JP2023142397A - Unit cable and method for manufacturing unit cable - Google Patents

Abstract

To provide a unit cable and a method for manufacturing the unit cable in which release of a mold can be suppressed even if a crack is generated in the mold.SOLUTION: A unit cable includes: a first cable 100 including first to third insulated electric wires 110 to 130; and a second cable 200 including fourth to sixth insulated electric wires 210 to 320. The first cable has first to third exposed parts 113 to 133 in which conductors of the first to third insulated electric wires are exposed in a middle part 101 in a longitudinal direction. The second cable has fourth to sixth exposed parts 213 to 233 in which conductors of the fourth to sixth insulated electric wires are exposed in a middle part 201 in a longitudinal direction, and has a first connection part where the first and fourth exposed parts are electrically connected, a second connection part where the second and fifth exposed parts are electrically connected, a third connection part where the third and sixth exposed parts are electrically connected, and an insulative mold covering the first to third connection parts. The first to third connection parts are electrically insulated by tubes 612, 622 and 632.SELECTED DRAWING: Figure 3

Description

The present disclosure relates to a unit cable and a method of manufacturing the unit cable.

A unit cable in which branch cables are connected to a trunk cable is used for indoor wiring and the like. Patent Documents 1 and 2 disclose that an insulated wire included in a flat cable is connected to an insulated wire included in another flat cable to form a connecting portion, and a plurality of connecting portions are arranged in the width direction of the flat cable, A molded unit cable is shown.

Japanese Patent Application Publication No. 2015-56327 Utility Model Publication No. 4-16821

The unit cable may be subjected to external shocks. Additionally, heat may be generated when electricity is applied to the insulated wire. In a unit cable equipped with a conventional mold, there is a risk that the mold may crack due to impact or heat, and the mold may separate from the connection portion.

An object of the present disclosure is to provide a unit cable and a method for manufacturing the unit cable that can suppress detachment of the mold even if a crack occurs in the mold.

The unit cable of the present disclosure includes a first cable that includes a first insulated wire, a second insulated wire, and a third insulated wire, and a fourth insulated wire, a fifth insulated wire, and a sixth insulated wire that are arranged along the first cable. a second cable including an insulated wire, and the first cable has a first exposed portion where the conductor of the first insulated wire is exposed in a first region in the longitudinal direction thereof, and a first exposed portion of the second insulated wire. The second cable has a second exposed part where the conductor is exposed and a third exposed part where the conductor of the third insulated wire is exposed, and the second cable has a second exposed part where the conductor of the third insulated wire is exposed, and the second cable has a second exposed part where the conductor of the third insulated wire is exposed. a fourth exposed portion in which the conductor of the fifth insulated wire is exposed, a fifth exposed portion in which the conductor of the fifth insulated wire is exposed, and a sixth exposed portion in which the conductor of the sixth insulated wire is exposed; a first connection part in which the exposed part and the fourth exposed part are electrically connected to each other; a second connection part in which the second exposed part and the fifth exposed part are electrically connected to each other; a third connection portion in which the exposed portion and the sixth exposed portion are electrically connected to each other; and an electrically insulating mold that covers the first connection portion, the second connection portion, and the third connection portion; The first connecting portion, the second connecting portion, and the third connecting portion are electrically insulated from each other, and the first connecting portion and the second connecting portion have a cross section perpendicular to the longitudinal direction. The second connecting portion and the third connecting portion are aligned along a first direction, and the second connecting portion and the third connecting portion are aligned along a second direction different from the first direction in the cross section.

According to the present disclosure, even if a crack occurs in the mold, separation of the mold can be suppressed.

FIG. 1 is a perspective view showing a unit cable according to the first embodiment. FIG. 2 is a top view showing the unit cable according to the first embodiment. FIG. 3 is an exploded perspective view showing the unit cable according to the first embodiment. FIG. 4 is a sectional view (part 1) showing the unit cable according to the first embodiment. FIG. 5 is a cross-sectional view (part 2) showing the unit cable according to the first embodiment. FIG. 6 is a cross-sectional view (part 3) showing the unit cable according to the first embodiment. FIG. 7 is a diagram showing an example of a hot melt molding machine. FIG. 8 is a sectional view (part 1) showing the unit cable according to the second embodiment. FIG. 9 is a cross-sectional view (part 2) showing the unit cable according to the second embodiment.

[Description of embodiments of the present disclosure]
First, embodiments of the present disclosure will be listed and described.

[1] A unit cable according to one aspect of the present disclosure includes a first cable including a first insulated wire, a second insulated wire, and a third insulated wire, a fourth insulated wire arranged along the first cable, a second cable including a fifth insulated wire and a sixth insulated wire, the first cable having a first exposed portion in which the conductor of the first insulated wire is exposed in a first region in the longitudinal direction thereof; , the second cable has a second exposed part in which the conductor of the second insulated wire is exposed, and a third exposed part in which the conductor of the third insulated wire is exposed, and the second cable has a second region in the longitudinal direction thereof. , a fourth exposed portion where the conductor of the fourth insulated wire is exposed, a fifth exposed portion where the conductor of the fifth insulated wire is exposed, and a sixth exposed portion where the conductor of the sixth insulated wire is exposed; a first connection part in which the first exposed part and the fourth exposed part are electrically connected to each other; and a second connection part in which the second exposed part and the fifth exposed part are electrically connected to each other. a third connecting portion in which the third exposed portion and the sixth exposed portion are electrically connected to each other; and an electrically insulating material that covers the first connecting portion, the second connecting portion, and the third connecting portion. a mold, the first connection part, the second connection part, and the third connection part are electrically insulated from each other, and the first connection part and the second connection part are connected to the longitudinal direction. In the cross section perpendicular to the direction, the second connecting portion and the third connecting portion are lined up along the first direction, and the second connecting portion and the third connecting portion are lined up along the second direction different from the first direction in the cross section.

In a cross section perpendicular to the longitudinal direction, the first connecting portion and the second connecting portion are lined up along the first direction, and the second connecting portion and the third connecting portion are lined up along the second direction different from the first direction. . Therefore, a large area of the surface of the mold that follows the outer periphery of the first, second, and third connecting parts can be ensured, and even if a crack occurs in the mold, separation of the mold can be suppressed.

[2] In [1], the first connecting portion is located between the second connecting portion and the third connecting portion when viewed from a direction perpendicular to the longitudinal direction and the second direction. It's okay. In this case, detachment of the mold can be more easily suppressed.

[3] In [1] or [2], the filling area may be surrounded by the first connection part, the second connection part, and the third connection part and filled with the mold. In this case, detachment of the mold can be more easily suppressed.

[4] In [1] to [3], an electrically insulating tube may be provided to cover the first connection portion, and the mold may cover the first connection portion covered with the tube. In this case, it is easy to electrically insulate the first connection part from the second connection part and the third connection part.

[5] In [4], the tube may be provided with a cut. In this case, it is easy to fit the first connection part into the tube.

[6] In [4] or [5], air may exist inside the tube. When forming a mold, the inside of the tube may not be filled with the mold material.

[7] In [4] or [5], the inside of the tube may be filled with the mold. When forming the mold, the inside of the tube may be filled with the mold material.

[8] In [1] to [3], an electrically insulating sheet may be provided to cover the first connection portion, and the mold may cover the first connection portion covered with the sheet. In this case, it is easy to electrically insulate the first connection part from the second connection part and the third connection part.

[9] In [8], air may exist inside the sheet. When forming a mold, the mold material may not be filled to the inside of the sheet.

[10] In [1] to [9], at least a portion of the first connection portion may be located outside the outer periphery of the first cable when viewed from the longitudinal direction. Due to the relative positional relationship of the first connecting portion, the second connecting portion, and the third connecting portion, at least a portion of the first connecting portion tends to be located outside the outer periphery of the first cable when viewed from the longitudinal direction. .

[11] In [1] to [10], the first connecting portion may include a connector that electrically connects the first exposed portion and the fourth exposed portion to each other. In this case, it is easy to electrically connect the first exposed portion and the fourth exposed portion while fixing them to each other.

[12] In [1] to [11], the first cable may be a first flat cable, and the second cable may be a second flat cable. In this case, the unit cable can be constructed using a commonly used flat cable.

[13] In [12], the first flat cable has a first plane and a second plane along the longitudinal direction, and one end of the first plane in the transverse direction perpendicular to the longitudinal direction. a first curved surface connecting one end of the second plane; and a second curved surface connecting the other end of the first plane and the other end of the second plane in the lateral direction. The second flat cable has a third plane and a fourth plane along the longitudinal direction, one end of the third plane and one end of the fourth plane in the transverse direction. and a fourth curved surface that connects the other end of the third plane and the other end of the fourth plane in the lateral direction, the second plane and the fourth plane. The three planes may face each other. In this case, it is easy to line up the first flat cable and the second flat cable.

[14] In [13], in the mold, the first flat cable and the second flat cable are not connected to each other except for the first connection part, the second connection part, and the third connection part. They may be separated. In this case, it is easy to fix the first flat cable and the second flat cable when forming the mold.

[15] In [14], the gap between the first flat cable and the second flat cable may be filled with the mold. In this case, it is easy to fix the first flat cable and the second flat cable with the mold.

[16] In [12] to [15], the first flat cable may have a sheath that covers the first insulated wire, the second insulated wire, and the third insulated wire. In this case, the first insulated wire, the second insulated wire, and the third insulated wire can be bundled using the sheath.

[17] In [12] to [15], the first flat cable has a sheath that covers the first insulated wire and the second insulated wire, and the third insulated wire extends along the longitudinal direction. may be in contact with the sheath. In this case, the first insulated wire and the second insulated wire can be bundled by the sheath.

[18] In [16] or [17], the sheath may contain foamed resin. In this case, it is easy to obtain good flexibility.

[19] In [16] to [18], the sheath may be on both sides of the first region in the longitudinal direction of the first flat cable, and the mold may be in contact with the sheath. In this case, the position of the first flat cable can be fixed through the sheath.

[20] In [1] to [19], the conductor of the first insulated wire is either a copper wire, a copper alloy wire, or a copper clad aluminum wire in which a copper layer is formed on the surface of an aluminum core wire. It's okay. In this case, it is easy to obtain good conductivity.

[21] In [1] to [20], the material of the mold may be at least one selected from the group consisting of polyamide, polyester, olefin, and urethane. In this case, the mold can be formed by hot melt molding.

[22] A unit cable according to another aspect of the present disclosure includes a first cable including a first insulated wire, a second insulated wire, and a third insulated wire, and a fourth insulated wire arranged along the first cable. a second cable including an electric wire, a fifth insulated wire, and a sixth insulated wire, wherein the first cable has a first exposed conductor in which the conductor of the first insulated wire is exposed in a first region in the longitudinal direction of the first cable. a second exposed portion in which the conductor of the second insulated wire is exposed; and a third exposed portion in which the conductor of the third insulated wire is exposed; In the two regions, a fourth exposed portion where the conductor of the fourth insulated wire is exposed, a fifth exposed portion where the conductor of the fifth insulated wire is exposed, and a sixth exposed portion where the conductor of the sixth insulated wire is exposed. and a first connection part in which the first exposed part and the fourth exposed part are electrically connected to each other, and the second exposed part and the fifth exposed part are electrically connected to each other. A second connection part, a third connection part in which the third exposed part and the sixth exposed part are electrically connected to each other, and electrical insulation covering the first connection part, the second connection part, and the third connection part. the first connection part, the second connection part, and the third connection part are electrically insulated from each other, and the material of the mold is polyamide, polyester, olefin, or urethane. At least one type selected from the group consisting of:

[23] A unit cable according to another aspect of the present disclosure includes a first cable including a first insulated wire and a second insulated wire, and a third insulated wire and a fourth insulated wire arranged along the first cable. a second cable including an electric wire, and the first cable has a first exposed portion in which the conductor of the first insulated wire is exposed in a first region in the longitudinal direction thereof, and a conductor of the second insulated wire. a second exposed portion where the conductor of the third insulated wire is exposed, and the second cable has a third exposed portion where the conductor of the third insulated wire is exposed in a second region of the second cable in the longitudinal direction; a fourth exposed portion in which a conductor is exposed; a first connecting portion in which the first exposed portion and the third exposed portion are electrically connected to each other; and the second exposed portion and the fourth exposed portion. have a second connection part that is electrically connected to each other, and an electrically insulating mold that covers the first connection part and the second connection part, the first connection part and the second connection part, They are electrically insulated from each other, and at least a portion of the first connection portion is located outside the outer periphery of the first cable when viewed from the longitudinal direction.

[24] The method for manufacturing a unit cable according to [1] to [22], including the first insulated wire, the second insulated wire, and the third insulated wire, and the first exposed portion and the second exposed portion. a first cable having a portion and a third exposed portion, a fourth insulated wire, a fifth insulated wire, and a sixth insulated wire, the fourth exposed portion, the fifth exposed portion, and the sixth exposed portion; a step of preparing a second cable having a section; a step of electrically connecting the first exposed section and the fourth exposed section to each other to form the first connecting section; a step of forming the second connecting portion in which the fifth exposed portions are electrically connected to each other; and a step of forming the third connecting portion in which the third exposed portion and the sixth exposed portion are electrically connected to each other. and a step of fixing the first cable and the second cable, on which the first connection part, the second connection part, and the third connection part are formed, to a mold, and the first cable and the second cable. a step of supplying a fluid electrically insulating material into the mold in which is fixed, and a step of curing the electrically insulating material supplied into the mold, has a cavity, an inlet, and an outlet, the inlet and the outlet are connected to the cavity, the first cable and the second cable are housed in the outlet and the cavity, and the first cable and the second cable are housed in the cavity. The first connection part, the second connection part, and the third connection part can be accommodated, and the step of fixing the first cable and the second cable to the mold includes the step of fixing the first connection part, the second connection part, and the third connection part to the mold. and the third connecting portion in the cavity; disposing the electrically insulating material into an outlet, and dispensing the electrically insulating material includes flowing the electrically insulating material from the inlet through the cavity and toward the outlet.

A mold can be formed by supplying an electrically insulating material to a mold to which the first cable and the second cable are fixed, and then curing the electrically insulating material.

[Details of embodiments of the present disclosure]
Hereinafter, embodiments of the present disclosure will be described in detail, but the present disclosure is not limited thereto. Note that, in this specification and the drawings, components having substantially the same functional configurations may be given the same reference numerals to omit redundant explanation. In this specification and the drawings, the X1-X2 direction, the Y1-Y2 direction, and the Z1-Z2 direction are directions that are orthogonal to each other. The plane including the X1-X2 direction and the Y1-Y2 direction is the XY plane, the plane including the Y1-Y2 direction and the Z1-Z2 direction is the YZ plane, and the plane including the Z1-Z2 direction and the X1-X2 direction is the ZX plane. do. For convenience, the Z1 direction is defined as an upward direction, and the Z2 direction is defined as a downward direction. Furthermore, the unit cable has flexibility, and the term "plane" in the present disclosure is not limited to a strict "plane", but also includes a surface that can be considered a "plane" according to social conventions.

(First embodiment)
The first embodiment relates to a unit cable. FIG. 1 is a perspective view showing a unit cable according to the first embodiment. FIG. 2 is a top view showing the unit cable according to the first embodiment. FIG. 3 is an exploded perspective view showing the unit cable according to the first embodiment. 4 to 6 are cross-sectional views showing the unit cable according to the first embodiment. FIG. 4 corresponds to a cross-sectional view taken along the line IV-IV in FIG. FIG. 5 corresponds to a cross-sectional view taken along line VV in FIG. FIG. 6 corresponds to a cross-sectional view taken along line VI-VI in FIG.

As shown in FIGS. 1 to 6, the unit cable 1 according to the first embodiment mainly includes a cable 100, a cable 200, a cable 300, and an electrically insulating mold 400. The unit cable 1 has a longitudinal direction in the X1-X2 direction. For example, cable 100 is located on the Z1 side of cable 200, and cable 200 is located on the Z1 side of cable 300.

The cable 100 is, for example, a flat cable such as a VVF (vinyl insulated vinyl sheathed flat-type cable) cable. The cable 100 has a longitudinal direction in the X1-X2 direction and a transversal direction in the Y1-Y2 direction. As shown in FIG. 4 and the like, the cable 100 includes an insulated wire 110, an insulated wire 120, an insulated wire 130, and a sheath 140. For example, the insulated wire 110 is located on the Y1 side of the insulated wire 120, and the insulated wire 120 is located on the Y1 side of the insulated wire 130. The insulated wire 110 includes a conductor 111 and an insulating layer 112 covering the conductor 111. The insulated wire 120 includes a conductor 121 and an insulating layer 122 covering the conductor 121. The insulated wire 130 includes a conductor 131 and an insulating layer 132 covering the conductor 131. Sheath 140 covers insulated wire 110 , insulated wire 120 , and insulated wire 130 . The insulated wire 110 is an example of a first insulated wire, the insulated wire 120 is an example of a second insulated wire, and the insulated wire 130 is an example of a third insulated wire. Cable 100 is an example of a first cable and a first flat cable.

Cable 100 has a flat surface 151, a flat surface 152, a curved surface 153, and a curved surface 154. Planes 151 and 152 are planes parallel to the XY plane. The plane 151 is located on the Z1 side of the plane 152. The curved surface 153 is located on the Y1 side of the insulated wire 110. The curved surface 153 connects the end of the plane 151 on the Y1 side and the end of the plane 152 on the Y1 side. The curved surface 153 is a curved surface along the outer peripheral surface of the insulated wire 110. The curved surface 154 is located on the Y2 side of the insulated wire 130. The curved surface 154 connects the end of the plane 151 on the Y2 side and the end of the plane 152 on the Y2 side. The curved surface 154 is a curved surface along the outer peripheral surface of the insulated wire 130. The plane 151 is an example of a first plane, the plane 152 is an example of a second plane, the curved surface 153 is an example of a first curved surface, and the curved surface 154 is an example of a second curved surface.

The cable 200 is, for example, a flat cable such as a VVF cable. The cable 200 has a longitudinal direction in the X1-X2 direction and a transversal direction in the Y1-Y2 direction. As shown in FIG. 4 and the like, the cable 200 includes an insulated wire 210, an insulated wire 220, an insulated wire 230, and a sheath 240. For example, the insulated wire 210 is located on the Y1 side of the insulated wire 220, and the insulated wire 220 is located on the Y1 side of the insulated wire 230. The insulated wire 210 includes a conductor 211 and an insulating layer 212 covering the conductor 211. The insulated wire 220 includes a conductor 221 and an insulating layer 222 covering the conductor 221. The insulated wire 230 includes a conductor 231 and an insulating layer 232 covering the conductor 231. Sheath 240 covers insulated wire 210 , insulated wire 220 , and insulated wire 230 . The insulated wire 210 is an example of the fourth insulated wire, the insulated wire 220 is an example of the fifth insulated wire, and the insulated wire 230 is an example of the sixth insulated wire. Cable 200 is an example of a second cable and a second flat cable.

Cable 200 has a flat surface 251, a flat surface 252, a curved surface 253, and a curved surface 254. Planes 251 and 252 are planes parallel to the XY plane. The plane 251 is located on the Z1 side of the plane 252. The curved surface 253 is located on the Y1 side of the insulated wire 210. The curved surface 253 connects the end of the plane 251 on the Y1 side and the end of the plane 252 on the Y1 side. The curved surface 253 is a curved surface along the outer peripheral surface of the insulated wire 210. The curved surface 254 is located on the Y2 side of the insulated wire 230. The curved surface 254 connects the end of the plane 251 on the Y2 side and the end of the plane 252 on the Y2 side. The curved surface 254 is a curved surface along the outer peripheral surface of the insulated wire 230. The plane 251 is an example of a third plane, the plane 252 is an example of a fourth plane, the curved surface 253 is an example of a third curved surface, and the curved surface 254 is an example of a fourth curved surface.

The cable 300 is, for example, a flat cable such as a VVF cable. The cable 300 has a longitudinal direction in the X1-X2 direction and a transversal direction in the Y1-Y2 direction. As shown in FIG. 4 and the like, the cable 300 includes an insulated wire 310, an insulated wire 320, an insulated wire 330, and a sheath 340. For example, the insulated wire 310 is located on the Y1 side of the insulated wire 320, and the insulated wire 320 is located on the Y1 side of the insulated wire 330. The insulated wire 310 includes a conductor 311 and an insulating layer 312 covering the conductor 311. The insulated wire 320 includes a conductor 321 and an insulating layer 322 covering the conductor 321. The insulated wire 330 includes a conductor 331 and an insulating layer 332 covering the conductor 331. Sheath 340 covers insulated wire 310, insulated wire 320, and insulated wire 330.

Cable 300 has a flat surface 351, a flat surface 352, a curved surface 353, and a curved surface 354. Planes 351 and 352 are planes parallel to the XY plane. The plane 351 is located on the Z1 side of the plane 352. The curved surface 353 is located on the Y1 side of the insulated wire 310. The curved surface 353 connects the end of the plane 351 on the Y1 side and the end of the plane 352 on the Y1 side. The curved surface 353 is a curved surface along the outer peripheral surface of the insulated wire 310. The curved surface 354 is located on the Y2 side of the insulated wire 330. The curved surface 354 connects the end of the plane 351 on the Y2 side and the end of the plane 352 on the Y2 side. The curved surface 354 is a curved surface along the outer peripheral surface of the insulated wire 330.

As shown in FIG. 3, etc., the cable 100 has an exposed portion 113 where the conductor 111 of the insulated wire 110 is exposed, and an exposed portion 123 where the conductor 121 of the insulated wire 120 is exposed, in the intermediate portion 101 in the X1-X2 direction. and an exposed portion 133 where the conductor 131 of the insulated wire 130 is exposed. In the X1-X2 direction, there is a sheath 140 on both sides of the intermediate section 101, and between the sheath 140 and the intermediate section 101, the insulating layers 112, 122, and 132 are exposed from the sheath 140. The intermediate portion 101 is an example of the first region. The exposed portion 113 is an example of a first exposed portion, the exposed portion 123 is an example of a second exposed portion, and the exposed portion 133 is an example of a third exposed portion.

As shown in FIG. 3 and the like, the cable 200 has an exposed part 213 where the conductor 211 of the insulated wire 210 is exposed, and an exposed part 223 where the conductor 221 of the insulated wire 220 is exposed, in the middle part 201 in the X1-X2 direction. and an exposed portion 233 where the conductor 231 of the insulated wire 230 is exposed. In the X1-X2 direction, there is a sheath 240 on both sides of the intermediate section 201, and between the sheath 240 and the intermediate section 201, the insulating layers 212, 222, and 232 are exposed from the sheath 240. The intermediate portion 201 is an example of the second region. The exposed portion 213 is an example of a fourth exposed portion, the exposed portion 223 is an example of a fifth exposed portion, and the exposed portion 233 is an example of a sixth exposed portion.

As shown in FIG. 3, etc., the cable 300 has an exposed portion 313 where the conductor 311 of the insulated wire 310 is exposed, and an exposed portion 323 where the conductor 321 of the insulated wire 320 is exposed, at an intermediate portion 301 in the X1-X2 direction. and an exposed portion 333 where the conductor 331 of the insulated wire 330 is exposed. In the X1-X2 direction, there is a sheath 340 on both sides of the intermediate section 301, and between the sheath 340 and the intermediate section 301, the insulating layers 312, 322, and 332 are exposed from the sheath 340.

As shown in FIG. 3 and the like, the unit cable 1 further includes a crimp terminal 611, a crimp terminal 621, a crimp terminal 631, a tube 612, a tube 622, and a tube 632. Tubes 612, 622 and 632 are electrically insulating tubes.

The exposed parts 113, 213, and 313 are accommodated in the crimp terminal 611, and the crimp terminal 611 is caulked. The crimp terminal 611 electrically connects the exposed portions 113, 213, and 313 to each other. The exposed parts 123, 223, and 323 are accommodated in the crimp terminal 621, and the crimp terminal 621 is caulked. The crimp terminal 621 electrically connects the exposed portions 123, 223, and 323 to each other. The exposed parts 133, 233, and 333 are accommodated in the crimp terminal 631, and the crimp terminal 631 is caulked. The crimp terminal 631 electrically connects the exposed portions 133, 233, and 333 to each other. In this way, the unit cable 1 includes a connection part 501 in which the exposed parts 113, 213 and 313 are electrically connected to each other, a connection part 502 in which the exposed parts 123, 223 and 323 are electrically connected to each other, and an exposed part 502 in which the exposed parts 123, 223 and 323 are electrically connected to each other. The portions 133, 233, and 333 have a connecting portion 503 that is electrically connected to each other. The connecting portion 501 is an example of a first connecting portion, the connecting portion 502 is an example of a second connecting portion, and the connecting portion 503 is an example of a third connecting portion. The crimp terminal 611 is an example of a connector.

A slit 613 extending in the X1-X2 direction is formed in the tube 612, a slit 623 extending in the X1-X2 direction is formed in the tube 622, and a slit 633 extending in the X1-X2 direction is formed in the tube 632. As shown in FIG. 5 etc., the connecting portion 501 is accommodated in the tube 612 through the slit 613. Tube 612 covers connection portion 501. The connecting portion 502 is accommodated in the tube 622 through the slit 623. Tube 622 covers connection 502. The connecting portion 503 is accommodated in the tube 632 through the slit 633. Tube 632 covers connection portion 503. Connections 501, 502 and 503 are electrically insulated from each other by tubes 612, 622 and 632. The slit 613 is an example of a cut.

As shown in FIG. 5, etc., in a cross section perpendicular to the longitudinal direction (YZ plane), connection parts 502 and 503 are aligned in the Y1-Y2 direction, and connection parts 501 and 502 are inclined from the Y1-Y2 direction and the Z1-Z2 direction. The connecting portions 503 and 501 are arranged in a direction inclined from the Y1-Y2 direction and the Z1-Z2 direction. The direction in which the connecting portions 501 and 502 are lined up is different from the direction in which the connecting portions 503 and 501 are lined up. For example, the connecting portion 501 is located on the Z1 side of the midpoint between the connecting portions 502 and 503. That is, when viewed from the Z1-Z2 direction perpendicular to the X1-X2 direction and the Y1-Y2 direction, the connecting portion 501 is located between the connecting portion 502 and the connecting portion 503. The direction in which the connecting portions 501 and 502 are lined up is an example of the first direction, and the direction in which the connecting portions 502 and 503 are lined up is an example of the second direction.

When viewed in the longitudinal direction, at least a portion of the connecting portion 501, at least a portion of the connecting portion 502, and at least a portion of the connecting portion 503 are located outside the outer periphery of the cables 100, 200, and 300. In a cross section perpendicular to the longitudinal direction, if the connecting parts 501 and 502 are lined up along the first direction and the connecting parts 502 and 503 are lined up along the second direction, such an arrangement is likely to occur due to their positional relationship. .

As shown in FIG. 5 etc., the mold 400 covers the connection parts 501, 502, and 503. The mold 400 has, for example, a rectangular solid shape. The material of the mold 400 is, for example, at least one selected from the group consisting of polyamide, polyester, olefin, and urethane. The mold 400 covers the connection part 501 covered by the tube 612, covers the connection part 502 covered by the tube 622, and covers the connection part 503 covered by the tube 632. For example, the inside of each of tubes 612, 622, and 632 is filled with mold 400. The unit cable 1 has a region 410 surrounded by connection parts 501, 502, and 503. Region 410 is filled with mold 400. Region 410 is an example of a filling region.

As shown in FIG. 6 and the like, a plane 152 on the Z2 side of the cable 100 and a plane 251 on the Z1 side of the cable 200 face each other, and a plane 252 on the Z2 side of the cable 200 and a plane 351 on the Z1 side of the cable 300 face each other. are doing. In the mold 400, except for the connecting portions 501, 502, and 503, the cable 100 and the cable 200 are spaced apart from each other, and the plane 152 and the plane 251 are spaced apart from each other. In the mold 400, except for the connecting portions 501, 502, and 503, the cable 200 and the cable 300 are spaced apart from each other, and the plane 252 and the plane 351 are spaced apart from each other. Mold 400 has surfaces 421 and 422 perpendicular to the longitudinal direction. Surface 421 is located on the X1 side of surface 422. Cables 100, 200 and 300 pass through surfaces 421 and 422. In terms of appearance, the cable 100 and the cable 200 are spaced apart from each other on the surfaces 421 and 422, and the plane 152 and the plane 251 are spaced apart from each other. Cable 200 and cable 300 are spaced apart from each other, and plane 252 and plane 351 are spaced apart from each other. Further, the gap between cable 100 and cable 200 is filled with mold 400, and the gap between cable 200 and cable 300 is filled with mold 400.

Next, a method for manufacturing the unit cable 1 will be explained. The unit cable 1 can be manufactured using, for example, a hot melt molding method. Here, first, a hot melt molding machine used in the hot melt molding method will be explained. FIG. 7 is a diagram showing an example of a hot melt molding machine.

The hot melt molding machine 5 includes a mold 10, a gun 30, a tank 40, and a hose 50.

The mold 10 has a lower mold 11 and an upper mold 12. The mold 10 has a cavity 21, an inlet 22, and an outlet 23. For example, the cavity 21 and the outlet 23 are formed in the lower mold 11 and the upper mold 12, and the inlet 22 is formed in the upper mold 12. An inlet 22 and an outlet 23 are connected to the cavity 21. The cavity 21 is configured to accommodate the connection parts 501, 502, and 503, and the outlet 23 is configured to accommodate a portion of the cable 100 where the sheath 140 remains, a portion of the cable 200 where the sheath 240 remains, and a portion where the sheath 340 of the cable 300 remains. The structure is such that it can accommodate the remaining parts.

Tank 40 contains electrically insulating material. The tank 40 is provided with a temperature control device such as a heater, and stores the electrically insulating material in a fluid state. The gun 30 and the tank 40 are connected by a hose 50, and a fluid electrically insulating material is supplied from the tank 40 to the gun 30 through the hose 50. The gun 30 is provided with a nozzle 31 that can be inserted into the inlet 22. Electrically insulating material is discharged from the nozzle 31 into the inlet 22 .

When manufacturing the unit cable 1, first, the cables 100, 200, and 300 shown in FIG. 3, crimp terminals 611, 621, and 631, and tubes 612, 622, and 632 are prepared.

Next, the exposed portions 113, 213, and 313 are accommodated in the crimp terminal 611, and the crimp terminal 611 is caulked. Further, the exposed portions 123, 223, and 323 are accommodated in the crimp terminal 621, and the crimp terminal 621 is caulked. Further, the exposed portions 133, 233, and 333 are accommodated in the crimp terminal 631, and the crimp terminal 631 is caulked. In this way, connection parts 501, 502 and 503 are formed.

Next, the connecting portion 501 is housed in the tube 612 through the slit 613, the connecting portion 502 is housed in the tube 622 through the slit 623, and the connecting portion 503 is housed in the tube 632 through the slit 633.

Next, the cables 100, 200, and 300 are stacked so that the cable 200 is sandwiched between the cables 100 and 300, and the cables 100, 200, and 300 are placed in the mold 10. At this time, the connecting parts 501, 502, and 503 are housed in the cavity 21, and the sheaths 140, 240, and 340 are sandwiched between the lower mold 11 and the upper mold 12 at the outlet 23.

Next, a fluid electrically insulating material is supplied from the tank 40 to the gun 30, and the electrically insulating material is supplied from the gun 30 to the mold 10. Electrically insulating material flows into cavity 21 via inlet 22 and further towards outlet 23 . In this way, cavity 21 and outlet 23 are filled with electrically insulating material. Next, the electrically insulating material is hardened by cooling or the like. As a result, mold 400 is formed. Then, the mold 10 is opened.

In this way, the unit cable 1 according to the first embodiment can be manufactured.

In the unit cable 1, in the cross section (YZ plane) perpendicular to the X1-X2 direction (longitudinal direction), the connection parts 501 and 502 are arranged along the first direction, and the connection parts 502 and 503 are arranged in the first direction, which is different from the first direction. They are lined up along two directions (Y1-Y2 direction). Therefore, a large area of the surface of the mold 400 that follows the outer periphery of the connecting portions 501, 502, and 503 can be secured. Therefore, even if a crack occurs in the mold 400, separation of the mold 400 from the connecting portions 501, 502, and 503 can be suppressed.

In particular, when viewed from the direction perpendicular to the longitudinal direction and the second direction (Z1-Z2 direction), the connecting portion 501 is located between the connecting portions 502 and 503, thereby making it easier to remove the mold 400. Easy to suppress. Furthermore, since the region 410 is filled with the mold 400, detachment of the mold 400 can be more easily suppressed.

By using the electrically insulating tubes 612, 622, and 632, it is easy to electrically insulate the connecting portions 501, 502, and 503 from each other. Since the slits 613, 623 and 633 are formed in the tubes 612, 622 and 632, respectively, the connection parts 501, 502 and 503 can be easily accommodated in the tubes 612, 622 and 632, respectively. The insides of the tubes 612, 622, and 632 may not be filled with the electrically insulating material of the mold 400, and air may exist inside the tubes 612, 622, and 632. The insides of the tubes 612, 622, and 632 may be filled with the electrically insulating material of the mold 400, and the insides of the tubes 612, 622, and 632 may be filled with the mold 400. In place of the electrically insulating tubes 612, 622, and 632, electrically insulating sheets may be used. In this case, air may exist inside the sheet without filling the electrically insulating material of the mold 400 to the inside of the sheet.

Moreover, since the crimp terminal 611 is used, it is easy to electrically connect the exposed parts 113, 213, and 313 while fixing them to each other. Since the crimp terminal 621 is used, it is easy to electrically connect the exposed parts 123, 223, and 323 while fixing them to each other. Since the crimp terminal 631 is used, it is easy to electrically connect the exposed parts 133, 233, and 333 while fixing them to each other.

When the cables 100, 200, and 300 are flat cables, the unit cable 1 can be constructed using commonly used flat cables. At this time, when the plane 152 and the plane 251 are facing each other, it is easy to line up the cable 100 and the cable 200, and when the plane 252 and the plane 351 are facing each other, it is easy to line up the cable 200 and the cable 300. Further, if the cables 100 and 200 are spaced apart from each other in the mold 400 except for the connection parts 501, 502, and 503, it is easier to fix the cables 100 and 200 when forming the mold 400, and the cables 200 and 300 are separated from each other. If they are spaced apart, it is easier to fix the cables 200 and 300 when forming the mold 400. Furthermore, if the gap between the cables 100 and 200 is filled with the mold 400, the cables 100 and 200 are easily fixed by the mold 400, and the gap between the cables 200 and 300 is filled with the mold 400. If the cables 200 and 300 are fixed easily by the mold 400.

When the sheath 140 covers the insulated wires 110, 120, and 130, the sheath 140 can bundle the insulated wires 110, 120, and 130. Sheath 140 may cover insulated wires 110 and 120, and insulated wire 130 may be in contact with sheath 140 along the longitudinal direction. In this case, the insulated wires 110 and 120 can be bundled by the sheath 140. When the sheath 240 covers the insulated wires 210, 220, and 230, the sheath 240 can bundle the insulated wires 210, 220, and 230. Sheath 240 may cover insulated wires 210 and 220, and insulated wire 230 may contact sheath 240 along the longitudinal direction. In this case, the insulated wires 210 and 220 can be bundled by the sheath 240. When the sheath 340 covers the insulated wires 310, 320, and 330, the sheath 340 can bundle the insulated wires 310, 320, and 330. A sheath 340 may cover the insulated wires 310 and 320, and the insulated wire 330 may be in contact with the sheath 340 along the longitudinal direction. In this case, the insulated wires 310 and 320 can be bundled by the sheath 340. When the sheaths 140, 240, and 340 contain foamed resin, it is easy to obtain good flexibility in the cables 100, 200, and 300, respectively.

If the sheath 140 is on both sides of the intermediate portion 101 in the longitudinal direction of the cable 100 and the mold 400 is in contact with the sheath 140, the position of the cable 100 can be fixed through the sheath 140. If the sheath 240 is on both sides of the intermediate portion 201 in the longitudinal direction of the cable 200 and the mold 400 is in contact with the sheath 240, the position of the cable 200 can be fixed through the sheath 240. When the sheath 340 is on both sides of the intermediate portion 301 in the longitudinal direction of the cable 300 and the mold 400 is in contact with the sheath 340, the position of the cable 300 can be fixed through the sheath 340.

The conductors 111, 121, 131, 211, 221, 231, 311, 321 and 331 are either copper wires, copper alloy wires, or copper clad aluminum wires in which a copper layer is formed on the surface of an aluminum core wire, Easy to obtain good conductivity.

When the material of the mold 400 is at least one selected from the group consisting of polyamide, polyester, olefin, and urethane, the mold 400 can be formed by a hot melt molding method.

(Second embodiment)
Next, a second embodiment will be described. The second embodiment differs from the first embodiment mainly in the number of insulated wires included in each cable. 8 and 9 are cross-sectional views showing a unit cable according to the second embodiment.

The unit cable 2 according to the second embodiment mainly includes cables 100A, 200A, and 300A instead of the cables 100, 200, and 300.

As shown in FIG. 8, the cable 100A includes an insulated wire 110, an insulated wire 120, and a sheath 140, but does not include an insulated wire 130. The cable 200A includes an insulated wire 210, an insulated wire 220, and a sheath 240, but does not include an insulated wire 230. The cable 300A includes an insulated wire 310, an insulated wire 320, and a sheath 340, but does not include an insulated wire 330. The insulated wire 110 is an example of a first insulated wire, and the insulated wire 120 is an example of a second insulated wire. The insulated wire 210 is another example of the third insulated wire, and the insulated wire 220 is another example of the fourth insulated wire.

Further, the unit cable 2 includes a crimp terminal 611, a crimp terminal 621, a tube 612, and a tube 622, but does not have a crimp terminal 631 and a tube 632.

As shown in FIG. 9, at least a portion of the connecting portion 501 and at least a portion of the connecting portion 502 are located outside the outer periphery of the cables 100, 200, and 300 when viewed from the longitudinal direction.

The other configurations are the same as in the first embodiment.

The second embodiment also provides the same effects as the first embodiment. That is, even if a crack occurs in the mold 400, separation of the mold 400 from the connecting portions 501, 502, and 503 can be suppressed.

Note that, for example, one of the cables 100, 200, and 300 may be a main line, and the other two may be branch lines. The insulated wire included in the main line may be thicker than the insulated wire included in the branch line. The insulated wire included in the main line and the insulated wire included in the branch line may have the same thickness.

Cables 100, 200 and 300 are not limited to VVF cables. For example, round cables such as VCT (vinyl cabtire) cables may be used for cables 100, 200, and 300. Furthermore, the number of insulated wires included in each cable may be four or more. Further, the number of insulated wires included in the cables does not need to be the same among the plurality of cables.

Further, the cable may be divided in the longitudinal direction at the exposed portion. In this case, the ends of the divided cable are examples of the first region, the second region, and the third region.

Although the embodiments have been described in detail above, they are not limited to specific embodiments, and various modifications and changes are possible within the scope of the claims.

1, 2: Unit cable 5: Hot melt molding machine 10: Mold 11: Lower mold 12: Upper mold 21: Cavity 22: Inlet 23: Outlet 30: Gun 31: Nozzle 40: Tank 50: Hose 100, 100A , 200, 200A, 300, 300A: Cable 101, 201, 301: Intermediate portion 110, 120, 130, 210, 220, 230, 310, 320, 330: Insulated wire 111, 121, 131, 211, 221, 231, 311, 321, 331: Conductor 112, 122, 132, 212, 222, 232, 312, 322, 332: Insulating layer 113, 123, 133, 213, 223, 233, 313, 323, 333: Exposed portion 140, 240 , 340: Sheath 151, 152, 251, 252, 351, 352: Plane 153, 154, 253, 254, 353, 354: Curved surface 400: Mold 410: Area 421, 422: Surface 501, 502, 503: Connection part 611 , 621, 631: Crimp terminal 612, 622, 632: Tube 613, 623, 633: Slit

Claims (24)

A first cable including a first insulated wire, a second insulated wire, and a third insulated wire;
a second cable arranged along the first cable and including a fourth insulated wire, a fifth insulated wire, and a sixth insulated wire;
has
The first cable has a first region in its longitudinal direction,
a first exposed portion in which a conductor of the first insulated wire is exposed;
a second exposed portion in which a conductor of the second insulated wire is exposed;
a third exposed portion in which a conductor of the third insulated wire is exposed;
has
In a second longitudinal region of the second cable,
a fourth exposed portion in which a conductor of the fourth insulated wire is exposed;
a fifth exposed portion in which a conductor of the fifth insulated wire is exposed;
a sixth exposed portion in which a conductor of the sixth insulated wire is exposed;
has
a first connection part in which the first exposed part and the fourth exposed part are electrically connected to each other;
a second connection part in which the second exposed part and the fifth exposed part are electrically connected to each other;
a third connection part in which the third exposed part and the sixth exposed part are electrically connected to each other;
an electrically insulating mold that covers the first connection part, the second connection part, and the third connection part;
has
The first connection part, the second connection part, and the third connection part are electrically insulated from each other,
The first connecting portion and the second connecting portion are arranged along the first direction in a cross section perpendicular to the longitudinal direction,
The second connecting portion and the third connecting portion are unit cables arranged along a second direction different from the first direction in the cross section. The unit cable according to claim 1, wherein the first connecting portion is located between the second connecting portion and the third connecting portion when viewed from a direction perpendicular to the longitudinal direction and the second direction. . The unit cable according to claim 1 or 2, further comprising a filling area surrounded by the first connecting part, the second connecting part, and the third connecting part and filled with the mold. an electrically insulating tube covering the first connection part;
The unit cable according to any one of claims 1 to 3, wherein the mold covers the first connection portion covered with the tube. The unit cable according to claim 4, wherein the tube is provided with a cut. The unit cable according to claim 4 or 5, wherein air exists inside the tube. The unit cable according to claim 4 or 5, wherein the inside of the tube is filled with the mold. an electrically insulating sheet covering the first connection portion;
The unit cable according to any one of claims 1 to 3, wherein the mold covers the first connection portion covered with the sheet. The unit cable according to claim 8, wherein air exists inside the sheet. The unit cable according to any one of claims 1 to 9, wherein at least a portion of the first connection portion is located outside an outer periphery of the first cable when viewed from the longitudinal direction. . The unit cable according to any one of claims 1 to 10, wherein the first connecting part includes a connector that electrically connects the first exposed part and the fourth exposed part to each other. The first cable is a first flat cable,
The unit cable according to any one of claims 1 to 11, wherein the second cable is a second flat cable. The first flat cable is
a first plane and a second plane along the longitudinal direction;
a first curved surface connecting one end of the first plane and one end of the second plane in the transverse direction perpendicular to the longitudinal direction;
a second curved surface connecting the other end of the first plane and the other end of the second plane in the lateral direction;
has
The second flat cable is
a third plane and a fourth plane along the longitudinal direction;
a third curved surface connecting one end of the third plane and one end of the fourth plane in the lateral direction;
a fourth curved surface connecting the other end of the third plane and the other end of the fourth plane in the lateral direction;
has
The unit cable according to claim 12, wherein the second plane and the third plane face each other. 14. The first flat cable and the second flat cable are spaced apart from each other in the mold, except for the first connecting part, the second connecting part, and the third connecting part. Unit cable listed. 15. The unit cable of claim 14, wherein a gap between the first flat cable and the second flat cable is filled with the mold. The unit cable according to any one of claims 12 to 15, wherein the first flat cable includes a sheath that covers the first insulated wire, the second insulated wire, and the third insulated wire. The first flat cable has a sheath that covers the first insulated wire and the second insulated wire,
The unit cable according to any one of claims 12 to 15, wherein the third insulated wire is in contact with the sheath along the longitudinal direction. The unit cable according to claim 16 or 17, wherein the sheath includes a foamed resin. The sheath is on both sides of the first region in the longitudinal direction of the first flat cable,
The unit cable according to any one of claims 16 to 18, wherein the mold is in contact with the sheath. 20. The conductor of the first insulated wire is any one of a copper wire, a copper alloy wire, or a copper clad aluminum wire in which a copper layer is formed on the surface of an aluminum core wire. Unit cable listed in. The unit cable according to any one of claims 1 to 20, wherein the mold material is at least one selected from the group consisting of polyamide, polyester, olefin, and urethane. A first cable including a first insulated wire, a second insulated wire, and a third insulated wire;
a second cable arranged along the first cable and including a fourth insulated wire, a fifth insulated wire, and a sixth insulated wire;
has
The first cable has a first region in its longitudinal direction,
a first exposed portion in which a conductor of the first insulated wire is exposed;
a second exposed portion in which a conductor of the second insulated wire is exposed;
a third exposed portion in which a conductor of the third insulated wire is exposed;
has
In a second longitudinal region of the second cable,
a fourth exposed portion in which a conductor of the fourth insulated wire is exposed;
a fifth exposed portion in which a conductor of the fifth insulated wire is exposed;
a sixth exposed portion in which a conductor of the sixth insulated wire is exposed;
has
a first connection part in which the first exposed part and the fourth exposed part are electrically connected to each other;
a second connection part in which the second exposed part and the fifth exposed part are electrically connected to each other;
a third connection part in which the third exposed part and the sixth exposed part are electrically connected to each other;
an electrically insulating mold that covers the first connection part, the second connection part, and the third connection part;
has
The first connection part, the second connection part, and the third connection part are electrically insulated from each other,
A unit cable in which the mold material is at least one selected from the group consisting of polyamide, polyester, olefin, and urethane. a first cable including a first insulated wire and a second insulated wire;
a second cable disposed along the first cable and including a third insulated wire and a fourth insulated wire;
has
The first cable has a first region in its longitudinal direction,
a first exposed portion in which a conductor of the first insulated wire is exposed;
a second exposed portion in which a conductor of the second insulated wire is exposed;
has
In a second longitudinal region of the second cable,
a third exposed portion in which a conductor of the third insulated wire is exposed;
a fourth exposed portion in which a conductor of the fourth insulated wire is exposed;
has
a first connection part in which the first exposed part and the third exposed part are electrically connected to each other;
a second connection part in which the second exposed part and the fourth exposed part are electrically connected to each other;
an electrically insulating mold that covers the first connection part and the second connection part;
has
The first connection part and the second connection part are electrically insulated from each other,
When viewed from the longitudinal direction, at least a portion of the first connection portion is located outside an outer periphery of the first cable. A method for manufacturing a unit cable according to any one of claims 1 to 22, comprising:
a first cable including the first insulated wire, the second insulated wire, and the third insulated wire, and having the first exposed portion, the second exposed portion, and the third exposed portion; and the fourth insulated wire, preparing a second cable including the fifth insulated wire and the sixth insulated wire and having the fourth exposed portion, the fifth exposed portion, and the sixth exposed portion;
electrically connecting the first exposed part and the fourth exposed part to each other to form the first connecting part;
forming the second connection part that electrically connects the second exposed part and the fifth exposed part to each other;
forming the third connection part that electrically connects the third exposed part and the sixth exposed part to each other;
fixing the first cable and the second cable in which the first connection part, the second connection part, and the third connection part are formed to a mold;
supplying a fluid electrically insulating material into the mold to which the first cable and the second cable are fixed;
curing the electrically insulating material supplied into the mold;
has
The mold has a cavity, an inlet and an outlet,
the inlet and the outlet are connected to the cavity;
The first cable and the second cable can be accommodated within the outlet and the cavity,
The first connection part, the second connection part, and the third connection part can be accommodated in the cavity,
The step of fixing the first cable and the second cable to a mold includes:
arranging the first connection part, the second connection part, and the third connection part in the cavity;
arranging portions of the first cable on both sides of the first region and portions of the second cable on both sides of the second region in the outlet;
has
A method for manufacturing a unit cable, wherein the step of supplying an electrically insulating material includes a step of flowing the electrically insulating material from the inlet through the cavity toward the outlet.

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