JP2018101627A - Method for manufacturing wiring material, wiring material, and wiring structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a wiring material capable of easily producing a wiring material capable of being routed to various wiring routes while suppressing occupation of a wiring space; a wiring material; and a wiring structure.SOLUTION: A method for manufacturing a wiring material 10 in which a round portion 21 that is covered with an insulator 12 where an outer periphery of a conductor 11 formed of a braided wire knitted with an elemental wire formed of a conductive metal material is formed of a resin and has a round shape in cross-sectional view and a flat portion 22 having a rectangular shape in cross-sectional view are provided at least a part in the longitudinal direction includes: a conductor formation step of knitting a plurality of elemental wires to be a conductor 11R having a circle shape in cross-sectional view; an insulator covering step of covering the outer periphery of a conductor 11R with the insulator 12 to the wiring material 10 formed of the round portion 21; and a flat portion formation step of pressing a predetermined portion of the wiring material 10 to form a flat portion 22.SELECTED DRAWING: Figure 7

Description

  The present invention relates to a method for manufacturing a routing material, a routing material, and a routing structure.

  For example, in an automobile driven by an engine, a hybrid automobile, or the like, in which a battery is mounted on the rear part of the vehicle, a routing material that is a battery cable for feeding power from an alternator that is a power generation device or a motor generator is routed. (For example, refer to Patent Document 1).

Japanese Unexamined Patent Publication No. 2016-32387

  For example, when power is supplied from an alternator to a battery mounted at the rear of the vehicle, a routing material is routed from the alternator to the battery at the rear of the vehicle along the vehicle body panel.

  By the way, with the need for expansion of the living space in the passenger compartment, the wiring space for the wiring material has become narrow, and it is required to route the wiring material in this narrow wiring space. On the other hand, a large-diameter round electric wire is generally used as a wiring material for power transmission. However, in this large-diameter round electric wire, the height of the arrangement space is bulky, and the arrangement is made in a narrow space. May be difficult.

  In this case, if a thin wiring material made of flat electric wires is used, the height of the wiring space can be suppressed as much as possible while securing the cross-sectional area of the electric wire. The type wire is difficult to bend in the width direction, and the routing route is limited.

  For this reason, a routing material that can be routed to various routing routes while suppressing the occupation of the routing space is required.

  This invention is made | formed in view of the situation mentioned above, The objective is to manufacture easily the routing material which can be routed to various routing paths, suppressing the occupation of routing space. It is providing the wiring material manufacturing method, wiring material, and wiring structure which can be performed.

In order to achieve the above-described object, the wiring material manufacturing method according to the present invention is characterized by the following (1) to (3).
(1) The outer periphery of a conductor made of a braided wire made of a conductive metal material is covered with an insulator made of resin, and has a round shape with a circular shape in cross section and a flat shape with a rectangular shape or an elliptical shape in cross section. Each is a method for producing a wiring material provided in at least a part in the longitudinal direction,
A conductor forming step of weaving a plurality of strands into the conductor in a circular shape in cross section,
An insulator covering step of covering the outer periphery of the conductor with the insulator and making the wiring member made of the round portion;
A flat part forming step of forming the flat part by pressing a predetermined portion of the routing material;
A method for manufacturing a wiring material, comprising:
(2) The routing material is a conductive path for transmitting vehicle power,
The routing material according to (1), wherein, in the flat portion forming step, a predetermined portion that is routed along a floor portion that constitutes the vehicle body of the vehicle is pressed into a flat shape. Manufacturing method.
(3) The wiring material manufacturing method according to (1) or (2), wherein the wiring material is divided and the divided portions are connected by an extended wiring material.

According to the manufacturing method of the routing material having the configuration of (1) above, it is possible to route in a circular portion having a circular shape in cross-sectional view that is relatively easy to bend in various directions and a space with a narrow height dimension. It is possible to easily manufacture a wiring member having a flat portion having a thin rectangular shape or an elliptical shape in cross section. Moreover, since the strands are knitted into a conductor made of a braided wire, for example, a wiring material that can be bent more easily than a wiring material made of a simple stranded wire or a single wire can be obtained.
According to the method for manufacturing the routing material having the configuration of (2) above, in order to secure a large living space in the passenger compartment, the flat portion is located along the floor where it is difficult to secure the height dimension as the routing space. It can be. Thereby, the routing material used suitably as a conductive path for electric power transmission routed to the vehicle body can be obtained.
According to the method of manufacturing the routing material having the configuration of (3) above, the routing material is divided, and the divided portions are connected with the extended routing material according to the vehicle body, for example, and the length is adjusted. A common routing material can be used for the body of each vehicle type. In addition, for example, a power distribution box that distributes power to an auxiliary machine such as an electrical equipment device can be connected to the extended wiring material connected to the middle of the wiring material. As a result, the wiring material number can be reduced and the cost can be reduced due to the common wiring material in each vehicle type.

In order to achieve the above-described object, the routing material according to the present invention is characterized by the following (4).
(4) a conductor made of a braided wire woven with a wire made of a conductive metal material;
An insulator made of resin covering the outer periphery of the conductor;
With
A routing material characterized in that a round portion having a circular shape in cross section and a flat portion having a rectangular shape or an elliptical shape in cross section are provided in at least a part in the longitudinal direction.

  According to the routing material configured as described in (4) above, the flat portion is rectangular or elliptical in cross-sectional view and has a small thickness, so that it can be easily routed in a narrow space, Further, since the round portion is circular in cross section, it can be bent in various directions. That is, it is possible to route to various routing routes while suppressing the occupation of the routing space. Moreover, since it has the conductor which consists of a braided wire which braided the strand, it can be easily bent compared with the wiring material which consists of a simple twisted wire or a single wire, for example, and can be along a predetermined wiring path | route.

In order to achieve the above-described object, the routing structure according to the present invention is characterized by the following (5).
(5) In the routing material according to (4), a part of the conductor in the longitudinal direction is replaced with a hard material having higher rigidity than the braided wire.
A routing structure characterized by that.

  According to the routing structure having the configuration of (5) above, the rigidity of a part of the routing material is maintained while maintaining the characteristic that the routing material can be bent easily and along the predetermined routing route. It can be further increased.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of a routing material and routing material which can manufacture easily the routing material which can be routed to various routing paths, suppressing the occupation of a routing space And can provide a routing structure.

  The present invention has been briefly described above. Further, the details of the present invention will be further clarified by reading through a mode for carrying out the invention described below (hereinafter referred to as “embodiment”) with reference to the accompanying drawings. .

FIG. 1 is a schematic perspective view of a vehicle panel on which a routing material manufactured by the routing material manufacturing method according to the first embodiment is routed. FIG. 2 is a perspective view of the routing material manufactured by the routing material manufacturing method according to the first embodiment. FIG. 3 is a view showing the structure of the routing material manufactured by the routing material manufacturing method according to the first embodiment, and FIG. 3A is a cross-sectional view along the horizontal direction, and FIG. Is a cross-sectional view along the vertical direction. FIG. 4 is a diagram illustrating the structure of the routing material manufactured by the routing material manufacturing method according to the first embodiment, and FIG. 4A is a cross-sectional view orthogonal to the axial direction of the round portion. FIG. 4B is a cross-sectional view orthogonal to the axial direction of the flat mold portion. FIG. 5 is a diagram showing the structure of the routing material manufactured by the routing material manufacturing method according to the first embodiment, and FIG. 5A shows the conductor exposed from the insulator in the round portion. FIG. 5B is a perspective view in which the conductor is exposed from the insulator in the flat portion. FIG. 6 is a side view of the conductor for explaining the method of manufacturing the routing material according to the first embodiment. FIG. 7 is a diagram for explaining a method for manufacturing a routing material according to the first embodiment, in which FIG. 7A is a cross-sectional view along the vertical direction of the routing material before pressing, and FIG. It is sectional drawing which follows the perpendicular direction of the wiring material after a press. FIG. 8 is a schematic perspective view of the vehicle panel in which the routing structure according to the second embodiment is routed. FIG. 9 is a schematic perspective view of a vehicle panel in which a routing material according to a modified example is routed. FIG. 10 is a perspective view of the extended routing material connected to the routing material.

  Specific embodiments relating to the present invention will be described below with reference to the drawings.

(First embodiment)
FIG. 1 is a schematic perspective view of a vehicle panel on which a routing material manufactured by the routing material manufacturing method according to the first embodiment is routed. FIG. 2 is a perspective view of the routing material manufactured by the routing material manufacturing method according to the first embodiment. FIG. 3 is a view showing the structure of the routing material manufactured by the routing material manufacturing method according to the first embodiment, and FIG. 3A is a cross-sectional view along the horizontal direction, and FIG. Is a cross-sectional view along the vertical direction.

First, the routing material will be described.
As shown in FIG. 1, the routing material 10 is routed along the surface of a vehicle body panel (vehicle body) 1 of the vehicle. The vehicle body panel 1 has a floor portion 1a and a partition wall portion 1b that partitions the vehicle into a room side and an engine room side.

  A battery 2 is mounted on the rear portion of the vehicle body panel 1. Further, an alternator 3 that generates electric power by the rotational force of the engine is provided on the front side of the partition wall portion 1b of the vehicle body panel 1. The routing material 10 is connected to the battery 2 and the alternator 3, and power is supplied from the alternator 3 to the battery 2. That is, the routing material 10 is routed to the vehicle body panel 1 of the vehicle as a conductive path for power transmission.

  In addition, the routing material 10 is supplied with electric power generated by the alternator 3 to the battery 2 and is supplied with electric power supplied from the battery 2 to various auxiliary devices mounted on the vehicle. The surface of the floor portion 1 a is formed in an uneven shape in the vehicle body panel 1, and the routing material 10 is routed along a predetermined routing route along the uneven surface of the vehicle body panel 1. . Further, the routing material 10 extends through the partition wall 1 b to the alternator 3 and is connected to the alternator 3.

  As shown in FIGS. 2 and 3A and 3B, the routing member 10 includes a conductor 11 and an insulator 12. The conductor 11 is a braided wire in which a strand made of a conductive metal material such as copper or a copper alloy is knitted. For example, the conductor 11 is configured by braiding about 1000 to 2000 strands having an outer diameter of about 0.1 mm. Has been. The insulator 12 is made of an insulating resin such as polyvinyl chloride. The periphery of the conductor 11 is covered with an insulator 12. The routing material 10 has a round part 21 and a flat part 22. The conductor 11 may be a braided wire in which a strand made of aluminum is knitted. In this case, the weight of the routing material 10 can be reduced.

  FIG. 4 is a diagram showing the structure of the routing material manufactured by the routing material manufacturing method according to the present embodiment, and FIG. 4A is a cross-sectional view orthogonal to the axial direction of the round portion. 4 (b) is a cross-sectional view orthogonal to the axial direction of the flat mold portion. FIG. 5 is a diagram showing the structure of the routing material manufactured by the routing material manufacturing method according to the present embodiment, and FIG. 5A is a perspective view in which the conductor is exposed from the insulator in the round portion. FIG. 5 and FIG. 5B are perspective views in which the conductor is exposed from the insulator in the flat mold portion.

  As shown in FIGS. 4A and 5A, the round portion 21 is configured such that the insulator 12 covers the periphery of a conductor 11R made of a braided wire formed in a circular shape in cross section. . As shown in FIGS. 4B and 5B, the flat portion 22 is configured such that the insulator 12 covers the periphery of the conductor 11F formed of a braided wire formed in a rectangular shape in cross section. . The conductor 11F of the flat portion 22 may be an elliptical shape with a small thickness.

Next, a manufacturing method according to the present embodiment for manufacturing the routing material 10 will be described.
FIG. 6 is a side view of a conductor for explaining a method for manufacturing a routing material according to the present embodiment. FIG. 7 is a diagram for explaining a method for manufacturing a routing material according to the present embodiment, in which FIG. 7A is a cross-sectional view along the vertical direction of the routing material before pressing, and FIG. It is sectional drawing which follows the vertical direction of the routing material after.

(Conductor formation process)
As shown in FIG. 6, a conductor 11R made of a braided wire having a circular cross-sectional view is manufactured. Specifically, strands are drawn from a plurality of bobbins and formed into a circular line in cross-sectional view while weaving these strands.

(Insulator coating process)
The outer periphery of the conductor 11R made of a braided wire having a circular cross-sectional view formed in the conductor forming step is covered with the insulator 12, and the routing member 10 having the round portion 21 is manufactured over the entire length. For example, the cylindrical insulator 12 is formed by extrusion molding, and the routing material 10 having the entire length of the round portion 21 is formed in the insulator 12 through the conductor 11R. Alternatively, the outer periphery of the conductor 11 </ b> R is extruded by an extruder to coat the outer periphery of the conductor 11 </ b> R with the insulator 12, thereby forming the routing material 10 having the entire length of the round portion 21.

(Flat part machining process)
The flat part 22 is processed and formed in a predetermined part of the routing material 10 whose overall length is the round part 21. Specifically, as shown in FIG. 7A, a predetermined portion of the routing material 10 is disposed between the lower mold 31 and the upper mold 32, and as shown in FIG. 10, the lower die 31 and the upper die 32 are brought close to each other and pressed. In this way, the routing material 10 is crushed in the portion pressed by the lower mold 31 and the upper mold 32, and the periphery of the conductor 11F made of a braided wire formed in a rectangular shape in cross section is covered with the insulator 12. A flat portion 22 is formed. In addition, it is preferable to heat-press using a thermoplastic resin as resin of the insulator 12 to make the flat part 22. In this way, since the insulator 12 made of a thermoplastic resin is molded into a processed shape, the shape after processing the flat portion 22 can be reliably maintained.

  The routing material 10 manufactured in this way is routed along a predetermined routing route with respect to the vehicle body panel 1 (see FIG. 1). For example, the routing material 10 has its flat portion 22 routed along the surface of the uneven floor portion 1a of the vehicle body panel 1, and the round portion 21 is raised from the floor portion 1a. It is routed along the partition wall portion 1b so as to penetrate the partition wall portion 1b and be drawn out to the engine room side.

  As described above, according to the routing material manufacturing method according to the present embodiment, a plurality of strands are knitted into a conductor 11R having a circular shape in cross section, and the outer periphery of the conductor 11R is covered with the insulator 12 and rounded. A flat mold portion 22 is formed by pressing the predetermined portion of the routing material 10 with the routing material 10 including the mold portion 21. As a result, a circular section 21 having a circular shape in cross section that is relatively easy to bend in various directions, and a flat section having a rectangular shape in cross section that is thin enough to be routed in a space having a narrow height dimension. 22 can be easily manufactured. Moreover, since it has the conductor 11 which consists of the braided wire which braided the strand, it can be set as the wiring material 10 which can be bent easily compared with the wiring material which consists of a simple twisted wire or a single wire, for example.

  In particular, if a predetermined portion that is routed along the floor portion 1a of the vehicle body panel 1 that constitutes the vehicle body of the vehicle is pressed, in order to secure a large living space in the vehicle interior, A location along the floor portion 1a that is difficult to secure can be the flat portion 22. Thereby, the routing material 10 used suitably as a conductive path for electric power transmission routed to the vehicle body can be obtained.

  And according to the routing material 10 manufactured with the manufacturing method of this embodiment, since the flat part 22 is made into the rectangular shape in cross section, and thickness is made thin, it is on the floor part 1a and the floor part 1a. It can be easily routed in a narrow space between the assembled sheet and the like, and the round portion 21 of the routing material 10 is bent in various directions since it is circular in cross section. Can do. That is, it is possible to route to various routing routes while suppressing the occupation of the routing space. Moreover, since it has the conductor 11 which consists of the braided wire which braided the strand, it can be easily bent compared with the wiring material which consists of a mere twisted wire or a single wire, for example, and can be along a predetermined wiring path | route.

(Second Embodiment)
In 1st Embodiment, although the conductor 11 whole of the wiring material 10 is comprised by the braided wire, depending on the object to be wired and the environment to be used, it may be further in the one part area | region of a wiring material. There may be a need to provide high rigidity. Therefore, as shown as the routing material 40 in the second embodiment, a part of the braided wire may be replaced with a hard material having higher rigidity than the braided wire.

  For example, in the routing material 40, a part of the flat portion 22 is replaced with a hard material 41 in the routing material 10 of the first embodiment. As the hard material 41, a material having conductivity and higher rigidity than the braided wire, such as an aluminum plate or a copper plate, is selected. The flat portion 22 and the hard material 41 are connected by ultrasonic bonding, adhesive bonding, laser welding, cold pressure welding, or connection between terminals attached to each end using a method such as caulking. This is realized by a known method.

Thus, according to the routing structure using the routing material 40 of the present embodiment, not only can the effect described in the first embodiment be obtained, but also by replacing a part of the braided wire with a hard material, It is possible to further increase the rigidity of the portion where high mechanical strength is required.
In the present embodiment, the wiring structure in which the hard material 41 is connected to the flat mold portion 22 is shown, but the hard material 41 may be connected to the round shape portion 21. Further, the routing material 40 may have a plurality of hard materials 41.

  In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably. In addition, the material, shape, dimensions, number, arrangement location, and the like of each component in the above-described embodiment are arbitrary and are not limited as long as the present invention can be achieved.

  For example, as shown in FIG. 9 and FIG. 10, the flat portion 22 of the wiring material 10 is divided in the middle, and the divided portions are connected by the extended wiring material 50 for adjusting the length composed of the conductors 51. Also good. In this way, the wiring material 10 is divided, and the divided portions are connected to the vehicle body panel 1 by the extended wiring material 50 and the length is adjusted, so that it is common to the vehicle body panel 1 of each vehicle type. The routing material 10 can be used. Further, for example, a power distribution box that distributes power to an auxiliary machine such as an electrical device can be connected to the extended wiring member 50 connected to the middle of the wiring member 10. Thereby, by sharing the wiring material 10 in each vehicle type, the wire product number can be reduced, and the cost can be suppressed.

  A braided wire is used for the conductor 51 of the extended wiring member 50. By connecting the extended wiring member 50 having the conductor 51 made of the braided wire, the extended wiring member 50 expands and contracts, so that the length of the wiring member 10 can be adjusted smoothly. Moreover, you may use the hard material whose rigidity is higher than a braided wire as the conductor 51 of the extended wiring material 50. FIG. In this case, the length of the routing material 10 can be adjusted smoothly by giving the extended routing material 50 an extra length. Moreover, weight reduction can be achieved by using aluminum or an aluminum alloy as the material of the conductor 51 of the extended wiring member 50.

  In order to connect the extended wiring material 50 to the divided ends of the wiring material 10, first, the covering of the insulator 12 is removed at the divided ends of the wiring material 10 to expose the conductor 11. Then, the conductor 51 of the extended wiring member 50 is joined to the exposed conductor 11. Thereafter, the entire connecting portion including the conductor 51 of the extended wiring member 50, the exposed conductor 11 and the joint portion 52 of the conductors 11, 51 is covered with a covering material such as a heat-shrinkable tube.

  In order to perform the waterproof treatment on the joint portion, an adhesive material such as hot melt is interposed between the joint portion and the covering material that covers the connecting portion by the extended wiring member 50. Also, in the case of joining the conductors 11 and 51, ultrasonic bonding, adhesive bonding, laser welding, cold welding, or connection between terminals attached to each end using a method such as caulking, etc. This is realized by a known method. In addition, when the conductor 51 of the extended wiring material 50 is a braided wire, the bonding of the wiring material 10 to the conductor 11 is preferably performed by ultrasonic bonding. The extended routing material 50 may be provided on the round portion 21 of the routing material 10.

Here, the features of the embodiment of the wiring material manufacturing method, the wiring material, and the wiring structure according to the present invention described above are briefly summarized and listed in the following [1] to [5], respectively.
[1] The outer periphery of a conductor (11, 11R, 11F) made of a braided wire woven with a wire made of a conductive metal material is covered with an insulator (12) made of resin, and has a circular shape (21 ) And a flat portion (22) having a rectangular shape or an elliptical shape in cross-section, each of which is a manufacturing method of a routing material (10) provided in at least a part in the longitudinal direction,
A conductor forming step of weaving a plurality of strands into the conductor (11R) having a circular shape in cross section,
An insulator covering step of covering the outer periphery of the conductor (11R) with the insulator (12) and forming a wiring member (10) comprising the round portion (21);
A flat part forming step of forming the flat part (22) by pressing a predetermined portion of the routing material (10);
A method for manufacturing a wiring material, comprising:
[2] The routing member (10) is a conductive path for transmitting electric power of the vehicle,
In the flat part forming step, a predetermined part arranged in a place along the floor part (1a) constituting the vehicle body (vehicle body panel 1) of the vehicle is pressed into a flat part. ] The manufacturing method of the routing material of description.
[3] The wiring material manufacturing method according to [1] or [2], wherein the wiring material (10) is divided and the divided portions are connected by an extended wiring material (50).
[4] Conductors (11, 11R, 11F) made of braided wires obtained by braiding strands made of a conductive metal material;
An insulator (12) made of a resin covering the outer periphery of the conductor (11, 11R, 11F);
With
A routing material characterized in that a round part (21) having a circular shape in cross section and a flat part (22) having a rectangular or elliptical shape in cross section are provided in at least a part in the longitudinal direction.
[5] In the routing material (40) according to the above [4], a part of the conductor in the longitudinal direction is replaced with a hard material (41) having higher rigidity than the braided wire.
A routing structure characterized by that.

1 Body panel (body)
DESCRIPTION OF SYMBOLS 1a Floor part 2 Battery 3 Alternator 10, 40 Routing material 11, 11R, 11F Conductor 12 Insulator 21 Round shape part 22 Flat shape part 41 Hard material 50 Extension wiring material

Claims (5)

The outer periphery of a conductor made of a braided wire made of a conductive metal material is covered with an insulator made of a resin, and a circular portion having a circular shape in cross section and a flat portion having a rectangular shape or an elliptical shape in cross section. , Each is a method of manufacturing a routing material provided in at least a part in the longitudinal direction,
A conductor forming step of weaving a plurality of strands into the conductor in a circular shape in cross section,
An insulator covering step of covering the outer periphery of the conductor with the insulator and making the wiring member made of the round portion;
A flat part forming step of forming the flat part by pressing a predetermined portion of the routing material;
A method for manufacturing a wiring material, comprising: The routing material is a conductive path for transmitting vehicle power,
2. The routing material according to claim 1, wherein, in the flat portion forming step, a predetermined portion that is routed along a floor portion that constitutes a vehicle body of the vehicle is pressed into a flat shape. Production method. The method of manufacturing a routing material according to claim 1 or 2, wherein the routing material is divided and the divided portions are connected by an extended routing material. A conductor made of a braided wire woven with a wire made of a conductive metal material;
An insulator made of resin covering the outer periphery of the conductor;
With
A routing material characterized in that a round portion having a circular shape in cross section and a flat portion having a rectangular shape or an elliptical shape in cross section are provided in at least a part in the longitudinal direction. In the routing material according to claim 4, a part in the longitudinal direction of the conductor is replaced with a hard material having higher rigidity than the braided wire,
A routing structure characterized by that.

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