JP2016183744A - Method for engaging end piece of bowden cable with outer cable - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable a small-diameter formation and light weight of an outer cable to be attained at a Bowden cable, perform a simple and rigid connection between an end piece and a shield and attain a cost saving as well as its reduction and a light weight even if the end piece is provided with a fixing part and a bent pipe part for covering and enclosing the outer cable under its curved state.SOLUTION: A shield 4 of a Bowden cable is constituted by a hollow strand 22 made by stranding several metallic wires 21, an end part of this hollow strand 22 is exposed out of a shell 5, its end part is expanded at its diameter to form a first flare part 23, and an end part of a liner 3 is also expanded at its diameter to form a second flare part 24, an end piece E is injection molded to enclose both flare parts 23, 24, synthetic resin of raw material of the end piece E is fed between the metallic wires 21. The end piece E includes a fitting part T and a bent pipe part M covering and enclosing an outer circumference of the outer cable under its curved state and these T and M are integrally formed by injection molding.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a flexible inner wire, a flexible outer cable that is inserted through the inner wire and guides its sliding, and an end piece that is coupled to one end of the outer cable and is inserted into the inner wire. The outer cable is composed of a synthetic resin liner that directly guides the sliding of the inner wire, a hollow shield that accommodates and holds the liner, and a synthetic resin outer sheath that covers the outer periphery of the shield. The present invention relates to a connection structure between an end piece and an outer cable in a Bowden cable, and a method for connecting the end piece and the outer cable to obtain the connection structure.

  Such a Bowden cable is already known as disclosed in Patent Document 1 below.

JP 2009-138855 A

  FIG. 15 shows the configuration of a conventional Bowden cable B ′. In the figure, reference numeral 01 is an inner wire, 02 is an outer cable, 03 is a liner, 04 is a shield, and 05 is an outer skin. In this conventional Bowden cable B ′, the shield 04 is configured by tightly winding a metal strip m around the liner 03 in a coil shape. In such a shield 04, in order to secure the minimum strength, there is a limit to the minimum thickness of the metal strip m, and there is a limit to the minimum outer diameter from the viewpoint of coil formability. It has been difficult to reduce the diameter and thus to reduce the weight.

  In addition, if you want to separately manufacture the end piece of the Bowden cable and the bent tube part that covers and holds the outer cable in a bent state, separately, It is necessary to connect with a retrofit, and it is necessary to insert a resin pipe inner for protecting the inner wire into the inner circumference of the metal bent pipe part by retrofitting, and further, connect the metal bent pipe part and the outer cable end part. Since caulking is required, the number of parts and processing man-hours increase as a whole, resulting in increased costs and weight. In addition, there is a step at the joint between the bent pipe (resin pipe inner) and the outer cable end. As a result, the slidability of the inner wire is reduced.

  The present invention has been made in view of such circumstances. The outer cable can be significantly reduced in diameter and weight, and the end piece is made of synthetic resin. The connection structure of the end piece and the outer cable in the Bowden cable that can be firmly connected, and the bent pipe part and the mounting part in the end piece can be integrally formed with a synthetic resin, thereby eliminating the latter problem. It is another object of the present invention to provide a method for connecting an end piece and an outer cable to obtain the connection structure.

  In order to achieve the above object, the present invention comprises a flexible inner wire, a flexible outer cable that is inserted through the inner wire and guides its sliding, and one end of the outer cable. The outer cable is composed of an end piece inserted into the inner wire, and covers the outer cable with a synthetic resin liner that directly guides sliding of the inner wire, a hollow shield that accommodates and holds the liner, and an outer periphery of the shield. A hollow strand formed by twisting together a plurality of metal strands in which the shield is arranged so as to be in close contact with each other around the liner in a connection structure of an end piece and an outer cable in a Bowden cable composed of a synthetic resin sheath The end of the hollow strand is exposed from the outer skin, and the end of the hollow strand The first flare portion in which each metal element wire is dispersed is formed, and the end portion of the liner is also expanded to form a second flare portion adjacent to the first flare portion. The end piece is injection-molded so as to wrap the first and second flares, and the synthetic resin of the material of the end piece is inserted between the metal strands, and the end piece is fixedly supported by the support member. And a bent pipe part that covers and surrounds the outer end of the outer cable in a bent state, and the attached part and the bent pipe part are integrally formed by the injection molding. First feature.

  In addition to the first feature, the second feature of the present invention is that a gap for the synthetic resin to enter is provided between the first and second flare portions.

  In addition to the second feature, the present invention has a third feature that the second flare portion is formed to have a smaller diameter than the first flare portion.

  Furthermore, the present invention is a method for connecting an end piece and an outer cable to obtain a connection structure between an end piece and an outer cable in a Bowden cable having any one of the first to third characteristics, and is used for the injection molding. A cavity having at least an attachment portion forming cavity portion and a bent tube portion forming cavity portion for forming the attachment portion and the bent tube portion, respectively, is formed between a plurality of mold elements constituting the mold apparatus. In the state where the one end portion of the outer cable is inserted into at least the bent tube portion molding cavity portion of the cavity, and the shape-retaining core material having flexibility is inserted into the liner of the outer cable, The fourth feature is that the injection molding is performed such that a molten synthetic resin is injected into the cavity.

  According to the present invention, in addition to the fourth feature, a base end of the shape-retaining core is coupled to at least a part of the mold element, and the holding member is inserted into the liner of the outer cable before the injection molding. A fifth feature is that the shaping core is inserted from the tip side.

  In addition to the fourth or fifth feature of the present invention, at least a part of the mold element is inserted with the one end portion of the outer cable into the bent tube portion forming cavity portion of the cavity, A plurality of positioning protrusions for cooperating and centering the one end portion of the outer cable with respect to the bent tube portion forming cavity portion are provided, and the one end portion of the outer cable is formed during the injection molding by the positioning protrusions. According to a sixth aspect of the present invention, the bent tube portion molding cavity portion is correctly positioned and held at a predetermined set position.

  According to the present invention, the hollow shield of the Bowden cable is configured by the hollow strand formed by winding a plurality of metal strands arranged so as to be in close contact with each other around the liner. Can be configured to be sufficiently smaller in diameter than the shield in the conventional Bowden cable using the cable, and it is possible to reduce the diameter of the Bowden cable and to reduce the weight. In addition, the hollow strands have higher tensile and compressive strength and rigidity than conventional shields made by closely winding a metal strip in a coil shape. Can be sufficiently tolerated, the transmission efficiency of any operating force can be increased, and the flexibility is also excellent, so that its application can be widened. In addition, the end of the hollow strand is exposed from the outer shell, the end of the hollow strand is expanded to form a first flare portion in which each metal strand is discrete, and the end of the liner is also expanded. The second flare portion adjacent to the first flare portion is formed, and the end piece is injection-molded so as to wrap the first and second flare portions, and the synthetic resin of the material of the end piece is inserted between the metal strands. Therefore, the end piece can be easily obtained by injection molding, and a large number of discrete metal strands in the first flare portion and the second flare portion consisting of the end portion of the liner deeply bite into the end piece and exhibit an anchor effect. As a result, the coupling strength between the end piece and the outer cable can be effectively increased.

  In addition, the end piece includes an attachment portion for fixing and supporting the end piece to the support member, and a bent pipe portion that covers and surrounds the outer periphery of the outer cable in a bent state. Since the pipe part is integrally formed by the injection molding, it becomes possible to easily and accurately mold an end piece having a complicated three-dimensional shape including the mounting part and the bent pipe part by synthetic resin injection molding. In addition, even if the direction of action of one end of the Bowden cable is different from the direction of cable extension from the end piece, the end piece can reliably retain the curved form of one end of the outer cable that curves in accordance with the direction. Furthermore, it is not necessary to separately manufacture and attach the above-mentioned mounting part and bent pipe part with metal, and it is necessary to insert a resin pipe inner for protecting the inner wire into the inner periphery of the metal bent pipe part as a retrofit. Accordingly, the number of parts and the number of processing steps can be greatly reduced, which can contribute to cost saving and weight reduction. Also, since one end of the outer cable can be extended long through the bent pipe part to near the outer end of the end piece, there is no need to separately connect a resin pipe inner to the end of the outer cable. It is possible to avoid a decrease in the slidability of the inner wire due to the difference in level and a decrease in the operation feeling.

  Further, in particular, according to the second feature of the present invention, the first and second flare portions are independently deeply formed in the end piece by providing a gap for the synthetic resin to enter between the first and second flare portions. It can penetrate and exert a strong anchor effect, and can further increase the coupling strength between the end piece and the outer cable.

  In particular, according to the third feature of the present invention, the second flare portion is formed to have a smaller diameter than the first flare portion, so that when the end piece is formed, between the metal wires of the first flare portion and the second flare portion. The synthetic resin enters between the first and second flare portions better, and the anchor effect on the end pieces of the first and second flare portions can be further enhanced.

  In particular, according to the fourth feature of the present invention, one end portion of the outer cable is inserted into at least the bent tube portion forming cavity portion of the cavity of the mold apparatus used for the injection molding, and the outer cable liner is inserted into the outer cable liner. Since the synthetic resin in the molten state is injected into the cavity with the flexible shape-retaining core inserted, the shape-retaining core can sufficiently counter the molding pressure at the time of injection molding. For example, even when the outer cable has a relatively small diameter and low rigidity, or even when the outer cable is bent and a flat thin portion is formed in the outer skin, the outer cable is crushed and deformed due to high molding pressure. It can be effectively prevented by the material, and the slidability of the inner wire in the state where the inner wire is inserted into the outer cable after molding, and the operation feeling can be improved. That.

  In particular, according to the fifth feature of the present invention, the base end of the shape-retaining core is coupled to at least a part of the mold elements, and the shape-retaining core is placed in the outer cable liner before injection molding. Since it was inserted from the distal end side, the base end of the shape-retaining core can be placed in a pre-bonded state with some mold elements, and positioning and setting work of the shape-retaining core to the mold apparatus can be performed. Can be done efficiently.

  In particular, according to the sixth aspect of the present invention, at least a part of the mold element has one end portion of the outer cable in a state where the one end portion of the outer cable is inserted into the bent tube portion forming cavity portion of the cavity. Are provided with a plurality of positioning projections for cooperating and centering with respect to the bent tube portion forming cavity portion, so that one end portion of the outer cable is bent by the positioning protrusion during the injection molding. Therefore, the bent tube portion of the end piece can be arranged and fixed in an appropriate concentric posture around the centered outer cable, and the formability of the bent tube portion is improved.

The partially broken side view which shows the Bowden cable which concerns on embodiment of this invention, and its usage example. FIG. 2 is an enlarged sectional view taken along line 2-2 in FIG. 1. FIG. 3 is an enlarged sectional view taken along line 3-3 in FIG. 2. Cross-sectional view of the middle part of the Bowden cable (4-4 enlarged cross-sectional view of FIG. 1) Perspective view of end piece at the end of Bowden cable 6-6 enlarged sectional view of FIG. FIG. 7 is a cross-sectional view taken along line 7-7 in FIG. FIG. 8 is an enlarged sectional view taken along line 8-8 in FIG. 1. Enlarged side view and end view of one end of outer cable before end piece molding The perspective view which shows the state which set the middle mold | type and the shape-retaining core material between the upper and lower molds in the injection molding process of the end piece FIG. 10 is a partially cutaway cross-sectional view as seen from the direction of arrow 12 in FIG. 10, showing a state in which the middle mold and the shape-retaining core are set in the lower mold between the upper and lower molds. (A) is a cross-sectional view taken along 12 (A) -12 (A) in FIG. 11, and (B) is a cross-sectional view taken along 12 (B) -12 (B) in FIG. Sectional view along line 13-13 in FIG. 14-14 sectional view of FIG. Partially broken side view showing a conventional Bowden cable and cross-sectional view of the middle part thereof

  1 and 4, a Bowden cable B includes a flexible inner wire 1, a flexible outer cable 2 inserted through the inner wire 1 to guide its sliding, and both ends of the outer cable 2. The outer cable 2 includes a synthetic resin liner 3 that directly guides the sliding of the inner wire 1 and a hollow shield 4 that accommodates and holds the liner 3. And a synthetic resin outer skin 5 covering the outer periphery of the shield 4. And the connection terminals 1a and 1b formed in the column shape orthogonal to the inner wire 1 are respectively fixed by retrofitting to both ends of the inner wire 1 protruding outside the outer cable 2.

  Referring also to FIGS. 2 and 3, Bowden cable B is applied to, for example, a lock releasing device for a seat lock mechanism of a motorcycle. The end piece E on the operating side is a state in which the outer periphery of the end portion 2a of the outer cable 2 is bent and a bracket T as a mounting portion for fixing and supporting the end piece E on the body frame F of the motorcycle at an appropriate position. And a bent cylindrical pipe portion M that surrounds and surrounds the bracket T and the bent pipe portion M, at the same time as the end piece E is injection-molded with a synthetic resin as described later. It is formed. In addition, the bending pipe part M may have a straight pipe part in the part, or the whole may be curving.

  Further, in the illustrated example, the bent pipe portion M of the end piece E on the operation side has a connection end with the bracket T, that is, a portion where stress concentration is most likely to occur is formed with the largest diameter and thick wall, and gradually decreases in diameter and thickness as the distance from the portion increases. Formed. In addition, a pair of left and right reinforcing ribs Mr are integrally projected on the outer periphery of the bent pipe portion M from the middle in the longitudinal direction to the small diameter end. The bent pipe M is formed with a plurality of centering positioning projections p1, p1 ′; p2, p2 ′ of the outer cable 2 that are generated in an injection molding process described later. The

  In the present embodiment, the bracket T as the mounting portion is mainly composed of an L-shaped bracket body Tm formed integrally with first and second mounting walls 7 and 7 'orthogonal to each other. The second mounting walls 7, 7 'are brought into contact with the first and second support walls 8, 8' perpendicular to each other of the support member Fa and fastened by bolts b and nuts n penetrating the first mounting wall 7. Is done. The first mounting wall 7 is formed with a cylindrical protrusion 7a that fits into and engages with the engagement hole of the first support wall 8, and a bolt insertion hole 7b through which the bolt b is inserted.

  A lock operation mechanism 9 including a cylinder lock that can pull the Bowden cable B by inserting and rotating the key K is attached to the support member Fa, and an output member 10 of the operation mechanism 9 includes One connecting end 1a of the inner wire 1 of the Bowden cable B is coupled, and the output member 10 is moved upward in accordance with the rotation operation of the key K so that the inner wire 1 can be pulled. In FIG. 2, reference numeral 11 denotes a cowl for covering the vehicle body frame F, the lock operation mechanism 9, and the like with good appearance.

  Further, an annular locking groove 14 is provided on the outer periphery of the operated end piece E ′, and the locking groove 14 is formed on the bracket 13 of the seat lock mechanism 12 disposed immediately below the seat of the motorcycle. Locked. The other connection terminal 1 b of the inner wire 1 is connected to an unlock lever 15 of the seat lock mechanism 12, and this unlock lever 15 is urged and held in the retracted position, that is, the locked position by the urging force of the return spring 16.

  Thus, if the key K is inserted into the key hole of the lock operating mechanism 9 and rotated in the unlocking direction and the inner wire 1 is pulled by the output member 10, the lock releasing lever 15 is applied to the urging force of the return spring 16. Accordingly, the locked state of the seat lock mechanism 12 can be released, whereby the seat (not shown) can be opened. Further, if the key K is turned back and forth in the locking direction, the lock release lever 15 can be turned by the urging force of the return spring 16 to return the seat lock mechanism 12 to the locked state.

  By the way, the shield 4 is constituted by a hollow strand 22 formed by twisting together a plurality of metal strands 21, 21... Arranged so as to be in close contact with each other around the liner 3.

  FIG. 4 shows a design example of the Bowden cable B when the inner wire 1 having a diameter of 1.0 mm is used. Here, the diameter of the metal strands 21, 21... Is 0.4 mm, the number of the metal strands 21, 21... Is 18, the winding pitch of the metal strands 21, 21. , 21... Is an S type, the outer diameter of the shield is 2.6 mm, and the weight is 21 g / m.

  For comparison with this, FIG. 15 shows a design example of a conventional Bowden cable B ′ in the case where the inner wire 1 having a diameter of 1.0 mm is used as described above. In this case, the thickness of the metal strip m that is tightly wound in a coil to form the shield 04 is 0.5 mm, the outer diameter of the shield 04 is 4.0 mm, and the weight is 62 g / m.

  In the above, it should be noted that the shield 4 of the present invention has a thickness of 0.4 mm (= diameter of the metal strand), the outer diameter of 2.6 mm, and the thickness of the conventional shield 04 of 0.5 mm (= The thickness of the metal strip m) and the outer diameter of 4.0 mm.

  Here, the outer diameter of the conventional shield 04 (see FIG. 15) is 4.0 mm, which is a limit in forming the metal strip m having a thickness of 0.5 mm tightly wound in a coil shape. In order to make it less than 4.0 mm, it is necessary to make the plate | board thickness of the metal strip m less than 0.5 mm, but if it does so, it will become difficult to satisfy the intensity | strength of the shield 04.

  On the other hand, the fact that the outer diameter of the shield 4 of the present invention can be made significantly smaller than the outer diameter of the conventional shield 04 is that a plurality of metal strands 21, 21. This is because the hollow strands 22 are formed by being arranged so as to be in close contact with each other and forming the hollow strands 22, thereby forming the shield 4.

  As described above, the diameter of the shield 4 of the present invention is reduced (about 1 / 1.5 of the conventional product), so that the diameter of the Bowden cable B is reduced, and the weight is reduced (the weight is about 1/3 that of the conventional product). Can be planned. Moreover, the shield 4 made of the hollow strand 22 has higher tensile and compressive strength and rigidity than the conventional shield 04 in which the metal strip m is tightly wound in a coil shape. Of course, it can withstand push operation force sufficiently, can improve the transmission efficiency of any operation force, and also has excellent flexibility. Its application is very wide.

  Next, with reference to FIGS. 5 to 9 as well, the end piece E, E ′ made of synthetic resin and the connection structure between it and the outer cable 2 will be described.

  First, as shown in FIG. 9, by removing the outer skin 5 at both ends of the outer cable 2 to expose the end of the hollow strand 22 from the outer skin 5 and expanding the diameter of the end of the hollow strand 22, The 1st flare part 23 in which each metal strand was discrete is formed. Further, the end portion of the liner 3 is also enlarged in diameter to form a second flare portion 24 adjacent to the first flare portion 23. The second flare portion 24 is formed to have a smaller diameter than the first flare portion 23, and a gap is provided between the second flare portion 23 and the first flare portion 23.

  As shown in FIGS. 6 and 8, the end pieces E and E ′ are injection-molded using a synthetic resin as a material so as to wrap the first and second flare portions 23 and 24 and the end portions of the outer skin 5. At that time, the synthetic resin enters the gaps between the metal strands 21 constituting the first flare portion 23 and between the first and second flare portions 23 and 24.

  Thus, the end pieces E and E ′ can be easily obtained by injection molding. In addition, a large number of discrete metal strands 21 of the first flare portion 23 and the first flare portion 23 formed by the end portions of the liner 3 deeply bite into the end pieces E and E ′ to exert a strong anchor effect. Thus, the coupling strength between the end pieces E, E ′ and the outer cable 2 can be increased. Further, in particular, by providing a gap for the synthetic resin to enter between the first and second flare portions 23, 24, the first and second flare portions 23, 24 are independently deep in the end pieces E, E ′. The strong anchor effect is exerted by biting in, and the coupling strength between the end pieces E, E ′ and the outer cable 2 can be further increased. In addition, since the second flare portion 24 is formed to have a smaller diameter than the first flare portion 23, when the end pieces E and E ′ are formed, the metal flakes 21 between the first flare portion 23 and the first and second flare are formed. The penetration of the synthetic resin between the portions 23 and 24 becomes good, and the anchor effect on the end pieces E and E ′ of the first and second flare portions 23 and 24 is further enhanced.

  As in this embodiment, the thickness of the shield 4 can be made equal to the diameter of the metal strands 21, 21,... In addition, the coupling strength between the end pieces E, E ′ and the outer cable 2 can be increased without changing the shape and dimensions of the conventional end pieces E, E ′. Therefore, it is promising for use in various operating force transmission systems in motorcycles that require low fuel consumption.

  By the way, the end piece E on the operation side in particular is bent so as to cover and surround the bracket T as a mounting portion for fixing and supporting the support member Fa and the outer periphery of the end portion 2a of the outer cable 2 as described above. Since it has a tube portion M and has a complicated three-dimensional solid shape as a whole and is insert-molded so as to embed the one end portion 2a of the outer cable 2, it is special in its molding. It needs some ingenuity. Then, next, an example of the injection molding method of the operation-side end piece E will be described with reference to FIGS.

  A mold apparatus D used for this injection molding includes a plurality of mold elements, for example, a lower mold D1, an upper mold D2 that can be driven up and down by a driving means (not shown) with respect to the lower mold D1, and upper and lower It is divided into a middle mold D3 that can be interposed between the molds D1 and D2. A cavity C corresponding to the overall shape of the end piece E is formed between the lower mold D1, the upper mold D2, and the middle mold D3. The cavity C includes at least a bracket forming cavity portion Ct and a bent tube portion forming cavity portion Cm for forming the bracket T and the bent tube portion M, respectively.

  On the upper surface of the lower mold D1 (that is, the mating surface with the upper mold D2), the engagement concave portion 30 into which the lower end portion of the middle die D3 is fitted, and the first bent concave portion for forming the lower half portion of the bent pipe portion M 31 is formed. The engaging recess 30 is formed with a molding recess 30a for molding the bracket T in cooperation with the middle mold D3 and the upper mold D2.

  Further, on the lower surface of the upper mold D2, there are formed a recess 33 for receiving the upper part of the middle mold D3 set on the lower mold D1, and a second curved recess 34 for molding the upper half of the bent tube part M. The A bracket molding cavity Ct for molding the bracket T is defined by the lower mold D1, the middle mold D3 set on the lower mold D1, and the upper mold D2 covering the middle mold D3. . Further, the first and second bent concave portions 31 and 34 define a bent tube portion forming cavity Cm for forming the bent tube portion M, and the end portion 2a of the outer cable 2 is inserted in the end portion 2a. Piece E is injection molded.

  In the upper die D2 and the lower die D1, the one end 2a of the outer cable 2 is inserted into the bent tube portion forming cavity Cm, and the one end 2a of the outer cable 2 is connected to the bent tube portion forming cavity Cm. A plurality of positioning protrusions p1, p1 ′; p2, p2 ′ are provided for centering in cooperation with each other. That is, a plurality of pairs of upper and lower first positioning protrusions p1 and p1 ′ extending in a direction approaching each other are provided on the opposing surfaces of the upper mold D2 and the lower mold D1, and both the first positioning protrusions p1 and p1. By positioning the one end portion 2a of the outer cable 2 from above and below, the positioning in the vertical direction is performed. In addition, at least one of the opposing surfaces of the upper mold D2 and the lower mold D1 (lower mold D1 in the illustrated example) includes a plurality of left and right pair of second positioning pins p2 and p2 'that sandwich the one end portion 2a of the outer cable 2 from the left and right. A pair is projected. The one end 2a of the outer cable 2 is sandwiched between the second positioning protrusions p2 and p2 'from the left and right, thereby positioning in the left-right direction (the direction crossing the outer cable 2 horizontally).

  Thus, by these first and second positioning projections p1, p1 ′; p2, p2 ′, the one end portion 2a of the outer cable 2 is correctly positioned at a predetermined set position of the bent tube portion forming cavity portion Cm, that is, a normal centering position. Therefore, the bent pipe portion M of the end piece E can be arranged and fixed in an appropriate concentric posture around the centered outer cable 2, and the formability of the bent pipe portion is improved.

  By the way, in the injection molding of the end piece E, the molten synthetic resin is injected into the cavity C of the mold apparatus D in a state where the flexible shape-retaining core R is inserted into the liner 3 of the outer cable 2. To be executed. In the illustrated example, a rope made of a material (for example, nylon or the like) that is not deformed even by injection molding pressure is used as the shape retaining core R. The outer diameter of the shape retaining core R is slightly smaller than the inner diameter of the liner 3 of the outer cable 2. Therefore, the shape-retaining core material R can be smoothly slid and inserted / removed in the liner 3. Further, in the present embodiment, the base end portion of the shape-retaining core material R is coupled to the middle mold D3 (in the illustrated example, embedded integrally in the middle mold D3).

  The shape-retaining core material R is inserted into the liner 3 of the outer cable 2 from the front end side thereof, and the insertion work is performed before the end piece E is injection molded, in particular, the outer cable 2 is placed on the lower mold D1. This is done before setting.

  Further, a slightly tapered cylindrical projecting portion 38 surrounding the base end portion of the shape-retaining core material R is integrally projected on the molding surface of the middle mold D3 facing the bracket molding cavity Ct. The tip of the cylindrical protrusion 38 is the inner peripheral surface of the end of the liner 3 of the cable 2, particularly the diameter-expanded first, with the one end 2 a of the outer cable 2 inserted into the bent tube portion forming cavity Cm. The two flare portions 24 are in contact with the inner peripheral surface over the entire circumference. A hole 40 that concentrically surrounds the cylindrical protrusion 38 with the annular gap 39 interposed therebetween is formed in the middle mold D3 so as to open directly to the bracket molding cavity Ct. The annular gap 39 serves as a cavity for molding the cylindrical protrusion 7a formed on the first mounting wall 7 of the bracket T.

  In addition, a molding pin 41 for molding the bolt insertion hole 7b formed in the first mounting wall 7 so as to protrude from the bracket molding cavity Ct is fixed to the middle mold D3.

  Incidentally, a pouring gate (not shown) for introducing a molten resin into the cavity C, for example, the bracket molding cavity Ct, is formed at an appropriate position of the mold apparatus D, and a molten resin injection means (not shown) is formed at the pouring gate. From there, the pressurized molten resin can be supplied to the cavity C at any time.

  Next, a specific example of the process of injection molding the operation-side end piece E will be described.

  First, as shown in FIG. 9, the outer sheath 5 is removed at one end 2a of the outer cable 2 of the Bowden cable B so that the end of the hollow strand 22 is exposed from the outer sheath 5, and the end of the hollow strand 22 is expanded. By forming the diameter, the first flare portion 23 in which each metal wire is discrete is formed, and the end portion of the liner 3 is also enlarged to form the second flare portion 24 adjacent to the first flare portion 23. .

  Next, the outer cable 2 is inserted into the shape-retaining core material R coupled to the middle die D3 from the tip end side with the first and second flare portions 23 and 24 first. The insertion is performed until the first and second flare portions 23 and 24 face the bracket forming cavity Ct of the middle mold D3. Next, the middle die D3 is set on the lower die D1 together with the shape-retaining core material R and the outer cable 2, that is, the lower end portion of the middle die D3 is fitted into the recess 33 on the upper surface of the lower die D1, and one end of the outer cable 2 is fitted. The part 2a is inserted into the first bent recess 31 on the upper surface of the lower mold D1 while bending the part 2a. In this case, the one end portion 2a of the outer cable 2 is positioned and held at the centering position of the first bent concave portion 31 by the plurality of pairs of second positioning protrusions p2 and p2 ′ on the left and right sides.

  Further, the upper mold D2 is put on the lower mold D1 so as to sandwich the middle mold D3 therebetween, and a cavity C is defined between the molds D1 to D3. In this case, the one end portion 2a of the outer cable 2 is sandwiched from above and below by a plurality of pairs of first positioning projections p1 and p1 'so as to be between the first and second curved concave portions 31 and 34 (that is, the bent tube portion forming cavity portion Cm). ) At a predetermined set position, that is, a normal centering position.

  In this state, a molten synthetic resin is pressurized and injected into the cavity C from a gate (not shown), whereby an end piece E corresponding to the cavity C is injection molded. After the injection molding is completed, first, the upper mold D2 is raised and separated from the lower mold D1 and the middle mold D3, and then the middle mold D3 is lifted together with the molded product with respect to the lower mold D1, and the molded product is moved to the middle mold D3. Remove from the lower mold D1 together. Thereafter, the molded product is pulled out from the middle mold D3 in the direction along the axis of the molding pin 41, and at the same time, the outer cable 2 of the Bowden cable B is pulled out from the shape-retaining core R.

  The end piece E on the operation side is insert-molded on the one end 2a of the outer cable 2 through the above steps. The method of insert-molding the operated end piece E ′ at the other end of the outer cable 2 is basically the same as the above process. However, the end piece E ′ on the operated side has a simple mounting portion (locking groove 14) and has no bent portion in the tube portion that covers and surrounds the other end portion of the outer cable 2. The structure of the mold apparatus is simpler than that of the mold apparatus D.

  According to the embodiment, the end piece E on the operation side is covered with the bracket T as a mounting portion for fixing and supporting the end piece E on the support member Fa and the outer periphery of the end portion 1a of the outer cable 2 in a bent state. Since the bent tube portion M is enclosed and these T and M are integrally formed by injection molding, the end piece E including the mounting portion T and the bent tube portion M is formed into a complicated three-dimensional shape as a whole. It becomes possible to mold easily and accurately by injection molding of synthetic resin. Even if the pulling operation direction at one end of the Bowden cable B and the cable extending direction from the end piece E are different directions, the curved form of the outer cable one end 2a that curves in accordance with the direction is the bent pipe portion M of the end piece E. The shape can be reliably preserved.

  By the way, in the case where the mounting portion T and the bent pipe portion M are manufactured separately from metal, it is necessary to attach both of them by retrofitting, and the resin property for inner wire protection is provided on the inner periphery of the metal bent pipe portion M. It is necessary to insert the pipe inner by retrofitting, and further, the metal bent pipe part M and the end part of the outer cable 2 need to be caulked and joined. As a result, the number of parts and processing steps increase as a whole, and the cost increases. This may cause an increase in weight, and may cause problems such as a decrease in the slidability of the inner wire 1 due to a step formed at the connecting portion between the resin pipe inner in the bent tube portion M and the end of the outer cable 2. . On the other hand, in the present embodiment, since the bent pipe part M and the bracket T (attachment part) formed by insert molding the one end part 2a of the outer cable 2 are integrally formed with a synthetic resin, they are integrally coupled to each other. The above problem is eliminated. That is, the number of parts and the number of processing steps can be greatly reduced to reduce cost and weight, and one end 2a of the outer cable 2 can be extended through the bent pipe M to the vicinity of the outer end of the end piece E. Since it can be extended and there is no need to separately connect a plastic pipe inner to the end of the outer cable, it avoids a decrease in slidability of the inner wire 1 due to a step in the connecting portion, and a decrease in operation feeling. can do.

  In the present embodiment, the one end 2a of the outer cable 2 is inserted into at least the bent tube portion forming cavity Cm of the cavity C of the mold apparatus D, and flexibility is provided in the liner 3 of the outer cable 2. Since the molten synthetic resin is injected into the cavity C with the shape-retaining core R inserted therein, the shape-retaining core R can sufficiently counter the injection molding pressure. Thereby, for example, even when the outer cable 2 has a relatively small diameter and low rigidity, or when the outer cable 2 is bent and a flat thin portion is generated in the outer skin 5, the outer cable 2 is crushed due to high molding pressure. Since the shape-retaining core material R can be effectively prevented from being deformed, the slidability of the inner wire 1 in the state where the inner wire 1 is inserted into the outer cable 2 after molding, and the operation feeling is effectively enhanced. It is done.

  Further, in the present embodiment, the base end of the shape retaining core R is coupled to some mold elements, for example, the middle mold D3, and the shape retaining core R is placed in the liner 3 of the outer cable 2 before injection molding. It is inserted from the tip side. Thereby, since the base end of the shape-retaining core R can be placed in the middle mold D3 in advance, positioning and setting work of the shape-retaining core R to the mold apparatus D can be performed efficiently.

  The present invention is not limited to the above-described embodiment, and various design changes can be made without departing from the scope of the invention.

  For example, the shield 4 can be formed by forming the hollow strands 22 in a plurality of layers, and the strength and rigidity of the shield 4 can be further increased. In this case, the anchor effect on the end piece E of the first flare part 23 is enhanced by increasing the number of the metal strands 21 of the first flare part 23, and the coupling strength between the end piece E and the outer cable 2 is further increased. Can be increased.

  Moreover, in the said embodiment, although the L-shaped bracket T was illustrated as an attaching part of the end piece E by the side of operation, the form of an attaching part is not limited to the said embodiment, If it can attach to a support member, Various forms can be adopted.

  In the above embodiment, the operation-side end piece E is shown in which the mounting portion T and the bent tube portion M are integrally formed. However, the same structure can be implemented on the operated-side end piece. is there.

  In the above-described embodiment, the Bowden cable B is applied to the throttle valve operating system of the motorcycle engine. However, the Bowden cable of the present invention is an operating system other than the throttle valve operating system of the vehicle, such as a clutch and a brake. The present invention can be applied to an operation system such as the above, and may be applied to various operation systems other than a vehicle.

B ... Bowden cable C ... Cavity Ct ... Mounting section molding cavity Cm ... Bending pipe molding cavity D ... Mold device D1 ... Lower mold D2 as mold element ... Upper mold D3 as mold element ... Middle mold E as mold element ... End piece Fa ... Support members p1, p1 ' First positioning pins p2 and p2 'as a plurality of positioning projections Second positioning pin M as a plurality of positioning projections B bent tube portion T Bracket R as an attachment portion ... Shaping core 1 ... Inner wire 2 ... Outer cable 2a ... One end 3 of outer cable ... Liner 4 ... Shield 5 ... .... Outer skin 21 ... Metal wire 22 ... Hollow strand 23 ... · The first flare section 24 ... the second flare section

The present invention relates to a flexible inner wire, a flexible outer cable that is inserted through the inner wire and guides its sliding, and an end piece that is coupled to one end of the outer cable and is inserted into the inner wire. The outer cable is composed of a synthetic resin liner that directly guides the sliding of the inner wire, a hollow shield that accommodates and holds the liner, and a synthetic resin outer sheath that covers the outer periphery of the shield. It relates binding accompaniment method of the end piece and the outer cable in the Bowden cable.

  Such a Bowden cable is already known as disclosed in Patent Document 1 below.

JP 2009-138855 A

  FIG. 15 shows the configuration of a conventional Bowden cable B ′. In the figure, reference numeral 01 is an inner wire, 02 is an outer cable, 03 is a liner, 04 is a shield, and 05 is an outer skin. In this conventional Bowden cable B ′, the shield 04 is configured by tightly winding a metal strip m around the liner 03 in a coil shape. In such a shield 04, in order to secure the minimum strength, there is a limit to the minimum thickness of the metal strip m, and there is a limit to the minimum outer diameter from the viewpoint of coil formability. It has been difficult to reduce the diameter and thus to reduce the weight.

  In addition, if you want to separately manufacture the end piece of the Bowden cable and the bent tube part that covers and holds the outer cable in a bent state, separately, It is necessary to connect with a retrofit, and it is necessary to insert a resin pipe inner for protecting the inner wire into the inner circumference of the metal bent pipe part by retrofitting, and further, connect the metal bent pipe part and the outer cable end part. Since caulking is required, the number of parts and processing man-hours increase as a whole, resulting in increased costs and weight. In addition, there is a step at the joint between the bent pipe (resin pipe inner) and the outer cable end. As a result, the slidability of the inner wire is reduced.

The present invention has been made in view of such circumstances. The outer cable can be significantly reduced in diameter and weight, and the end piece is made of synthetic resin. and adapted to tightly bound, the latter problem as can be integrally molded with the bend pipe portion and the attachment portion in yet endpiece of synthetic resin also obtained wiped out, binding of the end piece and the outer cable in the Bowden cable an object of the present invention is to provide an mETHODS.

To achieve the above object, the present invention includes a flexible inner wire, a flexible outer cable the inner wire to guide the insertion and Teso Re sliding, is coupled to one end of the outer cable a hollow shield the outer cable name Ru Bowden cable more and end piece you inserting the inner wire, a synthetic resin liner for guiding the sliding of the inner wire directly accommodating the liner, which holds Te, the The shield is composed of a synthetic resin covering the outer periphery of the shield, and the shield is composed of a hollow strand formed by twisting together a plurality of metal strands arranged so as to be in close contact with each other around the liner. A first flare portion in which each end of the hollow strand is exposed from the outer skin and the end of the hollow strand is expanded to disperse each metal strand. None, the diameter of the end portion of the liner is also enlarged, the second flare portion adjacent to the first flare portion is formed, and the end piece is injection-molded so as to wrap the first and second flare portions, Synthetic resin of the material of the end piece is inserted between the metal strands, and the end piece is bent in a mounting portion for fixing and supporting the end piece to the support member and the outer periphery of the one end portion of the outer cable. A method for connecting an end piece and an outer cable in a Bowden cable, comprising a bent pipe portion that covers and surrounds, and the attachment portion and the bent pipe portion are integrally formed by the injection molding. Mounting portion forming cavity portion and bent tube portion forming for forming the mounting portion and the bent tube portion respectively between a plurality of mold elements constituting a mold apparatus used for forming. A cavity having at least a cavity portion is formed, and the one end portion of the outer cable is inserted into at least the bent tube portion forming cavity portion of the cavity, and the shape retaining shape having flexibility is provided in the liner of the outer cable. while inserting the precaution material, a first feature that you run the injection molding so as to emit molten synthetic resin into the cavity.

The present invention, in addition to the first feature, between the first and second flare section, and a second feature that it has a so that a gap in which the synthetic resin enters.

In addition to the second feature, the present invention has a third feature that the second flare portion is formed to have a smaller diameter than the first flare portion .

Or the present invention, in addition to any of the first to third features, at least in part of the mold elements are combined proximal end of the shape retention precaution material, outer cable prior to the injection molding A fourth feature is that the shape-retaining core material is inserted into the liner from the front end side.

According to the present invention, in addition to any one of the first to fourth features, at least a part of the mold element has the one end portion of the outer cable inserted into the bent tube portion forming cavity portion of the cavity. In this state, a plurality of positioning protrusions are provided for cooperating and centering the one end portion of the outer cable with respect to the bent tube portion forming cavity portion. A fifth feature is that the one end portion is correctly positioned and held at a predetermined set position of the bent tube portion forming cavity portion.

  According to the present invention, the hollow shield of the Bowden cable is configured by the hollow strand formed by winding a plurality of metal strands arranged so as to be in close contact with each other around the liner. Can be configured to be sufficiently smaller in diameter than the shield in the conventional Bowden cable using the cable, and it is possible to reduce the diameter of the Bowden cable and to reduce the weight. In addition, the hollow strands have higher tensile and compressive strength and rigidity than conventional shields made by closely winding a metal strip in a coil shape. Can be sufficiently tolerated, the transmission efficiency of any operating force can be increased, and the flexibility is also excellent, so that its application can be widened. In addition, the end of the hollow strand is exposed from the outer shell, the end of the hollow strand is expanded to form a first flare portion in which each metal strand is discrete, and the end of the liner is also expanded. The second flare portion adjacent to the first flare portion is formed, and the end piece is injection-molded so as to wrap the first and second flare portions, and the synthetic resin of the material of the end piece is inserted between the metal strands. Therefore, the end piece can be easily obtained by injection molding, and a large number of discrete metal strands in the first flare portion and the second flare portion consisting of the end portion of the liner deeply bite into the end piece and exhibit an anchor effect. As a result, the coupling strength between the end piece and the outer cable can be effectively increased.

  In addition, the end piece includes an attachment portion for fixing and supporting the end piece to the support member, and a bent pipe portion that covers and surrounds the outer periphery of the outer cable in a bent state. Since the pipe part is integrally formed by the injection molding, it becomes possible to easily and accurately mold an end piece having a complicated three-dimensional shape including the mounting part and the bent pipe part by synthetic resin injection molding. In addition, even if the direction of action of one end of the Bowden cable is different from the direction of cable extension from the end piece, the end piece can reliably retain the curved form of one end of the outer cable that curves in accordance with the direction. Furthermore, it is not necessary to separately manufacture and attach the above-mentioned mounting part and bent pipe part with metal, and it is necessary to insert a resin pipe inner for protecting the inner wire into the inner periphery of the metal bent pipe part as a retrofit. Accordingly, the number of parts and the number of processing steps can be greatly reduced, which can contribute to cost saving and weight reduction. Also, since one end of the outer cable can be extended long through the bent pipe part to near the outer end of the end piece, there is no need to separately connect a resin pipe inner to the end of the outer cable. It is possible to avoid a decrease in the slidability of the inner wire due to the difference in level and a decrease in the operation feeling.

In addition, one end of the outer cable is inserted into at least the bent tube portion molding cavity of the cavity of the mold apparatus used for the injection molding, and a flexible shape-retaining core material is placed in the liner of the outer cable. Since the synthetic resin in the molten state is injected into the cavity in the inserted state, the shape-retaining core material can sufficiently counter the molding pressure at the time of injection molding. For example, the outer cable has a relatively small diameter and low rigidity. Even when the outer cable is bent or a flat thin part is formed in the outer skin, the outer cable can be effectively prevented from being crushed and deformed due to high molding pressure. The slidability of the inner wire in a state where the inner wire is inserted through the cable, and the operation feeling can be enhanced.

According particularly to the second aspect of the present invention, between the first and second flare section, synthetic resin that was so that a gap from entering the first and second flare section are each independently End It is possible to deeply penetrate into the piece to exert a strong anchor effect, and to further increase the coupling strength between the end piece and the outer cable.

In particular, according to the third feature of the present invention, the second flare portion is formed to have a smaller diameter than the first flare portion, so that when the end piece is formed, between the metal wires of the first flare portion and the second flare portion. The synthetic resin enters between the first and second flare portions better, and the anchor effect on the end pieces of the first and second flare portions can be further enhanced .

According to a fourth aspect of or in particular the present invention, at least in part of the mold elements are combined proximal end of the shape retention precaution material, shape retaining beware material into the liner of the outer cable in front of the injection molding Since the base end of the shape-retaining core material can be previously connected to some mold elements, the shape-retaining core material is positioned and set in the mold apparatus. Can be performed efficiently.

In particular, according to the fifth feature of the present invention, at least a part of the mold element has one end portion of the outer cable in a state where the one end portion of the outer cable is inserted into the bent tube portion forming cavity portion of the cavity. Are provided with a plurality of positioning projections for cooperating and centering with respect to the bent tube portion forming cavity portion, so that one end portion of the outer cable is bent by the positioning protrusion during the injection molding. Therefore, the bent tube portion of the end piece can be arranged and fixed in an appropriate concentric posture around the centered outer cable, and the formability of the bent tube portion is improved.

The partially broken side view which shows the Bowden cable which concerns on embodiment of this invention, and its usage example. FIG. 2 is an enlarged sectional view taken along line 2-2 in FIG. 1. FIG. 3 is an enlarged sectional view taken along line 3-3 in FIG. 2. Cross-sectional view of the middle part of the Bowden cable (4-4 enlarged cross-sectional view of FIG. 1) Perspective view of end piece at the end of Bowden cable 6-6 enlarged sectional view of FIG. FIG. 7 is a cross-sectional view taken along line 7-7 in FIG. FIG. 8 is an enlarged sectional view taken along line 8-8 in FIG. 1. Enlarged side view and end view of one end of outer cable before end piece molding The perspective view which shows the state which set the middle mold | type and the shape-retaining core material between the upper and lower molds in the injection molding process of the end piece FIG. 10 is a partially cutaway cross-sectional view as seen from the direction of arrow 12 in FIG. 10, showing a state in which the middle mold and the shape-retaining core are set in the lower mold between the upper and lower molds. (A) is a cross-sectional view taken along 12 (A) -12 (A) in FIG. 11, and (B) is a cross-sectional view taken along 12 (B) -12 (B) in FIG. Sectional view along line 13-13 in FIG. 14-14 sectional view of FIG. Partially broken side view showing a conventional Bowden cable and cross-sectional view of the middle part thereof

  1 and 4, a Bowden cable B includes a flexible inner wire 1, a flexible outer cable 2 inserted through the inner wire 1 to guide its sliding, and both ends of the outer cable 2. The outer cable 2 includes a synthetic resin liner 3 that directly guides the sliding of the inner wire 1 and a hollow shield 4 that accommodates and holds the liner 3. And a synthetic resin outer skin 5 covering the outer periphery of the shield 4. And the connection terminals 1a and 1b formed in the column shape orthogonal to the inner wire 1 are respectively fixed by retrofitting to both ends of the inner wire 1 protruding outside the outer cable 2.

Referring also to FIGS. 2 and 3, Bowden cable B is applied to, for example, a lock releasing device for a seat lock mechanism of a motorcycle. The operation-side end piece E has a bracket T as a mounting portion for fixing and supporting the end piece E on a motorcycle body frame F at a proper position on the motorcycle body F , and an outer periphery of one end portion 2a of the outer cable 2. And a curved cylindrical bent tube portion M covering and enclosing in a state. The bracket T and the bent tube portion M are integrated with each other at the same time as the end piece E is injection-molded with a synthetic resin as will be described later. Formed. In addition, the bending pipe part M may have a straight pipe part in the part, or the whole may be curving.

  Further, in the illustrated example, the bent pipe portion M of the end piece E on the operation side has a connection end with the bracket T, that is, a portion where stress concentration is most likely to occur is formed with the largest diameter and thick wall, and gradually decreases in diameter and thickness as the distance from the portion increases. Formed. In addition, a pair of left and right reinforcing ribs Mr are integrally projected on the outer periphery of the bent pipe portion M from the middle in the longitudinal direction to the small diameter end. The bent pipe M is formed with a plurality of centering positioning projections p1, p1 ′; p2, p2 ′ of the outer cable 2 that are generated in an injection molding process described later. The

  In the present embodiment, the bracket T as the mounting portion is mainly composed of an L-shaped bracket body Tm formed integrally with first and second mounting walls 7 and 7 'orthogonal to each other. The second mounting walls 7, 7 'are brought into contact with the first and second support walls 8, 8' perpendicular to each other of the support member Fa and fastened by bolts b and nuts n penetrating the first mounting wall 7. Is done. The first mounting wall 7 is formed with a cylindrical protrusion 7a that fits into and engages with the engagement hole of the first support wall 8, and a bolt insertion hole 7b through which the bolt b is inserted.

  A lock operation mechanism 9 including a cylinder lock that can pull the Bowden cable B by inserting and rotating the key K is attached to the support member Fa, and an output member 10 of the operation mechanism 9 includes One connecting end 1a of the inner wire 1 of the Bowden cable B is coupled, and the output member 10 is moved upward in accordance with the rotation operation of the key K so that the inner wire 1 can be pulled. In FIG. 2, reference numeral 11 denotes a cowl for covering the vehicle body frame F, the lock operation mechanism 9, and the like with good appearance.

  Further, an annular locking groove 14 is provided on the outer periphery of the operated end piece E ′, and the locking groove 14 is formed on the bracket 13 of the seat lock mechanism 12 disposed immediately below the seat of the motorcycle. Locked. The other connection terminal 1 b of the inner wire 1 is connected to an unlock lever 15 of the seat lock mechanism 12, and this unlock lever 15 is urged and held in the retracted position, that is, the locked position by the urging force of the return spring 16.

  Thus, if the key K is inserted into the key hole of the lock operating mechanism 9 and rotated in the unlocking direction and the inner wire 1 is pulled by the output member 10, the lock releasing lever 15 is applied to the urging force of the return spring 16. Accordingly, the locked state of the seat lock mechanism 12 can be released, whereby the seat (not shown) can be opened. Further, if the key K is turned back and forth in the locking direction, the lock release lever 15 can be turned by the urging force of the return spring 16 to return the seat lock mechanism 12 to the locked state.

  By the way, the shield 4 is constituted by a hollow strand 22 formed by twisting together a plurality of metal strands 21, 21... Arranged so as to be in close contact with each other around the liner 3.

  FIG. 4 shows a design example of the Bowden cable B when the inner wire 1 having a diameter of 1.0 mm is used. Here, the diameter of the metal strands 21, 21... Is 0.4 mm, the number of the metal strands 21, 21... Is 18, the winding pitch of the metal strands 21, 21. , 21... Is an S type, the outer diameter of the shield is 2.6 mm, and the weight is 21 g / m.

  For comparison with this, FIG. 15 shows a design example of a conventional Bowden cable B ′ in the case where the inner wire 1 having a diameter of 1.0 mm is used as described above. In this case, the thickness of the metal strip m that is tightly wound in a coil to form the shield 04 is 0.5 mm, the outer diameter of the shield 04 is 4.0 mm, and the weight is 62 g / m.

  In the above, it should be noted that the shield 4 of the present invention has a thickness of 0.4 mm (= diameter of the metal strand), the outer diameter of 2.6 mm, and the thickness of the conventional shield 04 of 0.5 mm (= The thickness of the metal strip m) and the outer diameter of 4.0 mm.

  Here, the outer diameter of the conventional shield 04 (see FIG. 15) is 4.0 mm, which is a limit in forming the metal strip m having a thickness of 0.5 mm tightly wound in a coil shape. In order to make it less than 4.0 mm, it is necessary to make the plate | board thickness of the metal strip m less than 0.5 mm, but if it does so, it will become difficult to satisfy the intensity | strength of the shield 04.

  On the other hand, the fact that the outer diameter of the shield 4 of the present invention can be made significantly smaller than the outer diameter of the conventional shield 04 is that a plurality of metal strands 21, 21. This is because the hollow strands 22 are formed by being arranged so as to be in close contact with each other and forming the hollow strands 22, thereby forming the shield 4.

  As described above, the diameter of the shield 4 of the present invention is reduced (about 1 / 1.5 of the conventional product), so that the diameter of the Bowden cable B is reduced, and the weight is reduced (the weight is about 1/3 that of the conventional product). Can be planned. Moreover, the shield 4 made of the hollow strand 22 has higher tensile and compressive strength and rigidity than the conventional shield 04 in which the metal strip m is tightly wound in a coil shape. Of course, it can withstand push operation force sufficiently, can improve the transmission efficiency of any operation force, and also has excellent flexibility. Its application is very wide.

  Next, with reference to FIGS. 5 to 9 as well, the end piece E, E ′ made of synthetic resin and the coupling structure between the end piece E and the outer cable 2 will be described.

  First, as shown in FIG. 9, by removing the outer skin 5 at both ends of the outer cable 2 to expose the end of the hollow strand 22 from the outer skin 5 and expanding the diameter of the end of the hollow strand 22, The 1st flare part 23 in which each metal strand was discrete is formed. Further, the end portion of the liner 3 is also enlarged in diameter to form a second flare portion 24 adjacent to the first flare portion 23. The second flare portion 24 is formed to have a smaller diameter than the first flare portion 23, and a gap is provided between the second flare portion 23 and the first flare portion 23.

  As shown in FIGS. 6 and 8, the end pieces E and E ′ are injection-molded using a synthetic resin as a material so as to wrap the first and second flare portions 23 and 24 and the end portions of the outer skin 5. At that time, the synthetic resin enters the gaps between the metal strands 21 constituting the first flare portion 23 and between the first and second flare portions 23 and 24.

  Thus, the end pieces E and E ′ can be easily obtained by injection molding. In addition, a large number of discrete metal strands 21 of the first flare portion 23 and the first flare portion 23 formed by the end portions of the liner 3 deeply bite into the end pieces E and E ′ to exert a strong anchor effect. Thus, the coupling strength between the end pieces E, E ′ and the outer cable 2 can be increased. Further, in particular, by providing a gap for the synthetic resin to enter between the first and second flare portions 23, 24, the first and second flare portions 23, 24 are independently deep in the end pieces E, E ′. The strong anchor effect is exerted by biting in, and the coupling strength between the end pieces E, E ′ and the outer cable 2 can be further increased. In addition, since the second flare portion 24 is formed to have a smaller diameter than the first flare portion 23, when the end pieces E and E ′ are formed, the metal flakes 21 between the first flare portion 23 and the first and second flare are formed. The penetration of the synthetic resin between the portions 23 and 24 becomes good, and the anchor effect on the end pieces E and E ′ of the first and second flare portions 23 and 24 is further enhanced.

  As in this embodiment, the thickness of the shield 4 can be made equal to the diameter of the metal strands 21, 21,... In addition, the coupling strength between the end pieces E, E ′ and the outer cable 2 can be increased without changing the shape and dimensions of the conventional end pieces E, E ′. Therefore, it is promising for use in various operating force transmission systems in motorcycles that require low fuel consumption.

  By the way, the end piece E on the operation side in particular is bent so as to cover and surround the bracket T as a mounting portion for fixing and supporting the support member Fa and the outer periphery of the end portion 2a of the outer cable 2 as described above. Since it has a tube portion M and has a complicated three-dimensional solid shape as a whole and is insert-molded so as to embed the one end portion 2a of the outer cable 2, it is special in its molding. It needs some ingenuity. Then, next, an example of the injection molding method of the operation-side end piece E will be described with reference to FIGS.

  A mold apparatus D used for this injection molding includes a plurality of mold elements, for example, a lower mold D1, an upper mold D2 that can be driven up and down by a driving means (not shown) with respect to the lower mold D1, and upper and lower It is divided into a middle mold D3 that can be interposed between the molds D1 and D2. A cavity C corresponding to the overall shape of the end piece E is formed between the lower mold D1, the upper mold D2, and the middle mold D3. The cavity C includes at least a bracket forming cavity portion Ct and a bent tube portion forming cavity portion Cm for forming the bracket T and the bent tube portion M, respectively.

  On the upper surface of the lower mold D1 (that is, the mating surface with the upper mold D2), the engagement concave portion 30 into which the lower end portion of the middle die D3 is fitted, and the first bent concave portion for forming the lower half portion of the bent pipe portion M 31 is formed. The engaging recess 30 is formed with a molding recess 30a for molding the bracket T in cooperation with the middle mold D3 and the upper mold D2.

  Further, on the lower surface of the upper mold D2, there are formed a recess 33 for receiving the upper part of the middle mold D3 set on the lower mold D1, and a second curved recess 34 for molding the upper half of the bent tube part M. The A bracket molding cavity Ct for molding the bracket T is defined by the lower mold D1, the middle mold D3 set on the lower mold D1, and the upper mold D2 covering the middle mold D3. . Further, the first and second bent concave portions 31 and 34 define a bent tube portion forming cavity Cm for forming the bent tube portion M, and the end portion 2a of the outer cable 2 is inserted in the end portion 2a. Piece E is injection molded.

  In the upper die D2 and the lower die D1, the one end 2a of the outer cable 2 is inserted into the bent tube portion forming cavity Cm, and the one end 2a of the outer cable 2 is connected to the bent tube portion forming cavity Cm. A plurality of positioning protrusions p1, p1 ′; p2, p2 ′ are provided for centering in cooperation with each other. That is, a plurality of pairs of upper and lower first positioning protrusions p1 and p1 ′ extending in a direction approaching each other are provided on the opposing surfaces of the upper mold D2 and the lower mold D1, and both the first positioning protrusions p1 and p1. By positioning the one end portion 2a of the outer cable 2 from above and below, the positioning in the vertical direction is performed. In addition, at least one of the opposing surfaces of the upper mold D2 and the lower mold D1 (lower mold D1 in the illustrated example) includes a plurality of left and right pair of second positioning pins p2 and p2 'that sandwich the one end portion 2a of the outer cable 2 from the left and right. A pair is projected. The one end 2a of the outer cable 2 is sandwiched between the second positioning protrusions p2 and p2 'from the left and right, thereby positioning in the left-right direction (the direction crossing the outer cable 2 horizontally).

  Thus, by these first and second positioning projections p1, p1 ′; p2, p2 ′, the one end portion 2a of the outer cable 2 is correctly positioned at a predetermined set position of the bent tube portion forming cavity portion Cm, that is, a normal centering position. Therefore, the bent pipe portion M of the end piece E can be arranged and fixed in an appropriate concentric posture around the centered outer cable 2, and the formability of the bent pipe portion is improved.

  By the way, in the injection molding of the end piece E, the molten synthetic resin is injected into the cavity C of the mold apparatus D in a state where the flexible shape-retaining core R is inserted into the liner 3 of the outer cable 2. To be executed. In the illustrated example, a rope made of a material (for example, nylon or the like) that is not deformed even by injection molding pressure is used as the shape retaining core R. The outer diameter of the shape retaining core R is slightly smaller than the inner diameter of the liner 3 of the outer cable 2. Therefore, the shape-retaining core material R can be smoothly slid and inserted / removed in the liner 3. Further, in the present embodiment, the base end portion of the shape-retaining core material R is coupled to the middle mold D3 (in the illustrated example, embedded integrally in the middle mold D3).

  The shape-retaining core material R is inserted into the liner 3 of the outer cable 2 from the front end side thereof, and the insertion work is performed before the end piece E is injection molded, in particular, the outer cable 2 is placed on the lower mold D1. This is done before setting.

  Further, a slightly tapered cylindrical projecting portion 38 surrounding the base end portion of the shape-retaining core material R is integrally projected on the molding surface of the middle mold D3 facing the bracket molding cavity Ct. The tip of the cylindrical protrusion 38 is the inner peripheral surface of the end of the liner 3 of the cable 2, particularly the diameter-expanded first, with the one end 2 a of the outer cable 2 inserted into the bent tube portion forming cavity Cm. The two flare portions 24 are in contact with the inner peripheral surface over the entire circumference. A hole 40 that concentrically surrounds the cylindrical protrusion 38 with the annular gap 39 interposed therebetween is formed in the middle mold D3 so as to open directly to the bracket molding cavity Ct. The annular gap 39 serves as a cavity for molding the cylindrical protrusion 7a formed on the first mounting wall 7 of the bracket T.

  In addition, a molding pin 41 for molding the bolt insertion hole 7b formed in the first mounting wall 7 so as to protrude from the bracket molding cavity Ct is fixed to the middle mold D3.

  Incidentally, a pouring gate (not shown) for introducing a molten resin into the cavity C, for example, the bracket molding cavity Ct, is formed at an appropriate position of the mold apparatus D, and a molten resin injection means (not shown) is formed at the pouring gate. From there, the pressurized molten resin can be supplied to the cavity C at any time.

  Next, a specific example of the process of injection molding the operation-side end piece E will be described.

  First, as shown in FIG. 9, the outer sheath 5 is removed at one end 2a of the outer cable 2 of the Bowden cable B so that the end of the hollow strand 22 is exposed from the outer sheath 5, and the end of the hollow strand 22 is expanded. By forming the diameter, the first flare portion 23 in which each metal wire is discrete is formed, and the end portion of the liner 3 is also enlarged to form the second flare portion 24 adjacent to the first flare portion 23. .

  Next, the outer cable 2 is inserted into the shape-retaining core material R coupled to the middle die D3 from the tip end side with the first and second flare portions 23 and 24 first. The insertion is performed until the first and second flare portions 23 and 24 face the bracket forming cavity Ct of the middle mold D3. Next, the middle die D3 is set on the lower die D1 together with the shape-retaining core material R and the outer cable 2, that is, the lower end portion of the middle die D3 is fitted into the recess 33 on the upper surface of the lower die D1, and one end of the outer cable 2 is fitted. The part 2a is inserted into the first bent recess 31 on the upper surface of the lower mold D1 while bending the part 2a. In this case, the one end portion 2a of the outer cable 2 is positioned and held at the centering position of the first bent concave portion 31 by the plurality of pairs of second positioning protrusions p2 and p2 ′ on the left and right sides.

  Further, the upper mold D2 is put on the lower mold D1 so as to sandwich the middle mold D3 therebetween, and a cavity C is defined between the molds D1 to D3. In this case, the one end portion 2a of the outer cable 2 is sandwiched from above and below by a plurality of pairs of first positioning projections p1 and p1 'so as to be between the first and second curved concave portions 31 and 34 (that is, the bent tube portion forming cavity portion Cm). ) At a predetermined set position, that is, a normal centering position.

  In this state, a molten synthetic resin is pressurized and injected into the cavity C from a gate (not shown), whereby an end piece E corresponding to the cavity C is injection molded. After the injection molding is completed, first, the upper mold D2 is raised and separated from the lower mold D1 and the middle mold D3, and then the middle mold D3 is lifted together with the molded product with respect to the lower mold D1, and the molded product is moved to the middle mold D3. Remove from the lower mold D1 together. Thereafter, the molded product is pulled out from the middle mold D3 in the direction along the axis of the molding pin 41, and at the same time, the outer cable 2 of the Bowden cable B is pulled out from the shape-retaining core R.

  The end piece E on the operation side is insert-molded on the one end 2a of the outer cable 2 through the above steps. The method of insert-molding the operated end piece E ′ at the other end of the outer cable 2 is basically the same as the above process. However, the end piece E ′ on the operated side has a simple mounting portion (locking groove 14) and has no bent portion in the tube portion that covers and surrounds the other end portion of the outer cable 2. The structure of the mold apparatus is simpler than that of the mold apparatus D.

  According to the embodiment, the end piece E on the operation side is covered with the bracket T as a mounting portion for fixing and supporting the end piece E on the support member Fa and the outer periphery of the end portion 1a of the outer cable 2 in a bent state. Since the bent tube portion M is enclosed and these T and M are integrally formed by injection molding, the end piece E including the mounting portion T and the bent tube portion M is formed into a complicated three-dimensional shape as a whole. It becomes possible to mold easily and accurately by injection molding of synthetic resin. Even if the pulling operation direction at one end of the Bowden cable B and the cable extending direction from the end piece E are different directions, the curved form of the outer cable one end 2a that curves in accordance with the direction is the bent pipe portion M of the end piece E. The shape can be reliably preserved.

  By the way, in the case where the mounting portion T and the bent pipe portion M are manufactured separately from metal, it is necessary to attach both of them by retrofitting, and the resin property for inner wire protection is provided on the inner periphery of the metal bent pipe portion M. It is necessary to insert the pipe inner by retrofitting, and further, the metal bent pipe part M and the end part of the outer cable 2 need to be caulked and joined. As a result, the number of parts and processing steps increase as a whole, and the cost increases. This may cause an increase in weight, and may cause problems such as a decrease in the slidability of the inner wire 1 due to a step formed at the connecting portion between the resin pipe inner in the bent tube portion M and the end of the outer cable 2. . On the other hand, in the present embodiment, since the bent pipe part M and the bracket T (attachment part) formed by insert molding the one end part 2a of the outer cable 2 are integrally formed with a synthetic resin, they are integrally coupled to each other. The above problem is eliminated. That is, the number of parts and the number of processing steps can be greatly reduced to reduce cost and weight, and one end 2a of the outer cable 2 can be extended through the bent pipe M to the vicinity of the outer end of the end piece E. Since it can be extended and there is no need to separately connect a plastic pipe inner to the end of the outer cable, it avoids a decrease in slidability of the inner wire 1 due to a step in the connecting portion, and a decrease in operation feeling. can do.

  In the present embodiment, the one end 2a of the outer cable 2 is inserted into at least the bent tube portion forming cavity Cm of the cavity C of the mold apparatus D, and flexibility is provided in the liner 3 of the outer cable 2. Since the molten synthetic resin is injected into the cavity C with the shape-retaining core R inserted therein, the shape-retaining core R can sufficiently counter the injection molding pressure. Thereby, for example, even when the outer cable 2 has a relatively small diameter and low rigidity, or when the outer cable 2 is bent and a flat thin portion is generated in the outer skin 5, the outer cable 2 is crushed due to high molding pressure. Since the shape-retaining core material R can be effectively prevented from being deformed, the slidability of the inner wire 1 in the state where the inner wire 1 is inserted into the outer cable 2 after molding, and the operation feeling is effectively enhanced. It is done.

  Further, in the present embodiment, the base end of the shape retaining core R is coupled to some mold elements, for example, the middle mold D3, and the shape retaining core R is placed in the liner 3 of the outer cable 2 before injection molding. It is inserted from the tip side. Thereby, since the base end of the shape-retaining core R can be placed in the middle mold D3 in advance, positioning and setting work of the shape-retaining core R to the mold apparatus D can be performed efficiently.

  The present invention is not limited to the above-described embodiment, and various design changes can be made without departing from the scope of the invention.

  For example, the shield 4 can be formed by forming the hollow strands 22 in a plurality of layers, and the strength and rigidity of the shield 4 can be further increased. In this case, the anchor effect on the end piece E of the first flare part 23 is enhanced by increasing the number of the metal strands 21 of the first flare part 23, and the coupling strength between the end piece E and the outer cable 2 is further increased. Can be increased.

  Moreover, in the said embodiment, although the L-shaped bracket T was illustrated as an attaching part of the end piece E by the side of operation, the form of an attaching part is not limited to the said embodiment, If it can attach to a support member, Various forms can be adopted.

  In the above embodiment, the operation-side end piece E is shown in which the mounting portion T and the bent tube portion M are integrally formed. However, the same structure can be implemented on the operated-side end piece. is there.

  In the above-described embodiment, the Bowden cable B is applied to the throttle valve operating system of the motorcycle engine. However, the Bowden cable of the present invention is an operating system other than the throttle valve operating system of the vehicle, such as a clutch and a brake. The present invention can be applied to an operation system such as the above, and may be applied to various operation systems other than a vehicle.

B ... Bowden cable C ... Cavity Ct ... Mounting section molding cavity Cm ... Bending pipe molding cavity D ... Mold device D1 ... Lower mold D2 as mold element ... Upper mold D3 as mold element ... Middle mold E as mold element ... End piece Fa ... Support members p1, p1 ' First positioning pins p2 and p2 'as a plurality of positioning projections Second positioning pin M as a plurality of positioning projections B bent tube portion T Bracket R as an attachment portion ... Shaping core 1 ... Inner wire 2 ... Outer cable 2a ... One end 3 of outer cable ... Liner 4 ... Shield 5 ... .... Outer skin 21 ... Metal wire 22 ... Hollow strand 23 ... · The first flare section 24 ... the second flare section

Claims (6)

A flexible inner wire (1), a flexible outer cable (2) inserted through the inner wire (1) to guide its sliding, and one end (2a) of the outer cable (2) And an end piece (E) inserted through the inner wire (1), and the outer cable (2) is made of a synthetic resin liner (3) that directly guides the sliding of the inner wire (1). End piece and outer cable coupling structure in a Bowden cable composed of a hollow shield (4) for accommodating and holding the liner (3) and a synthetic resin sheath (5) covering the outer periphery of the shield (4) In
The shield (4) is constituted by a hollow strand (22) formed by twisting together a plurality of metal wires (21) arranged so as to be in close contact with each other around the liner (3), and this hollow strand (22) And the end of the hollow strand (22) is expanded to form a first flare portion (23) in which the metal strands (21) are discrete. The diameter of the end portion of the liner (3) is also expanded to form a second flare portion (24) adjacent to the first flare portion (23), and the first and second flare portions (23, 24) are formed. The end piece (E) is injection-molded so as to wrap, and the synthetic resin of the material of the end piece (E) enters between the metal strands (21), and the end piece (E) A mounting portion (T) for fixedly supporting (Fa); A bent tube portion (M) that covers and surrounds the one end portion (2a) of the outer cable (2) in a bent state, and the attachment portion (T) and the bent tube portion (M) A joint structure of an end piece and an outer cable in a Bowden cable, which is integrally formed by injection molding.   The coupling structure for an end piece and an outer cable in a Bowden cable according to claim 1, wherein a gap into which the synthetic resin enters is provided between the first and second flare portions (23, 24).   The connection structure of an end piece and an outer cable in a Bowden cable according to claim 2, wherein the second flare portion (24) is formed to have a smaller diameter than the first flare portion (23). A method for connecting an end piece and an outer cable to obtain a connection structure between an end piece and an outer cable in the Bowden cable according to any one of claims 1 to 3,
For forming the mounting part (T) and the bent pipe part (M) between a plurality of mold elements (D1 to D3) constituting the mold apparatus (D) used for the injection molding, respectively. Forming a cavity (C) having at least a mounting part molding cavity part (Ct) and a bent pipe part molding cavity part (Cm);
The one end portion (2a) of the outer cable (2) is inserted into at least the bent pipe portion forming cavity portion (Cm) of the cavity (C), and the outer cable (2) is inserted into the liner (3). The injection molding is performed by injecting molten synthetic resin into the cavity (C) with the flexible shape-retaining core (R) inserted. How to connect the end piece and outer cable in the cable.   At least a part of the mold element (D3) is coupled to a proximal end of the shape-retaining core (R), and the shape-retaining shape is inserted into the liner (3) of the outer cable (2) before the injection molding. 5. The method for connecting an end piece and an outer cable in a Bowden cable according to claim 4, wherein the precautionary material (R) is inserted from the distal end side thereof.   At least a part of the mold elements (D1, D2) in a state in which the one end portion (2a) of the outer cable (2) is inserted into the bending tube portion forming cavity portion (Cm) of the cavity (C). A plurality of positioning protrusions (p1, p1 ′; p2, p2 ′) for cooperating and centering the one end portion (2a) of the outer cable (2) with respect to the bent tube portion forming cavity portion (Cm) With the positioning protrusions (p1, p1 ′; p2, p2 ′), the one end portion (2a) of the outer cable (2) is predetermined in the bent tube portion forming cavity portion (Cm) during the injection molding. 6. The method for connecting an end piece and an outer cable in a Bowden cable according to claim 4 or 5, wherein the positioning is correctly held at the set position.

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