 52 of the coating head 50 has a flat diameter that is larger by the thickness of the insulating coating 13 than the cross-sectional shape of the bus bar continuous body 11A having both side surfaces 11a and 11a that are curved in a substantially arc shape on the outside. Since the bus bar continuum 11A coated with the urethane acrylate resin 60 passes through the opening 52a of the base 52 of the coating head 50 because it is formed in an elliptical shape (field track shape), the edge cover ratio is 60% or more. A thick urethane acrylate resin 60 can be coated on the surface of the bus bar continuous body 11A. As a result, the urethane acrylate resin 60 can be easily and surely covered with a substantially uniform thickness on the surrounding portion where the insulation of the bus bar continuous body 11A is necessary.

  Further, when the urethane acrylate resin 60 is applied to the bus bar continuous body 11A at predetermined intervals, for example, if the urethane acrylate resin 60 having a viscosity of 10 to 1000 Pa · s at 25 ° C. is used, it is photocurable (ultraviolet curable). It is possible to obtain a substantially uniform coating thickness by suppressing the dripping of the resin 60.

  Next, the bus bar continuum 11A passes through the ultraviolet irradiation device 70, whereby the urethane acrylate resin 60 is cured with ultraviolet rays in a short time.

  Next, the bus bar continuous body 11A in which the urethane acrylate resin 60 is cured passes through the take-up roller 80, the wire diameter monitor 90, and the like. After that, as shown in FIGS. 5A and 5B, the cutting device (not shown) cuts each portion of the bus bar continuous body 11A where the insulating coatings 13 are not formed (that is, the connecting portion 12). Thereby, the flat electric wire 10 shown in FIG.5 (c) is manufactured.

  In this way, the urethane acrylate resin 60 is applied at predetermined intervals to the peripheral portions of the bus bar continuous body 11A having both side surfaces 11a and 11a that are curved in a substantially circular arc shape on the outside, and then the urethane acrylate resin is applied. The bus bar continuum 11A coated with the resin 60 at predetermined intervals is passed through an elliptical base 52 having a flat opening 52a so that the urethane acrylate resin 60 is substantially uniform in the surrounding area where the bus bar continuum 11A needs to be insulated. Then, the insulating coating 13 is formed by covering the surface 11a to 11c of the bus bar 11 by cutting the portions 12 of the bus bar continuous body 11A where the insulating coating 13 is not formed. The flat electric wire 10 on which the insulating coating 13 having a substantially uniform thickness is formed can be manufactured in a short time and reliably at low cost.

  Furthermore, since the insulating coating 13 can be cured in a shorter time by using the urethane acrylate resin 60 as the photo-curable resin, for example, a necessary amount of the rectangular electric wire 10 can be obtained at the site such as an assembly line. It can be manufactured in a short time and reliably at low cost.

  In addition, according to the embodiment, the UV curable resin of the photocurable resin is used as the liquid insulating resin, but at least one of the visible light curable resin, the thermosetting resin, and the humidity curable resin is used. One can be used. The photocurable resin is not limited to the urethane acrylate resin, and other photocurable resins such as an epoxy acrylate resin and a polyester acrylate resin may be used.

  Moreover, according to the said embodiment, although the bus-bar was shape | molded with the material of aluminum or aluminum alloy, pure copper, copper alloy, etc. may be used for the material used for a bus-bar other than aluminum.

10 Flat wire 11 Bus bar 11a, 11a Both sides 11b Upper surface (plane part)
11c bottom surface (plane part)
12 Connection part (where the insulation coating is not formed)
11A Bus bar continuum 13 Insulating coating 52 Base 52a Elliptical opening 60 Urethane acrylate resin (photo-curing resin as a liquid insulating resin)

Claims (3)

In a flat electric wire provided with a bus bar having a substantially rectangular cross section and a resin insulating film covering the outer periphery of the bus bar,
The both sides of the bus bar are curved outwardly in a substantially arc shape, and the bus bar having both sides curved in a substantially arc shape on the outside is partially coated with a liquid insulating resin and then cured. Forming an insulating coating,
A rectangular electric wire characterized in that an edge cover ratio, which is a ratio of the thickness of the insulating coating on the edge portion of the bus bar divided by the thickness of the insulating coating on the flat portion of the bus bar, is 60% or more. The flat electric wire according to claim 1,
A flat electric wire characterized by using a photocurable resin as the insulating resin. In a method for manufacturing a rectangular electric wire comprising a bus bar having a substantially rectangular cross section and a resin insulating coating covering the outer periphery of the bus bar,
A liquid insulating resin is applied at predetermined intervals to a peripheral portion where insulation of the bus bar continuous body having both side surfaces curved in a substantially arc shape on the outside is required, and then the liquid insulating resin is applied at predetermined intervals. The applied bus bar continuum is passed through a base having an elliptical opening, and the liquid insulating resin is coated in a substantially uniform thickness on a peripheral portion where insulation of the bus bar continuum is required, and then cured. A method for producing a rectangular electric wire, wherein the insulating coating is formed and then the portions of the bus bar continuum where the insulating coating is not formed are cut.

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