JP2016081732A - Electric wire and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric wire capable of surely preventing breakage and destruction of terminal parts of an insulating film due to external factors, and capable of ensuring stable electric insulation properties.SOLUTION: An electric wire 10 includes a conductor 11 and a resin insulating film 12 to cover an outer periphery of the conductor 11. The insulating film 12 is formed by partially applying a liquid insulating resin to a circumferential portion of the conductor 11 which needs insulation. Terminal portions 12a and 12a on both end sides of the insulating film 12 are respectively made into a tapered (inclined) shape.SELECTED DRAWING: Figure 1

Description

  The present invention provides an electric wire and an electric 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 relates to a manufacturing method.

  As an electric wire routed between such short paths, one shown in FIG. 7 is known (for example, refer to Patent Document 1).

  As illustrated in FIG. 7, the electric wire 1 is a flat electric wire including 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.

JP2014-107201A (FIG. 1)

  However, in the conventional electric wire 1, when connecting the connection portion 2 a on which the insulating coating 3 of the bus bar 2 is not formed as it is by bolt fastening or the like, for example, to the electric motor and the inverter of the hybrid vehicle, both ends of the insulating coating 3 are connected. The terminal portions 3a, 3a on the side may be destroyed by external factors such as friction and wear.

  Therefore, the present invention has been made to solve the above-described problems, and can reliably prevent damage or destruction of the terminal portion of the insulating coating due to external factors and ensure stable electrical insulation. An object of the present invention is to provide an electric wire and a method for manufacturing the electric wire.

  According to a first aspect of the present invention, there is provided an electric wire including a conductor and a resin insulating film covering an outer periphery of the conductor, wherein the insulating film is formed by partially covering the conductor with a liquid insulating resin. The terminal portion of the insulating coating has a tapered shape.

  The invention according to claim 2 is the electric wire according to claim 1, wherein the conductor is a twisted wire in which a bus bar having a substantially rectangular cross section, a round single wire having a circular cross section, and a plurality of strands are twisted into a bundle. It is characterized by comprising either one.

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

  According to a fourth aspect of the present invention, there is provided a method of manufacturing an electric wire including a conductor and a resin insulating coating covering an outer periphery of the conductor, wherein the conductor includes a bus bar having a substantially rectangular cross section and a circular section having a circular cross section. Using any one of a single wire and a twisted wire in which a plurality of strands are twisted into a bundle, a liquid insulating resin is coated at predetermined intervals on a peripheral portion where insulation of the conductor continuous body is required, and Each of the insulating coatings is formed, the end portions of each insulating coating are formed in a tapered shape, and then the portions of the conductor continuum where the respective insulating coatings are not formed are cut off.

  As described above, according to the first aspect of the present invention, the insulating coating is formed by partially covering the conductor with the liquid insulating resin, and the end portion of the insulating coating is formed into a tapered shape, so that friction and wear are achieved. It is possible to reliably prevent the terminal portion of the insulating coating from being damaged or broken due to external factors such as the above, and to ensure stable electrical insulation.

  According to the invention of claim 2, the conductor is constituted by any one of a bus bar having a substantially rectangular cross section, a round single wire having a circular cross section, and a stranded wire formed by twisting a plurality of strands into a bundle. It is possible to select and wire an electric wire made of a conductor most suitable for a short path / narrow space such as a power circuit in which a relatively large voltage is applied to cause insulation problems.

  According to the invention of claim 3, since the insulating coating can be cured in a shorter time by using the photo-curable 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 4, as the conductor, any one of a bus bar having a substantially rectangular cross section, a round single wire having a circular cross section and a stranded wire formed by twisting a plurality of strands into a bundle is used. In addition, a liquid insulating resin is coated at predetermined intervals on surrounding portions where insulation of the continuum is required to form insulating coatings, and end portions of the respective insulating coatings are formed in a tapered shape. By cutting each portion of the continuum where each insulating coating is not formed, a wire that can prevent damage or destruction of the terminal portion of the insulating coating due to external factors such as friction and wear, and the like, in a short time It can be reliably manufactured at low cost.

It is a perspective view which shows the electric wire of 1st Embodiment of this invention. (A) is a side view of the said electric wire, (b) is sectional drawing which follows the AA line in the same (a). It is a schematic diagram which shows the various apparatuses used with the manufacturing method of the said electric wire. (A)-(c) is a schematic diagram which shows the manufacturing method of the said electric wire. (A) is a perspective view which shows the electric wire of 2nd Embodiment, (b) is a front view of the electric wire. (A) is a perspective view which shows the electric wire of 3rd Embodiment, (b) is a front view of the electric wire. It is a perspective view of the conventional electric wire.

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

  1 is a perspective view showing an electric wire according to a first embodiment of the present invention, FIG. 2A is a side view of the electric wire, FIG. 2B is a cross-sectional view taken along line AA in FIG. FIG. 3 is a schematic view showing various devices used in the method for producing the electric wire, and FIGS. 4A to 4C are schematic views showing the method for producing the electric wire.

  As shown in FIG. 1, an electric wire 10 includes a bus bar (conductor) 11 having a substantially rectangular cross section made of aluminum or an aluminum alloy, and a resin insulating coating 12 partially covering the outer periphery of the bus bar 11. , A flat wire.

  As shown in FIGS. 1 and 2 (a) and 2 (b), the surrounding area where the bus bar 11 needs to be insulated is covered with a urethane acrylate resin (photo-curing resin) as a liquid insulating resin for insulation. A coating 12 is formed. Each terminal part 12a, 12a on both ends of the insulating coating 12 has a tapered (inclined) shape, and the thickness of the insulating coating 12 becomes thinner toward the end.

  Further, both end portions of the bus bar 11 where the insulating coating 12 is not formed are the connection portions 11a and 11a on the other side. That is, one connection part 11a of the bus bar 11 is a terminal part connected to an electric motor of a hybrid vehicle, for example, and the other connection part 11a is a terminal part connected to an inverter. The tapered end portions 12a and 12a on both ends of the insulating coating 12 are necessary when the bus bar 11 is directly connected to the electric motor or inverter by bolt fastening or the like (attaching terminals and connectors to the wire terminals). In the case of a product, the tapered shape of the terminal portion 12a is not necessary). Moreover, as an application of the electric wire 10, it is suitable to be used as a connection bus bar between battery batteries provided together.

  According to the electric wire 10 of the embodiment described above, the insulating coating 12 is formed by covering the peripheral portion of the bus bar 11 where insulation is necessary with the urethane acrylate resin, and the end portions 12a and 12a on both ends of the insulating coating 12 are tapered. By reducing the thickness of the insulating coating 12 toward the terminal as a shape, for example, the electric motor of the hybrid car is directly connected to the connecting portions 11a and 11a on both ends where the insulating coating 12 of the bus bar 11 is not formed by bolt fastening or the like. When connecting to the inverter, it is possible to reliably prevent the end portions 12a, 12a on both ends of the insulating coating 12 from being twisted, broken, broken or the like due to external factors such as friction and wear, and stable electrical insulation. Can be secured.

  Further, by using the bus bar 11 having a substantially rectangular cross section as a conductor, the electric wire can be easily and surely provided 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. 10 can be routed.

  Next, the manufacturing method of the electric wire 10 is demonstrated using FIG.3 and FIG.4.

  First, as shown in FIG. 3, a bus bar continuous body (conductor continuous body) 11 </ b> A having a substantially rectangular cross section and continuously formed in a longitudinal direction by a press device (not shown) is used as a resin supply device by a guide 40 and a roller 41. The coating head 50 is guided.

  When the bus bar continuum 11A passes through the coating head 50, the urethane acrylate resin 60 is applied to the coating head 50 by a liquid feed pump 62 from a tank 61 in which a liquid urethane acrylate resin (photocurable resin) 60 is stored. By feeding every other time, the urethane acrylate resin 60 is applied to the bus bar continuum 11A at predetermined intervals (so-called intermittently). The application amount of the urethane acrylate resin 60 is gradually increased and then set to a constant amount, and finally the operation is stopped after the application amount is gradually decreased. Thereby, when the urethane acrylate resin 60 hardens | cures and the insulating coating 12 is formed, the terminal parts 12a and 12a of the both end sides become a taper shape (square pyramid surface shape), respectively.

  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. Thereafter, as shown in FIGS. 4A and 4B, the cutting device (not shown) cuts each portion of the bus bar continuous body 11 </ b> A where each insulating coating 12 is not formed (that is, the connecting portion 11 a). Thereby, the electric wire 10 shown in FIG.4 (c) is manufactured.

  In this way, the urethane acrylate resin 60 is coated at predetermined intervals on the surrounding portions where the insulation of the bus bar continuum 11A needs to be cured to form the insulating coatings 12, respectively. By forming the terminal portions 12a and 12a into a tapered shape and then cutting the connection portions 11a, which are portions where the respective insulating coatings 12 of the bus bar continuous body 11A are not formed, external factors such as friction and wear are obtained. The electric wire 10 capable of preventing the terminal portion of the insulating coating from being damaged or broken due to the above can be manufactured reliably in a short time and at low cost.

  Furthermore, since the insulating coating 12 can be cured in a shorter time by using the urethane acrylate resin (photo-curing resin) 60 as the liquid insulating resin, it is necessary in the field such as an assembly line. An amount of the electric wire 10 can be manufactured in a short time and reliably at low cost.

  Fig.5 (a) is a perspective view which shows the electric wire of 2nd Embodiment, FIG.5 (b) is a front view of the electric wire.

  As shown in FIGS. 5 (a) and 5 (b), the electric wire 20 has a circular single wire (conductor) 21 having a circular cross section made of copper or a copper alloy, and a partial outer periphery of the circular single wire 21. And a resin-made insulating coating 22.

  An insulating coating 22 is formed by coating and curing a urethane acrylate resin 60 as a photo-curing resin at a surrounding portion where the round single wire 21 needs to be insulated. Each end 22a, 22a on both ends of the insulating coating 22 has a tapered shape (conical surface shape), and the thickness of the insulating coating 22 becomes thinner toward the end. In the figure, reference numeral 21a denotes a connecting portion.

  Thereby, the electric wire 20 of the said 2nd Embodiment also has the effect | action and effect similar to the electric wire 10 of the said 1st Embodiment.

  Fig.6 (a) is a perspective view which shows the electric wire of 3rd Embodiment, FIG.6 (b) is a front view of the electric wire.

  As shown in FIGS. 6A and 6B, the electric wire 30 includes a stranded wire (conductor) 31 formed by twisting a plurality of strands made of copper or a copper alloy, and an outer periphery of the stranded wire 31. It is a round electric wire provided with a resin insulating coating 32 partially covering.

  An insulating coating 32 is formed by coating and curing a urethane acrylate resin 60 as an ultraviolet curable resin at a peripheral portion where insulation of the stranded wire 31 is necessary. Each end portion 32a, 32a on both ends of the insulating coating 32 has a tapered shape (conical surface shape), and the thickness of the insulating coating 32 decreases toward the end. In the figure, reference numeral 31a denotes a connecting portion.

  Thereby, the electric wire 30 of the said 3rd Embodiment also has the effect | action and effect similar to the electric wire 10 of the said 1st Embodiment.

  Further, as in each of the above embodiments, the conductor is one of the bus bar 11 having a substantially rectangular cross section, the round single wire 21 having a circular cross section, and the stranded wire 31 in which a plurality of strands are twisted into a bundle. It is composed of one, and the insulating coatings 12, 22, and 32 are formed on each of the conductors, so that a relatively large voltage is applied to a short path / narrow space such as a power circuit of a hybrid vehicle in which insulation is a problem. The electric wires 10, 20, 30 made of the most suitable conductor can be selected and wired.

  In addition, according to each said embodiment, although the ultraviolet curable resin of the photocurable resin was used as a liquid insulation resin, at least any one of a visible light curable resin, a thermosetting resin, and a 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 Electric wire 11 Bus bar (conductor)
11a Connection part (where the insulation coating is not formed)
11A bus bar continuum (conductor continuum)
12 Insulating coating 12a Terminal portion 20 Electric wire 21 Round single wire (conductor)
21a Connection part (where the insulation coating is not formed)
22 Insulating coating 22a Terminal part 30 Electric wire 31 Stranded wire (conductor)
31a Connection part (where the insulation coating is not formed)
32 Insulating coating 32a End portion 60 Urethane acrylate resin (photo-curing resin as a liquid insulating resin)

Claims (4)

In an electric wire comprising a conductor and a resin insulating coating covering the outer periphery of the conductor,
Partially covering the conductor with a liquid insulating resin to form the insulating coating;
An electric wire characterized in that a terminal portion of the insulating coating has a tapered shape. The electric wire according to claim 1,
An electric wire characterized in that the conductor is constituted by any one of a bus bar having a substantially rectangular cross section, a round single wire having a circular cross section, and a stranded wire formed by twisting a plurality of strands. The electric wire according to claim 1,
An electric wire characterized by using a photocurable resin as the insulating resin. In a method of manufacturing an electric wire comprising a conductor and a resin insulating coating covering the outer periphery of the conductor,
As the conductor, any one of a bus bar having a substantially rectangular cross section, a round single wire having a circular cross section, and a stranded wire in which a plurality of strands are twisted into a bundle is used, and insulation of the continuous body of the conductor is required. The insulating coating is formed by coating a liquid insulating resin on the surrounding portions at predetermined intervals, and the end portions of each insulating coating are formed in a tapered shape, and then each of the conductor continuums is formed. A method for producing an electric wire, characterized in that each of the portions where an insulating coating is not formed is cut.

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