JP2019102302A - Manufacturing method of wiring material - Google Patents

Abstract

To provide a manufacturing method of a wiring material thinner than conventional extruded molded cable that can form insulating layer for wiring material bent along a body panel.SOLUTION: A manufacturing method of a wiring material for vehicle 500 includes: an edge processing step processing an edge 12 extending to a longer direction of a flat package type conductor 11A (11B-11D) into round processing; a laminating step laminating the round processed multiple flat package type conductors 11A-11D in a board thickness direction; an insulation step insulating electrically by inter posing an insulating sheet material 13 between neighboring flat package type conductors; and an insulating layer forming step forming an insulating layer (15) around the laminated multiple flat package type conductors 11A-11D.SELECTED DRAWING: Figure 12

Description

  The present invention relates to a method of manufacturing a wiring material.

  For example, in a rear battery vehicle, a long battery cable for transmitting electricity from the rear to the front is required. As battery cables, round or flat heavy-duty electric wires for automobiles are generally used. In these electric wire manufacturing methods for heavy electric wires, there are many methods in which an insulation coating (polyvinyl chloride or the like) is extrusion-formed on a conductor (a material obtained by twisting copper wires) which is a wiring material. The extrusion of the insulation coating coats the insulating material on the outer periphery of the conductor by extruding the heat-melted insulating material together with the linear conductor from the die. Therefore, extrusion molding of the insulation coating requires that the conductors be twisted and soft.

  In addition, as a manufacturing method of an insulated conductor, the manufacturing method of the electric conductor which was made into a thin plate using the insulator ceramic insert of patent document 1, the manufacturing method of the oxide superconducting wire of patent document 2, etc. are known. .

JP-A-58-142708 Unexamined-Japanese-Patent No. 2000-268649

By the way, when wiring materials, such as a battery cable, are wired in a vehicle interior, according to the expansion needs of a vehicle interior living space, thickness reduction along wiring with a body panel and cable is calculated | required. In order to arrange the wiring material along the body panel, it is necessary to bend the wiring material according to the shape of the body panel.
However, it is difficult to bend a heavy-duty wire according to the shape of the body panel. In addition, for hard conductors such as bus bars that are bent along the body panel, extrusion molding of the insulation coating becomes difficult. Therefore, there is a demand for a wiring material in which an insulating coating is formed on a thin, bent conductor which can be routed along a body panel.

  The present invention has been made in view of the above situation, and its object is to make an insulating layer against a wiring material which is thin as compared with a conventional extruded coated electric wire and bent along a body panel or the like. An object of the present invention is to provide a method of manufacturing a wiring material that can be formed.

The above object of the present invention is achieved by the following constitution.
(1) A step of extruding a long flat conductor with a die having a hole type formed such that an edge portion extending in the longitudinal direction has a round shape, and laminating a plurality of the flat conductors in the thickness direction Forming an insulating layer for forming an insulating layer around the plurality of stacked flat conductors, and an insulating step of electrically insulating by interposing an insulating sheet material between adjacent flat conductors. A method of producing a wiring material comprising the steps of

According to the method of manufacturing the wiring material of the configuration of (1), the flat conductor is used as the wiring material, and the insulating sheet material is interposed between the plurality of flat conductors to form the flat conductor as a plate. By laminating in the thickness direction, it is possible to configure a plurality of circuit routing materials while suppressing the height compared to conventional thick wires. In this case, the plurality of flat conductors can suppress the expansion of the wiring space in the width direction of the wiring material, as compared with the conventional thick wire.
In addition, when laminating a plurality of flat conductors in the thickness direction, the insulating sheet material is interposed between the adjacent flat conductors to electrically insulate them, so that the flat conductors are easily and reliably insulated. Can.
Furthermore, the extruded flat conductor has a round shape at the edge, and the edge is exposed from the insulating layer formed around the flat conductor, or the insulating layer becomes thin at the edge. I have not. Therefore, the wiring material is prevented from lowering in withstand voltage and insulation resistance, and wear resistance and the like can be improved.

(2) an edge processing step of rounding at least a longitudinally extending edge of the flat conductor, a stacking step of stacking a plurality of the round shaped flat conductors in a thickness direction, and a distance between the adjacent flat conductors Wiring comprising: an insulation step of electrically insulating by interposing an insulation sheet material; and an insulation layer formation step of forming an insulation layer around the plurality of stacked flat conductors. Material manufacturing method.

According to the method of manufacturing the wiring material of the configuration of (2), the flat conductor is used as the wiring material, and the insulating sheet material is interposed between the plurality of flat conductors to form a flat conductor. By laminating in the thickness direction, it is possible to configure a plurality of circuit routing materials while suppressing the height compared to conventional thick wires. In this case, the plurality of flat conductors can suppress the expansion of the wiring space in the width direction of the wiring material, as compared with the conventional thick wire.
In addition, when laminating a plurality of flat conductors in the thickness direction, the insulating sheet material is interposed between the adjacent flat conductors to electrically insulate them, so that the flat conductors are easily and reliably insulated. Can.
Furthermore, for example, the edge extending in the longitudinal direction of the long flat conductor cut out from the plate material is subjected to round processing before forming the insulating layer. That is, the flat conductor has a round shape at the edge portion, and the edge is not exposed from the insulating layer formed around the flat conductor, and the insulating layer is not thinned at the edge portion. Therefore, the wiring material is prevented from lowering in withstand voltage and insulation resistance, and wear resistance and the like can be improved.

(3) The wiring material according to (1) or (2), including a bending step of bending the stacked flat conductors into a predetermined shape before forming the insulating layer. Production method.

  According to the method of manufacturing the wiring material of the configuration of (3), the plurality of stacked flat conductors are bent in advance into a shape or the like along the body panel. That is, the plurality of flat conductors stacked by interposing the flexible insulating sheet material can be collectively bent into a shape along the body panel or the like. Here, the flat conductor has a round shape at the edge portion, and bending workability is improved. The periphery of the plurality of bent flat conductors is further covered with an insulating layer. Generally, the surface of a body panel such as a floor panel along which a wiring material runs is a complex uneven surface due to cross members, reinforcing ribs and the like. When the heavy electric wire is wired along the body panel, the heavy electric wire is disposed on the convex portion. For this reason, the space | interval of a body panel and the interior material provided on it, for example, needs at least for the accommodation height of a thick article electric wire. Moreover, since it becomes difficult to bend a thick wire according to a convex part, it is restrict | limited to the position of a thick wire also in a recessed part, and the height of an interior material can not be made low. On the other hand, in the wiring material of this configuration, since the plurality of flat conductors stacked with the insulating sheet material interposed therebetween is bent, it can be easily processed into a shape along a complicated surface such as a body panel. It becomes possible. As a result, in the recess, there is no restriction as in a heavy electric wire that can not be bent, and the height of the interior material can be lowered. Further, an insulating layer is formed, for example, by powder coating on the surface of the wiring material obtained by laminating and bending the plurality of flat conductors with an insulating sheet material interposed therebetween. In powder coating, an insulating layer can be formed with a thickness of, for example, 0.1 to 0.2 mm while the insulating layer in the conventional extrusion molding has a thickness of 1 to 2 mm. Thereby, the wiring material of the said structure can reduce wiring space, for example, can reduce the space | interval of a body panel and an interior material.

(4) The method according to any one of the above (1) to (3), including a shield layer forming step of forming a shield layer around the plurality of flat conductors. .

  According to the manufacturing method of the wiring material of the configuration of the above (4), after forming the insulating layer around the plurality of flat conductors laminated with the insulating sheet material interposed therebetween, the conductive braid is wound around the insulating layer Cover with wire or foil material to form a shield layer. Therefore, the wiring material can suppress the emission of noise and prevent the influence of external noise. Furthermore, by providing an insulating layer on the outside if necessary, a wiring material having a shielding function can be easily manufactured using the same equipment.

  According to the method of manufacturing a wiring material according to the present invention, an insulating layer is formed on a wiring material which is thin and bent along a body panel or the like in comparison with a conventional extrusion-formed covered wire. Is possible.

  The present invention has been briefly described above. Furthermore, the details of the present invention will be further clarified by reading the modes for carrying out the invention described below (hereinafter referred to as "embodiments") with reference to the attached drawings. .

It is a whole perspective view of the cable arrangement concerning a 1st embodiment of the present invention. It is an II-II cross section arrow line view of the wiring material shown in FIG. It is a front view of the left end part in the wiring material shown in FIG. It is a top view of the left end part in the wiring material shown in FIG. It is a cross-sectional view of the wiring material which concerns on 2nd Embodiment of this invention. It is whole perspective view of the wiring material which concerns on 3rd Embodiment of this invention. It is a whole perspective view which shows the wiring material which concerns on the modification of 3rd Embodiment of this invention. It is a perspective view showing the example of wiring by the vehicle using two or more kinds of wiring materials. It is process drawing showing the procedure of the manufacturing method of the wiring material shown in FIG. It is process drawing showing the procedure of the electrostatic coating method. It is process drawing showing the procedure of the fluid immersion method. It is a principal part enlarged cross-sectional view for demonstrating the wiring material at the time of giving a round process to the edge of the flat type conductor cut out from the board | plate material. It is a principal part enlarged cross-sectional view for demonstrating the wiring material which concerns on the reference example at the time of not round-processing to the edge of the flat type conductor cut out from the board | plate material. It is a perspective view showing the example of wiring by the vehicle which used a thick article electric wire.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings.
FIG. 1 is an overall perspective view of a vehicle wiring material 100 according to a first embodiment of the present invention, and FIG. 2 is a sectional view taken along the line II-II of the vehicle wiring material 100 shown in FIG.
The vehicle wiring material 100 according to the first embodiment is a wiring material having a plurality of flat conductors 11A to 11D (see FIG. 2), an insulating sheet material 13, and an insulating layer 15.

  The plurality of flat conductors 11A to 11D according to the first embodiment are stacked in the thickness direction. Various conductive materials, such as a copper alloy and an aluminum alloy, can be used for flat type conductors 11A-11D. In the present embodiment, a flat conductor made of aluminum alloy will be described as an example.

  The insulating sheet material 13 is interposed between adjacent flat conductors to electrically insulate between the flat conductors. The insulating sheet material 13 may be a resin sheet material such as flexible PET (polyethylene terephthalate) or PEN (polyethylene naphthalate). These insulating sheet members 13 are provided on the entire front and back surfaces except for the connection portions 17 of the flat conductors 11A to 11D. Therefore, in the case of square flat conductors 11A to 11D, the end faces on the four sides may not be covered by the insulating sheet material 13. The end faces of the four sides are covered with the insulating layer 15. Therefore, only the connection portion 17 is exposed in the stacked flat conductors 11A to 11D.

  The insulating layer 15 is formed around the plurality of flat conductors 11A to 11D stacked with the insulating sheet material 13 interposed therebetween. The insulating layer 15 is formed, for example, by powder coating described later.

  The vehicle wiring material 100 according to the first embodiment can cope with multiple circuits by laminating the plurality of flat conductors 11A to 11D with the insulating sheet material 13 interposed therebetween. In this embodiment, although the case of the wiring material 100 for vehicles which consists of four flat conductors 11A-11D is illustrated, the number of layers (number of sheets) is not limited to this.

The connection part 17 of each flat conductor 11A-11D can be formed by the width | variety which divided the full width of the wiring material 100 for vehicles by the number of layers. As in the illustrated example, a bolt fixing hole 19 is bored in the connection portion 17.
When the vehicle wiring material 100 according to the first embodiment is used as, for example, a power cable, as shown in FIG. 2, the four circuits in the illustrated example are, for example, 48V minus, 48V plus, 12V from the lower layer. The flat conductors 11A to 11D can be stacked in the order of plus and minus 12V to configure the vehicle wiring material 100. In this case, adjacent layers preferably have the same polarity. In the vehicle wiring material 100 in the illustrated example, “48V plus” and “12V plus” are adjacent in the second layer and the third layer. The vehicle wiring material 100 in which multiple circuits are stacked can improve the noise resistance performance by arranging the same poles adjacent to each other.

As shown in FIG. 2, flat conductors 11A to 11D made of aluminum alloy and having a thickness (t) of 0.8 mm and a width (W1) of 70 mm, for example, are used as the vehicle wiring material 100. Therefore, the flat flat conductors 11A to 11D of the aluminum flat plate correspond to electric wires of 56sq.
Here, the flat conductors 11A to 11D are formed by extruding a long length from an aluminum alloy material by a die having a hole type formed such that an edge portion extending in the longitudinal direction has a round shape. That is, the flat conductors 11A to 11D extruded by a die having a flat oval hole shape have a round shape (round shape) at the edge portions at both end portions in the width direction, as shown in an enlarged manner in FIG. Round shape).

  Further, for example, four stacked flat conductors 11A to 11D are interposed between the flat conductors adjacent to the insulating sheet material 13 having a thickness (t1) of 0.2 mm, and the thickness (t2) is 0 The periphery is covered with an insulating layer 15 of .2 mm. Therefore, the distance between laminated conductors is 0.2 mm. Therefore, the full width (W) of the wiring material 100 for vehicles will be 70.4 mm, and the full thickness (T) will be 4.2 mm. Therefore, the thickness of the vehicle wiring material 100 can be reduced to half or less compared to the case of using a 50-sq aluminum wire having a standard finished outer diameter of 12.0 mm.

FIG.3 and FIG.4 is the front view and top view of the left end part in the wiring material 100. FIG.
As shown in FIG. 3, the width (w) of each connection part 17 in flat type conductors 11A-11D is 16.0 mm. Moreover, the space | interval (d) of adjacent connection parts is 2.0 mm. The width (w) of the connection portion 17 causes interference between the outer diameter of a tool used when fastening the nut to the bolt inserted into the bolt fixing hole 19 drilled in the connection portion 17 and the fastened nut. It has the minimum dimensions needed to avoid it.

Here, the plate thickness (t) of each of the flat conductors 11A to 11D in the vehicle wiring member 100 is (n) the number of circuits, and the width of the connection portion 17 at each end of each flat conductor 11A to 11D (w When the distance between adjacent connection parts 17 is (d) and the cross-sectional area of the required wiring material (electric wire sq) is (S), the following formula (A) can be used.
t ≧ S / (n × w + d (n−1)) (A)
That is, according to the above-mentioned formula (A), the plates of the required flat conductors 11A to 11D according to the wire sq (corresponding to the required cross-sectional area (S) of each wiring material) of the conventional wire The thickness (t) can be calculated, and the vehicle wiring material 100 can be easily replaced from the conventional wire.

FIG. 5 is a cross-sectional view of a vehicle wiring material 200 according to a second embodiment of the present invention.
As shown in FIG. 5, the vehicle wiring material 200 includes a shield layer 16 around the plurality of flat conductors 11A to 11D covered with the insulating layer 15. For example, a braided wire or a foil material can be used as the shield layer 16. The outer periphery of the shield layer 16 is further covered with the insulating layer 15. According to the vehicle wiring member 200 provided with the shield layer 16, it is possible to suppress the emission of noise and to prevent the influence of the external noise.

FIG. 6 is an overall perspective view of a vehicle wiring material 300 according to a third embodiment of the present invention.
The vehicle wiring material 300 according to the third embodiment is, for example, bent into a shape along the floor panel (body panel) 21 (see FIG. 8) of the vehicle. As will be described later, the vehicle wiring material 300 has a predetermined shape of the plurality of flat conductors 11A to 11D laminated with the flexible insulating sheet material 13 interposed therebetween before the insulating layer 15 is formed. Can be bent. And the wiring material 300 for vehicles is comprised by forming the insulating layer 15 around several bent flat type conductors 11A-11D.
The method of bending into a predetermined shape includes flatwise bending, edgewise bending, and twisting. In addition, bending into a predetermined shape includes various bendings such as bending with a crease or bending with a bending R.

  A concave bending portion 22 straddling the tunnel portion 24 of the floor panel 21 is formed in the vehicle wiring material 300. In the vehicle wiring material 300, four layers (four sheets) of flat conductors 11A to 11D stacked with the insulating sheet material 13 interposed therebetween are covered with the insulating layer 15 by powder coating, and both ends are respectively 4 Connection 17 is provided.

FIG. 7 is an overall perspective view showing a vehicle wiring material 400 according to a modification of the third embodiment of the present invention.
Like the vehicle wiring material 300, the vehicle wiring material 400 has a plurality of elongated members laminated with the flexible insulating sheet material 13 interposed therebetween before the insulating layer 15 is formed. The flat conductor is bent into a predetermined shape. And the wiring material 400 for vehicles is comprised by forming the insulating layer 15 around a plurality of these bent long flat type conductors.

  In the vehicle wiring material 400, in addition to a plurality of bending portions 29, 31, 33 and the like for being along the floor panel 21, a plurality of concave bending portions 35, 37 straddling the cross member of the floor panel 21 are formed. There is. In this vehicle wiring material 400, a long flat conductor of four layers (four sheets) stacked with the insulating sheet material 13 interposed is covered with the insulating layer 15 by powder coating, Connection 17 is provided.

FIG. 8 is a perspective view showing an example of wiring in a vehicle using a plurality of types of vehicle wiring materials.
When used as a power supply cable, for example, the pair of vehicle wiring materials 400 straddles the front cross member 23 on the front (Fr) side of the vehicle and the rear cross member 25 on the rear (Rr) side along the floor panel 21 It is wired in the longitudinal direction of the vehicle. In addition, the vehicle wiring material 300 is wired in the vehicle left-right direction along the floor panel 21 across the tunnel portion 24 of the vehicle, and electrically connected to the pair of vehicle wiring materials 400 via the branch box 27. Connected Furthermore, the vehicle wiring material 100 is electrically connected to the vehicle wiring material 400 via the branch box 27.

  The vehicle wiring materials 100, 300, and 400 are interconnected along the floor panel 21 across the front (Fr) side and the rear (Rr) side of the vehicle so that the on-vehicle battery Power can be supplied to devices in various places.

  These vehicle wiring materials 100, 300, 400 are made of a plurality of flat conductors stacked with the insulating sheet material 13 interposed therebetween, and are covered with the powder-coated thin insulating layer 15. It can be made thinner and lighter than electric wires. And by the thickness reduction of these wiring materials 100, 300, 400 for vehicles, a vehicle wiring space can be reduced. As a result, the vehicle wiring materials 100, 300, and 400 are also wired in a space-saving portion (for example, a gap between the floor panel 21 and the floor mat, etc.) where it is desired to minimize the wiring space as the vehicle interior living space expands. Is possible.

Next, the manufacturing method of the wiring material for vehicles which concerns on said each embodiment is demonstrated.
FIG. 9 is a process diagram showing the procedure of the method of manufacturing the wiring material 300 for a vehicle shown in FIG.
In the method of manufacturing the vehicle wiring material 300 according to the present embodiment, a step of extruding a long flat conductor 11A (11B to 11D), and laminating a plurality of flat conductors 11A to 11D in the thickness direction Insulating step: an insulating step of electrically insulating by interposing the insulating sheet material 13 between adjacent flat conductors, and an insulating step of forming the insulating layer 15 around the plurality of stacked flat conductors 11A to 11D And a layer forming step.

  In the step of extruding the long flat conductor 11A (11B to 11D), a die having a hole type formed such that an edge portion extending in the longitudinal direction of the flat conductor 11A (11B to 11D) has a round shape. The flat conductors 11A (11B to 11D) are extruded from the aluminum alloy material into a long length by (not shown).

  In the stacking step of stacking the plurality of flat conductors 11A to 11D in the thickness direction, as shown in FIG. 9A, the required number of flat conductors 11A to 11D (four in the example shown) are prepared. . The plurality of flat conductors 11A to 11D are electrically insulated by interposing the insulating sheet material 13 between adjacent flat conductors before bending, and the laminated flat conductors shown in FIG. It becomes 43.

  Before forming the insulating layer 15 on the outer periphery, the laminated flat conductor 43 is bent into a shape along the floor panel 21 or the like of the vehicle in a bending step, as shown in FIG. 9C. In particular, in the bending process of the laminated flat conductor 43, since a slight deformation is returned by spring back after the process, this is performed in anticipation of this.

As shown in (d) of FIG. 9, the laminated flat conductor 43 whose bending process is completed is powder-coated on the outer periphery, and the wiring material 300 for a vehicle having the insulating layer 15 formed on the surface. It becomes.
Under the present circumstances, the manufacturing method of the wiring material 300 for vehicles which concerns on this embodiment can provide a masking process in front of a coating process. In the masking step, for example, the surface of the portion to be the connection portion 17 at both ends of the laminated flat conductor 43 is masked by using a masking tape 45 or the like (see (c) in FIG. 9). At both ends of the masked laminated flat conductor 43, bolt fixing holes 19 are formed in advance by drilling. The insulating layer 15 is not formed on both ends of the masked laminated flat conductor 43. Therefore, the exposed portions at both ends of the laminated flat conductor 43 can be used as connection terminals. The connection terminal can be directly connected to the other harness, the battery electrode, the alternator terminal or the like by bolt fastening using the bolt fixing hole 19 described above.

  The insulating layer 15 is formed on the surface of the laminated flat conductor 43 which has been subjected to the bending process by powder coating with an insulating resin material. There are two main types of this powder coating, the "electrostatic coating method (spray coating)" and the "fluid immersion method (immersion coating)".

FIG. 10 is a process diagram showing the procedure of the “electrostatic coating method”.
The “electrostatic coating method” is a method in which a paint is charged by a spray gun 48 and applied to a grounded object using static electricity.
In the “electrostatic coating method” shown in FIG. 10, first, the laminated flat conductor 43 is washed in the pretreatment tank 47 and dried in the draining drying furnace 49.

  Next, in the powder coating booth 51, the powder coating material from the powder coating material supply tank 53 is sprayed by pressurized air from the compressor 55. At this time, a high voltage generator 57 is connected to the spray gun 48 to charge the paint. On the other hand, by keeping the laminated flat conductor 43 grounded, the surface of the laminated flat conductor 43 is covered with the coating of the powder coating. A recovery device 59 is connected to the powder coating booth 51.

  After the application of the powder coating, the coating film is formed by heating in a baking and drying furnace 61, and after being cooled, a coated laminated flat conductor 63 is obtained. The coated laminated flat conductor 63 is subjected to post processing such as removal of the masking tape 45 to become the vehicle wiring material 300. Although it is difficult to control the film thickness by the "fluid immersion method" described later, it becomes easy to control the coating film with a thin film of about 50 microns by the "electrostatic spray method".

  The thermosetting paint used in the "electrostatic spray method" causes a chemical change (crosslinking) by the application of heat and changes the characteristics. Since various properties can be added by the crosslinking reaction, a paint can be selected according to the application. The base resin to be used is generally polyester resin, acrylic resin, epoxy resin, hybrid (epoxy / polyester) resin or the like.

FIG. 11 is a process diagram showing the procedure of the “fluid immersion method”.
In the “fluid immersion method”, first, the laminated flat conductor 43 is washed in the pretreatment tank 47 and the laminated flat conductor 43 is preheated in the preheating furnace 65.

  Then, immersion is performed in the fluid immersion tank 67. In the immersion, a porous plate is disposed at the bottom of the fluid immersion tank 67, the paint is made to flow by sending compressed air 69 from the porous plate, and the preheated laminated flat conductor 43 is immersed in the flowing paint. Do. The paint in the fluid immersion tank 67 is fused to the laminated flat conductor 43 by heat to form a thick film.

  Thereafter, it may be passed through a post heating tank 71 for improving the smoothness. Thus, a coated laminated flat conductor 63 is obtained. The coated laminated flat conductor 63 is subjected to post processing such as removal of the masking tape 45 to become the vehicle wiring material 300. In the "fluid immersion coating method", a film thickness of usually 200 to 500 microns can be applied.

  Thermoplastic powder coatings used in the "fluid immersion method" can mainly use resins such as vinyl chloride, polyethylene and nylon. Thermoplastic coatings are characterized by being softened and changed in shape by the application of heat and stabilized in shape upon cooling. Thermoplastic powder coatings do not undergo chemical changes due to heat, and therefore, when heat is applied again, softening and changes in shape are repeated. Therefore, it is not a baking process like a thermosetting paint.

  Note that the method of manufacturing a vehicle wiring material according to the present embodiment includes a shield layer forming step of forming a shield layer around the coated laminated flat conductor 63 to which powder coating has been applied, It is also good. In the shield layer forming step, the periphery of the coated laminated flat conductor 63 is covered with a braided wire or a foil material as a shield layer. Thereafter, the outer periphery is further covered with an insulating layer 15 formed by powder coating, as necessary. According to the vehicle wiring material provided with the shield layer, it is possible to suppress the emission of noise and to prevent the influence of the external noise.

FIG. 12 is an enlarged cross-sectional view of an essential part for explaining the vehicle wiring material 500 when the edge 12 of the flat conductors 11A (11B to 11D) cut out from the plate material is subjected to round processing.
In the method of manufacturing the vehicle wiring material 500 according to the other embodiment of the present invention, as shown in (a) of FIG. 12, the flat conductors 11A (11B to 11D) are elongated from a plate made of aluminum alloy In the case of being cut out, or in the case where a sufficient round shape is not formed at the edge portion extending in the longitudinal direction of the flat conductor 11A (11B to 11D) extruded into a long shape from an aluminum alloy material, lamination Before the step, an edge processing step of rounding at least the longitudinally extending edge 12 of the flat conductors 11A (11B to 11D) is included.

In this edge processing step, the edge 12 extending in the longitudinal direction (the direction orthogonal to the sheet of FIG. 12) of the flat conductors 11A (11B to 11D) is rounded. That is, as shown in (b) of FIG. 10, round portions 14 are formed by cutting or grinding at the edge portions at both ends in the width direction of the flat conductor 11A (11B to 11D). Therefore, as illustrated in an enlarged manner in (b) of FIG. 10, the flat conductors 11A (11B to 11D) have round shapes (square round shapes) at edge portions at both end portions in the width direction.
Then, similarly to the above-described vehicle wiring materials 100, 200, 300, and 400, the lamination step of laminating the plurality of flat conductors 11A to 11D in the thickness direction, and the insulating sheet material 13 between adjacent flat conductors. (C) in FIG. 12 through an insulation step of electrically insulating by interposing an insulating layer, and an insulation layer forming step of forming the insulating layer 15 around the plurality of stacked flat conductors 11A to 11D. As shown in the figure, the vehicle wiring material 500 is manufactured.

Next, the operation of the above configuration will be described.
In the method of manufacturing the vehicle wiring material 100, 200, 300, 400, 500 according to the above embodiment, the flat conductors 11A to 11D are used as the wiring material, and the insulating sheet material 13 is interposed between the plurality of flat conductors. By laminating the flat conductors 11A to 11D in the thickness direction, the vehicle wiring material of a plurality of circuits can be configured while suppressing the height compared to the conventional thick wire. In this case, the plurality of flat conductors 11A to 11D can suppress the expansion of the wiring space in the width direction of the wiring material as compared with the conventional thick wire.

  Further, according to the wiring material 200 provided with the shield layer 16, it is possible to suppress the release of noise and to prevent the influence of the external noise.

  In the method of manufacturing the vehicle wiring material 100, 200, 300, 400, 500 according to the present embodiment, when laminating the plurality of flat conductors 11A to 11D in the thickness direction, an insulating sheet is provided between adjacent flat conductors. Since the material 13 is interposed to electrically insulate, it is possible to easily and reliably insulate between the flat conductors.

  Furthermore, the extruded flat conductors 11A to 11D have a round shape at the edge portion, and the edge 12 is exposed from the insulating layer 15 formed around the flat conductors 11A to 11D, or the edge portion And the insulating layer 15 does not become thin (see FIG. 2). Therefore, the vehicle wiring materials 100, 200, 300, and 400 can be prevented from lowering in withstand voltage and insulation resistance, and wear resistance and the like can be improved.

FIG. 13: is a principal part expansion cross section for demonstrating the vehicle wiring material 600 which concerns on the reference example at the time of not round-processing to the edge 12 of flat type | mold conductor 11A (11B-11D) cut out from the board material. FIG.
By the way, as shown to (a) of FIG. 13, the flat type conductor 11A (11B-11D) cut out long from the board | plate material made from aluminum alloy has the edge extended in a longitudinal direction (paper surface orthogonal direction in FIG. 13). 12 stands. Also, there may be a burr or the like on the edge 12.
Then, when the insulating layer 15 is formed around the plurality of flat conductors 11A to 11D stacked with the edge 12 as described above to manufacture the vehicle wiring material 600, as shown in FIG. As such, the insulating layer 15 may be thinned at the edge portion, or the edge 12 may be exposed from the insulating layer 15. When a high voltage is applied to the vehicle wiring material 600 according to such a reference example, dielectric breakdown may occur at an edge portion where the film thickness of the insulating layer 15 is thin, and a leak current may flow.

  On the other hand, in the method of manufacturing the vehicle wiring member 500 according to the other embodiment of the present invention shown in FIG. 12, for example, the flat conductors 11A (11B to 11D) are cut out from the aluminum alloy plate In this case, the edge 12 extending in the longitudinal direction of the flat conductors 11A (11B to 11D) is rounded before the insulating layer 15 is formed. That is, the flat conductors 11A to 11D have a round shape at the edge portion, and the edge 12 is exposed from the insulating layer 15 formed around the flat conductors 11A to 11D, or the insulating layer 15 at the edge portion Does not become thin (see (c) in FIG. 12). Therefore, the wiring material 500 for a vehicle is prevented from lowering in voltage resistance and insulation resistance, and wear resistance and the like can be improved.

  Moreover, in the manufacturing method of the wiring material 300,400 for vehicles, the several flat type conductor 11A-11D laminated | stacked is bent in the shape which follows the floor panel 21 previously. That is, the plurality of flat conductors 11A to 11D (that is, the laminated flat conductors 43) stacked by interposing the flexible insulating sheet material 13 are collectively bent in a shape along the floor panel 21. It can be processed. Here, the flat conductors 11A to 11D have round shapes at edge portions, and bending workability is improved. The periphery of the bent flat conductor 43 is covered with the insulating layer 15.

Generally, the surface of the floor panel 21 along which the wiring material runs is a complicated uneven surface due to the front cross member 23 and the rear cross member 25 and the like.
For example, as shown in FIG. 14, when connecting a thick wire 73 along the floor panel 21 to connect the front alternator 41 etc. to the fuse box 39 connected to the rear battery 38, the front cross The heavy electric wire 73 is disposed on the convex portions of the member 23 and the rear cross member 25 and the like. For this reason, the space between the floor panel 21 and, for example, the interior material provided on the floor panel 21 needs to be at least the height at which the heavy electric wire 73 is accommodated. In addition, since it becomes difficult to bend the thick wire 73 following the convex portions of the front cross member 23 and the rear cross member 25, the height of the interior material is restricted also in the concave portion by the position of the heavy wire 73. Can not be lowered.

  On the other hand, in the vehicle wiring materials 300 and 400 configured as described above, since the plurality of flat conductors 11A to 11D (laminated flat conductors 43) stacked with the insulating sheet material 13 interposed therebetween are bent in advance, It becomes possible to process easily in the shape which followed the uneven surface of the complicated floor panel 21. FIG. As a result, in the recess, there is no restriction as in the case of the heavy electric wire 73 which can not be bent, and the height of the interior material can be lowered (see FIG. 8). An insulating layer 15 is formed, for example, by powder coating on the surface of the wiring material obtained by laminating and bending the plurality of flat conductors A to 11D with the insulating sheet material 13 interposed therebetween. In powder coating, the insulating layer 15 can be formed with a thickness of, for example, 0.1 to 0.2 mm, while the insulating layer 15 in the conventional extrusion molding has a thickness of 1 to 2 mm. As a result, the vehicle wiring materials 300 and 400 can reduce the vehicle wiring space, and for example, can reduce the distance between the floor panel 21 and the interior material.

  Further, in the method of manufacturing the vehicle wiring material 200, after the insulating layer 15 is formed around the plurality of flat conductors 11A to 11D stacked with the insulating sheet material 13 interposed therebetween, the periphery of the insulating layer 15 is shielded By covering with the layer 16 and further providing the insulating layer 15 by powder coating on the outside if necessary, the vehicle installation material 200 having a shielding function can be easily made using the same equipment (for example, powder coating apparatus) Can be manufactured.

  Therefore, according to the manufacturing method of the vehicle wiring material 100, 200, 300, 400, 500 according to each of the above-described embodiments, it is thinner along the floor panel 21 as compared with the conventional extrusion molded covered wire. It is possible to form the insulating layer 15 on the bent wiring material.

  The present invention is not limited to the above-described embodiments, but the configurations of the embodiments may be combined with one another, or modified or applied by those skilled in the art based on the description of the specification and the well-known techniques. It is intended for the invention, and is included in the scope for which protection is sought.

  For example, the insulating layer formed around the flat conductor is not limited to the powder coating described above, and various forming methods such as a method of dipping in a paint (dip coating) can be adopted. Moreover, although it was set as the structure which electrically connects several wiring material 100,300,400 for vehicles via the branch box 27 in said example of a structure, one wiring material for vehicles is the front-back direction of a vehicle It is needless to say that it can also be configured to be wired. Furthermore, in the above embodiment, although the method of manufacturing the vehicle wiring material 100, 200, 300, 400, 500 used as the wiring material for the power cable of the vehicle has been described as an example, the wiring material of the present invention It is needless to say that the present invention is not limited to this, and can be applied to various methods of manufacturing a wiring material.

Here, the features of the embodiment of the method of manufacturing a cable arrangement according to the present invention described above will be briefly summarized and listed in the following [1] to [4].
[1] A process of extruding a long flat conductor (11A to 11D) with a die having a hole mold formed such that an edge portion extending in the longitudinal direction has a round shape;
Laminating the plurality of flat conductors (11A to 11D) in the thickness direction;
An insulating step of electrically insulating by interposing an insulating sheet material (13) between the adjacent flat conductors;
An insulating layer forming step of forming an insulating layer (15) around the plurality of stacked flat conductors (11A to 11D);
A manufacturing method of a wiring material (wiring material 100, 200, 300, 400 for vehicles) characterized by including.
[2] an edge processing step of rounding at least a longitudinally extending edge (12) of the flat conductor (11A to 11D);
Laminating the plurality of round shaped flat conductors (11A to 11D) in the thickness direction;
An insulating step of electrically insulating by interposing an insulating sheet material (13) between the adjacent flat conductors;
An insulating layer forming step of forming an insulating layer (15) around the plurality of stacked flat conductors (11A to 11D);
A manufacturing method of a wiring material (wiring material 500 for vehicles) characterized by including.
[3] The method according to the above [1] or [2], including the step of bending the stacked flat conductors (11A to 11D) into a predetermined shape before forming the insulating layer (15). ] The manufacturing method of the wiring material (wiring material 300,400 for vehicles) as described in these.
[4] In any one of the above [1] to [3], including a shield layer forming step of forming a shield layer (16) around the plurality of flat conductors (11A to 11D) The manufacturing method of the wiring material (200) of description.

11A to 11D: Flat conductor 13: Insulating sheet material 15: Insulating layer 16: Shield layer 100, 200, 300, 400, 500: Wiring material (wiring material) for vehicle

Claims (4)

Extruding a long flat conductor by means of a die having a hole mold formed such that the edge portion extending in the longitudinal direction has a round shape;
Laminating a plurality of the flat conductors in the thickness direction;
An insulating step of electrically insulating by interposing an insulating sheet material between the adjacent flat conductors;
An insulating layer forming step of forming an insulating layer around the plurality of stacked flat conductors;
A manufacturing method of a wiring material characterized by including. An edge processing step of rounding at least a longitudinally extending edge of the flat conductor;
Stacking a plurality of round shaped flat conductors in a thickness direction;
An insulating step of electrically insulating by interposing an insulating sheet material between the adjacent flat conductors;
An insulating layer forming step of forming an insulating layer around the plurality of stacked flat conductors;
A manufacturing method of a wiring material characterized by including.   The method according to claim 1 or 2, further comprising a bending step of bending the stacked flat conductors into a predetermined shape before forming the insulating layer.   The method according to any one of claims 1 to 3, further comprising a shield layer forming step of forming a shield layer around the plurality of flat conductors.

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