JP6075275B2 - Manufacturing method of cable with resin mold - Google Patents

Description

The present invention relates to a method for manufacturing a cable with a resin mold.

  2. Description of the Related Art Conventionally, a cable with a resin mold in which a resin mold is formed at the tip of the cable is known (see, for example, Patent Document 1).

  In a cable with a resin mold, a resin mold is formed so that the tip of the cable and the members (sensor part, terminal, circuit board, etc.) connected to the tip of the cable are collectively covered. A sheath (insulator formed on the outermost periphery of the cable) is welded to be waterproof.

  As a cable with a resin mold in which a sensor part is built in a resin mold, for example, an ABS sensor or a torque sensor is known.

Japanese Patent No. 4487551

  By the way, when attaching a cable with a resin mold, there is a case where it is desired to route the cable in a direction perpendicular to a direction in which the cable extends from the resin mold (referred to as a cable extension direction).

  In particular, when the wiring space is small, such as a vehicle, it is desired to make the cable wiring space as small as possible. When routing the cable in the direction perpendicular to the cable extension direction, the resin in the cable extension direction is required. It is desirable to make the protruding length of the cable from the mold as small as possible.

  However, in a conventional cable with a resin mold, if the protruding length of the cable in the extending direction from the resin mold is to be shortened, the cable is bent with a small radius of curvature, and the cable from the resin mold in the cable that is the starting point of the bending There is a problem that stress concentrates on the extended portion, and stress is repeatedly applied to the extended portion of the cable due to vibration, thereby causing breakage of the conductor and damage to an insulator such as a sheath.

  Therefore, the object of the present invention is to solve the above problems, and when the cable is routed from the resin mold in the direction perpendicular to the cable extension direction, the protruding length of the cable from the resin mold in the cable extension direction can be shortened, And it is providing the cable with a resin mold which can suppress the disconnection of a conductor and the damage of an insulator.

  The present invention was devised to achieve the above object, and a resin having a conductor and an insulator provided around the conductor and a resin molded so as to cover the outer periphery of the tip of the cable. A resin-molded cable comprising: a resin mold formed in such a manner that at least a portion of a corner of a peripheral edge of the cable extension portion of the resin mold is rounded; It is a cable with a resin mold in which a guide portion serving as a guide for guiding the cable when bent in a direction perpendicular to the outgoing direction is formed.

  You may form the said guide part over the perimeter of the periphery of the cable extension part of the said resin mold.

  The curvature radius of the guide part may be 0.1 mm or more.

  A gap may be provided around the cable extension part, and the guide part may be provided at the periphery of the gap.

  The depth of the gap along the cable longitudinal direction may be 0.1 mm or more, and the width of the gap along the radial direction of the cable may be 0.1 mm or more.

  The resin mold may be formed so as to cover an outer periphery of a sensor unit, a terminal, or a circuit board connected to the tip of the cable.

  According to the present invention, when a cable is routed from the resin mold in the direction perpendicular to the cable extending direction, the length of the cable protruding from the resin mold in the cable extending direction can be shortened, and the conductor is disconnected or insulated. It is possible to provide a cable with a resin mold that can suppress damage to the cable.

It is a figure which shows the cable with a resin mold which concerns on one Embodiment of this invention, (a) is a side view in the state which does not bend a cable, (b) is a side view when a cable is bent, (c) is a cable FIG. 4D is a rear view when the cable is bent, and FIG. It is a principal part expanded sectional view which shows the modification of the cable with a resin mold of FIG. It is a figure explaining the manufacturing method of the cable with a resin mold of FIG. It is a principal part expanded sectional view which shows the modification of the cable with a resin mold of FIG.

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

  FIG. 1 is a view showing a resin-molded cable according to the present embodiment, wherein (a) is a side view without bending the cable, (b) is a side view when the cable is bent, and (c) is a side view. The rear view when a cable is bent, (d) is a principal part expanded sectional view when a cable is bent.

  As shown in FIGS. 1A to 1D, a cable 1 with a resin mold includes a cable 2 and a resin mold 3 formed by molding a resin so as to cover the outer periphery of the distal end portion of the cable 2. I have.

  The cable 2 includes a plurality of insulated wires 4 provided with an insulator 4b around a conductor 4a, and a sheath 5 that is an insulator formed so as to collectively cover the periphery of the plurality of insulated wires 4. Yes. In the present embodiment, the insulator formed on the outermost periphery of the cable 2 is referred to as a sheath 5. Here, although the case where the 2-core cable 2 provided with the two insulated wires 4 is used is demonstrated, the number of the insulated wires 4 provided in the cable 2 may be three or more. Further, an external conductor or the like may be provided between the plurality of insulated wires 4 and the sheath 5.

  The resin mold 3 is formed so as to cover the outer periphery of a member such as a sensor unit, a terminal, or a circuit board connected to the tip of the cable 2. Examples of the resin-molded cable 1 in which the sensor part is built in the resin mold 3 include an ABS sensor, a torque sensor, a rotation sensor, and a temperature sensor.

  In a normal cable with a resin mold, the resin mold 3 is generally formed so as to cover the sheath 5 of the cable 2. In this case, the cable 2 is arranged in a direction perpendicular to the cable extending direction from the resin mold 3. Since the diameter of the cable 2 at the portion of the cable 2 to be bent becomes large, the radius of curvature at the time of bending the cable 2 increases, and the protruding length d of the cable 2 from the resin mold 3 in the cable extending direction increases. The protrusion length d of the cable 2 is more specifically defined between the intersection point O between the central axis O1 of the cable 2 before bending and the central axis O2 of the cable 2 after bending, and the end surface of the resin mold 3. It represents the distance along the cable extension direction.

  Therefore, in the present embodiment, the plurality of insulated wires 4 are exposed from the sheath 5 at the distal end portion of the cable 2, and the resin mold 3 is formed so as to cover the outer periphery of the exposed plurality of insulated wires 4. .

  As a result, it is possible to bend the cable 2 in a direction perpendicular to the cable extending direction by simply bending the insulated wire 4 having a small outer diameter, and to reduce the protruding length d of the cable 2 in the cable extending direction. become.

  The outer diameter of the insulated wire 4 is 1.0 mm or more and 3.0 mm or less, preferably 1.2 mm or more and 1.7 mm or less. This is because if the outer diameter of the insulated wire 4 is too large, the radius of curvature at the time of bending increases and the protruding length d of the cable 2 in the cable extending direction increases, and if the outer diameter of the insulated wire 4 is too small, This is because the mechanical strength of the insulated wire 4 is lowered and the reliability is lowered. Here, an insulated wire 4 having an outer diameter of 1.5 mm was used.

  The Shore A hardness of the insulator 4b of the insulated wire 4 is preferably 40 or more and 95 or less. If the hardness of the insulator 4b is too large, the radius of curvature at the time of bending becomes large, and the protruding length d of the cable 2 in the cable extending direction becomes large. If the hardness of the insulator 4b is too small, the conductor by the insulator 4b This is because 4a cannot be sufficiently protected.

  The thickness of the insulator 4b of the insulated wire 4 is preferably 0.2 mm or more and 1.3 mm or less. If the thickness of the insulator 4b is too large, the radius of curvature at the time of bending increases, and the protruding length d of the cable 2 in the cable extending direction increases. If the thickness of the insulator 4b is too small, the insulator 4b This is because the conductor 4a cannot be sufficiently protected.

  In the cable 1 with a resin mold, the insulator 4b is welded to the resin mold 3 when the resin mold 3 is formed, and the insulator 4b and the resin mold 3 are sealed in a watertight manner. As the material of the insulator 4b, it is necessary to use a material that is easily welded to the resin mold 3 when the resin mold 3 is formed. For example, when a nylon resin is used as the resin mold 3, a urethane resin can be used as the insulator 4b. Moreover, when using PBT (polybutylene terephthalate) as the resin mold 3, EVA (ethylene vinyl acetate) can be used as the insulator 4b.

  The distance between the resin mold 3 and the sheath 5, that is, the distance at which the insulated wire 4 is exposed from the end portion of the sheath 5 to the resin mold 3, can be made as small as possible to suppress damage to the insulated wire 4 due to chipping. Desirably, 20 mm or less is desirable. Here, the distance between the resin mold 3 and the sheath 5 was 10 mm.

  If the sheath 5 interferes with the resin mold 3 when the cable 2 is bent in the direction perpendicular to the extending direction, the cable 2 has a large wiring space. It is desirable that the distance is such that the resin mold 3 and the sheath 5 do not interfere when the cable 2 is bent in a direction perpendicular to the extending direction.

  The insulated wire 4 is extended from the resin mold 3 while being aligned in a straight line, and is bent and wired in a direction perpendicular to the arrangement direction and the cable extending direction. ing. By comprising in this way, since the insulated wire 4 does not overlap in the bending direction, the protruding length d of the cable 2 in the cable extending direction can be further reduced.

  Now, in the cable 1 with a resin mold according to the present embodiment, the resin mold 3 is provided at the tip of the insulated wire 4 exposed from the end of the sheath 5 as described above. In the cable 1 with a resin mold, the insulated wire 4 having a small outer diameter is bent. Therefore, the insulated wire 4 is bent with an extremely small radius of curvature, or the insulated wire 4 is extended from the resin mold 3. When the stress is concentrated in the protruding portion, the conductor 4a is easily disconnected or the insulator 4b is easily damaged when a stress is repeatedly applied to the bent portion of the cable 2 due to vehicle vibration or the like.

  Therefore, in the cable 1 with the resin mold, at least a part of the corner of the periphery of the cable extension portion of the resin mold 3 (here, the extension portion of the insulated wire 4) is rounded, and the cable 2 is A guide portion 6 is formed as a guide along which the cable 2 (insulated wire 4 here) runs when bent in the direction perpendicular to the extending direction.

  By forming the guide portion 6, the cable 2 (insulated wire 4 here) is bent along the guide portion 6, so that the radius of curvature when bent in the direction perpendicular to the cable extension direction is extremely large. It is possible to suppress the reduction. Further, since the bent portion of the cable 2 (here, the insulated wire 4) can be supported on the surface by the guide portion 6, it is possible to suppress the concentration of stress on the extended portion from the resin mold 3. Thus, it is possible to prevent the conductor 4a from being broken or the insulator 4b from being damaged due to vehicle vibration or the like.

  In this embodiment, in order to improve versatility without limiting the bending direction of the cable 2, the guide portion 6 is formed over the entire periphery of the cable extension portion of the resin mold 3. If the bending direction is determined, the guide portion 6 may be formed only in the bending direction.

  The radius of curvature of the guide portion 6 is desirably 0.1 mm or more. This is because if the curvature radius of the guide portion 6 is reduced to less than 0.1 mm, the guide portion 6 becomes close to a rounded state, and the effect of forming the guide portion 6 cannot be sufficiently obtained. If the radius of curvature of the guide portion 6 is excessively increased, the resin mold 3 is increased in size. Therefore, the radius of curvature of the guide portion 6 is 0.1 mm to 2.5 mm, preferably 0.3 mm to 1.5 mm. .

  In the cable 1 with a resin mold of FIG. 1, a gap 7 is provided around the cable extension portion, and a guide portion 6 is provided on the periphery of the gap 7. However, the present invention is not limited to this, and it is of course possible to omit the gap 7 and form only the guide portion 6 as shown in FIG.

  Here, the advantage of providing the gap 7 will be described.

  As shown in FIG. 3, the resin mold 3 is formed by using a mold 31 and flowing a resin from a resin inlet 32 of the mold 31. In FIG. 3, the case where the sensor part 34 is incorporated in the resin mold 3 is shown. As the mold 31, it is necessary to use a portion in which the projection 33 is formed in a portion where the guide portion 6 is formed. However, when only the guide portion 6 is formed without forming the gap 7, In some cases, the tip becomes thin and sufficient mechanical strength cannot be obtained. By forming the gap 7, it is possible to secure the thickness of the protrusion 33 and improve the mechanical strength, thereby enabling stable production.

  In order to maintain the mechanical strength of the protrusion 33, the depth d of the gap 7 along the cable longitudinal direction is preferably 0.1 mm or more, and the width w of the gap 7 along the radial direction of the cable 2 is 0. It is desirable that it is 1 mm or more. In addition, when the width w of the gap 7 is increased, stress may be concentrated on a portion of the cable 2 (here, the insulated wire 4) extending to the gap 7, but in this case, as shown in FIG. Further, the second guide portion 41 can be formed by forming the peripheral edge of the extension portion of the cable 2 (here, the insulated wire 4) into the gap 7 in a rounded shape.

  Furthermore, the guide portion 6 may be formed in three or more stages. That is, it is possible to form the guide portion 6 in multiple stages by forming the gap 7 in a stepped manner so that the diameter increases, and forming the rounded guide portions 6 at the corner portions where the diameter changes. Is possible. By combining the gap 7 and the guide portion 6, local stress applied to the cable 2 (here, the insulated wire 4) is dispersed at the cable extension portion of the resin mold 3, thereby breaking or insulating the conductor 4 a. It is possible to further reduce the risk of damage to the body 4b.

  In addition, when resin is molded using the mold 31, the resin is welded to the outermost insulating layer (here, the insulator 4b). As long as the guide portion 6 is not formed, a shape corresponding to the guide portion 6 is not formed around the cable extension portion by chance.

  As described above, in the cable 1 with a resin mold according to this embodiment, at least a part of the peripheral edge of the cable extension portion of the resin mold 3 is formed to be rounded, and the cable 2 is extended. A guide portion 6 is formed as a guide for guiding the cable 2 (here, the insulated wire 4) when bent in the direction perpendicular to the direction.

  By forming the guide portion 6, the cable 2 (here, the insulated wire 4) is bent along the guide portion 6 when the cable 2 is routed from the resin mold 3 in the direction perpendicular to the cable extension direction. Thus, it can be suppressed that the radius of curvature at the time of bending becomes extremely small. Further, by forming the guide portion 6, the bent portion of the cable 2 (here, the insulated wire 4) can be supported by the surface, and stress is prevented from concentrating on the extended portion from the resin mold 3. It becomes possible. As a result, it is possible to prevent the conductor 4a from being broken or the insulator 4b from being damaged due to vehicle vibration or the like.

  Moreover, since it becomes possible to suppress problems, such as a disconnection, by forming the guide part 6, it becomes possible to use the small diameter cable 2 (here, the insulated wire 4), and the cable from the resin mold 3 in the cable extending direction. The projection length d of 2 can be reduced, and the limited wiring space can be used effectively.

  Moreover, in the cable 1 with a resin mold according to the present embodiment, a plurality of insulated wires 4 are exposed from the sheath 5 at the distal end portion of the cable 2, and the resin is so covered as to cover the outer periphery of the exposed plurality of insulated wires 4. A mold 3 is formed.

  As a result, it is possible to bend the cable 2 in a direction perpendicular to the cable extending direction by simply bending the insulated wire 4 having a small outer diameter, and to reduce the protruding length d of the cable 2 in the cable extending direction. become.

  Moreover, since it becomes possible to bend the cable 2 in the direction perpendicular to the cable extension direction by simply bending the insulated wire 4 having a small outer diameter, it is possible to suppress the concentration of large stress on the cable extension portion of the resin mold 3. As a result, the disconnection of the conductor 4a and the damage to the insulator 4b can be suppressed.

  Furthermore, in the cable 1 with a resin mold, since the sheath 5 is separated from the resin mold 3, it is possible to use a sheath 5 that is difficult to weld to the resin mold 3. Therefore, an inexpensive material can be used as the material used for the sheath 5, or a material having a specific function can be used as necessary.

  The present invention is not limited to the above-described embodiment, and it is needless to say that various modifications can be made without departing from the spirit of the present invention.

  For example, in the said embodiment, although the resin mold 3 was formed so that the outer periphery of the insulated wire 4 extended from the front-end | tip part of the cable 2 might be covered, for example, when the diameter of the cable 2 to be used is small, etc. You may form the resin mold 3 so that the outer periphery of a front-end | tip part may be covered. That is, the present invention is naturally applicable to a general structure in which the resin mold 3 is formed so as to cover the outer periphery of the sheath 5 that covers the outermost periphery of the multi-core cable 2, and the same effect can be obtained. it can.

1 Cable with Resin Mold 2 Cable 3 Resin Mold 4 Insulated Wire 4a Conductor 4b Insulator 5 Sheath 6 Guide 7 Clearance

Claims (6)

A cable having a conductor and an insulator provided around the conductor, and a resin mold formed by molding a resin so as to cover the outer periphery of the tip of the cable ,
A gap was provided around the cable extension portion of the resin mold, and at least a part of the corner of the periphery of the gap was formed to be rounded, and the cable was bent in a direction perpendicular to the extension direction. A method of manufacturing a cable with a resin mold in which a guide portion serving as a guide along the cable is formed ,
A resin-molded cable characterized by forming a resin mold by using a mold in which a protrusion is formed in a portion that forms the gap with the guide portion, and allowing a resin to flow from a resin inlet of the mold . Manufacturing method . The manufacturing method of the cable with a resin mold of Claim 1. The said guide part was formed over the perimeter of the peripheral edge of the cable extension part of the said resin mold. The manufacturing method of the cable with a resin mold of Claim 1 or 2 whose curvature radius of the said guide part is 0.1 mm or more. The manufacturing method of the cable with a resin mold in any one of Claims 1-3 which welds the said insulator to the said resin mold when forming the said resin mold, and seals between the said insulator and the said resin mold watertight . Producing depth of the gap along the cable longitudinal direction is at 0.1mm or more, the width of the gap in the radial direction of the cable of the resin mold with cable according to claim 4, wherein at 0.1mm or more Way . The method for manufacturing a cable with a resin mold according to claim 1, wherein the resin mold is formed so as to cover an outer periphery of a sensor unit, a terminal, or a circuit board connected to the tip of the cable.

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