JP7316980B2 - Flat electric wire, wire harness, and flat electric wire manufacturing method - Google Patents

Description

The present invention relates to a flat electric wire that can be used as a high-voltage wire harness for vehicles having high-voltage circuits such as electric vehicles, a wire harness, and a method for manufacturing a flat electric wire.

2. Description of the Related Art In recent years, development of vehicles such as electric vehicles and hybrid vehicles using motors as a drive source has been progressing. Electric wires (wire harnesses) such as power lines installed in these vehicles generate more heat when energized with the increase in the output of motors, and tend to reach high temperatures.

In response to such problems, for example, in Patent Document 1, as a wire harness that has excellent heat dissipation compared to conventional wire harnesses in which a plurality of wires are bundled, a plurality of conductors are arranged in parallel and covered with a resin coating. A wire harness is proposed in which flat electric wires are bundled together. 1(B), 4(B), 4(C), 6, 8, and 9(A) of Patent Document 1 are known as the cross section of the flat electric wire. there is

Further, a flat electric wire 200 in which a braided conductor 201 that is a flat braided wire is covered with an insulating coating 202 as shown in FIG. 9 in this specification can also be used as a wire harness. The braided conductor 201, which is a flat braided wire, has a structure in which a plurality of braided wires in which bundled strands are braided are arranged in parallel, and the braided wire itself is a flexible conductor.

However, the flat electric wire (the conductor cross section is not shown in detail) shown as a conventional example in Patent Document 1 and FIG. ) has the characteristic that it is easy to bend, but it is difficult to bend in the width direction (the long side direction of the cross section: edgewise) of the flat electric wire where there is a large path difference between the outside in the bending direction and the inside in the bending direction.

Specifically, as shown in FIG. 10, when a wire harness made up of flat electric wires is bent in an edgewise direction Ew from a straight line indicated by a broken line in FIG. Therefore, the flat electric wire f is twisted so as to eliminate the route difference, and the demand for space saving of the wiring space cannot be satisfied. In addition, since the flat electric wire f is twisted so as to stand up in the bending direction, it becomes impossible to wire it in a wiring route with a narrow space in the thickness direction, or if it is forcedly wired, there is a risk that the internal conductor will be damaged. .

In addition, Patent Document 1 discloses a wire harness in which a plurality of flat electric wires are arranged in the width direction, the vicinity of the bent portion is fixed with a clamp, and the wire harness is laminated at the bent portion. also shows the clamping of the bends. However, the technique of Patent Document 1 does not solve the problem that the flat electric wire f itself is twisted and rises at the bent portion as shown in FIG. There was a risk that the clamps that attach the clamps might break during or after routing.

Furthermore, the exterior parts are limited to those that can accommodate the bent portion where the flat electric wire f is twisted and rises. The problem remains that the space efficiency of the cable is not improved.

JP 2012-125079 A

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a flat electric wire, a wire harness, and a method for manufacturing a flat electric wire having excellent edgewise flexibility.

The present invention relates to a flat stranded wire conductor having a substantially rectangular cross-section, in which a plurality of strands are twisted together in one direction in a circumferential shape to form an uneven outer surface, and an insulating coating part that covers the flat stranded wire conductor. The flat stranded conductor has a two-layer structure, and the plurality of strands constituting the flat stranded conductor are twisted in a substantially flat shape in cross section so that they can move relative to each other. , the insulating coating portion in the front view cross section is configured in a substantially rectangular shape covering the flat stranded conductor so as to maintain the cross-sectional shape of the bent flat stranded conductor, and the insulating coating portion in the front view cross section The inner surface is formed of a smooth surface that is slightly larger than an outline connecting convex portions of the flat stranded conductor having an uneven outer surface and does not bite into between the plurality of twisted strands, and is formed in the longitudinal direction of the cross section. The outer surface of the flat stranded conductor and the inner surface of the insulating coating part move relative to each other while maintaining the cross-sectional shape of the flat stranded conductor in which the insulating coating part is bent edgewise along the edgewise edge. , the strands constituting the flat stranded conductor move relative to each other and unravel in a fan shape, absorb the path difference between the inside of the bend and the outside of the bend, and maintain a flat state without rising in the bending direction. It is characterized by being a flat electric wire.

The wire includes not only a circular wire but also a substantially rectangular wire, and also includes a wire having excellent conductivity such as copper, copper alloy, aluminum, or aluminum alloy.
The substantially rectangular cross-section is, for example, a substantially rectangular cross-section formed by compressing strands twisted into an elliptical, oval, rectangular shape, or the like, a substantially rectangular cross-section formed by twisting the strands, or a substantially rectangular shape. A substantially rectangular cross section can be obtained by forming a desired shape by compression-molding the strands twisted together to have a substantially rectangular cross section.

If the insulating coating portion is configured such that the outer surface of the flat stranded conductor and the inner surface of the insulating coating portion are relatively movable so as to ensure the edgewise flexibility of the flat electric wire, Insulation covered parts covered by general covering methods such as extrusion molding, heat-shrinkable tube covering, baking, electrodeposition, vapor deposition, and laminate covering shall be included.

A flat stranded conductor having a substantially rectangular cross section, in which the above-described plurality of strands are twisted together in one direction in a circumferential shape to form an uneven outer surface, is obtained by Relative movement is possible. That is, the twisted strands are not fixed to each other and are relatively movable relative to each other. Further, as described above, the insulating coating is provided so as to ensure the edgewise flexibility of the flat electric wire. For example, by forming the inner surface of the insulating coating portion larger than the outer surface of the flat stranded conductor, or by interposing a separate slidable member at the boundary portion, the insulating coating portion is formed between the twisted strands. , and the insulating coating portion does not adhere to the outer surface of the above-described flat stranded conductor.
According to the present invention, edgewise flexibility can be improved.

More specifically, the flat electric wire of the present invention has a substantially rectangular cross section with high heat dissipation, and a plurality of strands that constitute a flat stranded conductor by being twisted together in one direction in a circumferential shape and having a substantially flat cross section. The inner surface of the insulating coating portion is formed as a convex portion in the flat stranded conductor having an uneven outer surface so that the flat electric wire can be relatively moved by being twisted and the edgewise flexibility of the flat electric wire is ensured. The inner surface of the insulation coating portion that covers the flat stranded conductor and the outer surface of the flat stranded conductor are composed of a smooth surface that is slightly larger than the outline connecting the and does not bite into between the plurality of strands that are twisted. is relatively movable, the flat electric wire is not twisted so as to stand up against the path difference between the inner side and the outer side of the bend that occurs when the flat electric wire is bent edgewise, and the plurality of strands, Further, the outer surface of the flat stranded conductor and the inner surface of the insulating coating part move relative to each other, so that edgewise flexibility can be improved.

Therefore, the flat electric wire of the present invention can save the wiring space and improve the wiring performance. In addition, since it has a larger surface area than an electric wire with a circular cross-section having the same conductor cross-sectional area and has high heat dissipation, it can be used as a high-voltage power line or wiring electric wire.
In addition, since the flat stranded conductor has a two-layer structure, edgewise flexibility can be further enhanced.

As an aspect of the present invention, the flattened stranded conductor may have an oblateness (width/thickness) of 8-15.
As an aspect of the present invention, the flat stranded conductor is configured by twisting 20 to 500 strands with a diameter of 0.1 to 2.0 mm in one direction at a twist pitch of 30 mm to 500 mm. may be

As an aspect of the present invention, a connection terminal can be attached to an end portion of the flat stranded conductor.
Advantageous Effects of Invention According to the present invention, it is possible to connect to an electric circuit through a connection terminal while having the effect of saving the wiring space and improving the wiring performance.

In general, in a flat electric wire to which a connection terminal is attached, the flat stranded wire conductor and the insulation coating portion are fixed by the connection terminal. A decrease in flexibility appears more remarkably. In other words, the edgewise flexibility is reduced, but the flat electric wire of the present invention is a flat twisted wire having a substantially rectangular cross section in which a plurality of wires are twisted together in one direction in a circumferential shape, and the outer surface has an uneven shape. A wire conductor is provided, and the plurality of strands constituting the flat stranded conductor move relative to each other, and the inner surface of the insulation covering covering the flat stranded conductor and the outer surface of the flat stranded conductor Due to the relative movement, the flat electric wire is not twisted so as to stand up, and a decrease in edgewise flexibility can be suppressed.

Moreover, as a mode of this invention, at least one of a shield layer and a waterproof layer can be provided outside the insulating coating portion.
Either the shield layer or the waterproof layer may be arranged so as to cover the outer side of the insulating coating portion, or the outer side of one of the shield layer and the waterproof layer covering the outer side of the insulating coating portion may be arranged. may be positioned such that the other further covers the other. Furthermore, the shield layer and the waterproof layer may be integrated with the insulating coating portion.

Advantageous Effects of Invention According to the present invention, a flat electric wire having excellent edgewise flexibility and at least one of shielding property and waterproof property can be configured, and versatility and applications can be expanded. In addition, there is no need to separately provide a shield member or a waterproof member for the flat electric wire.

Further, the present invention is characterized in that it is a wire harness in which a plurality of flat electric wires described above are bundled.
According to the present invention, a wire harness having edgewise flexibility can be constructed. In addition, since it has a larger surface area than an electric wire with a circular cross-section having the same conductor cross-sectional area, and has high heat dissipation, it can be used as a wire harness for high voltage or an electric wire for wiring.

Further, as an aspect of the present invention, the plurality of flat electric wires may be arranged in the longitudinal direction of the cross section in at least part of the longitudinal direction, and the plurality of flat electric wires may be arranged in at least part of the longitudinal direction. may be arranged in the short side direction of the cross section, and further, in a part of the longitudinal direction, the plurality of flat wires are arranged in the long side direction of the cross section, and the part in the longitudinal direction is A plurality of the flat wires may be arranged in the short side direction of the cross section in different portions.
According to these inventions, a wire harness having a plurality of flat electric wires can be configured in various modes according to applications and specifications without impairing edgewise flexibility.

Moreover, as an aspect of the present invention, at least one of the shield layer and the waterproof layer can be provided outside the wire harness composed of a plurality of flat electric wires.
Advantageous Effects of Invention According to the present invention, a wire harness having excellent edgewise flexibility and at least one of shielding property and waterproof property can be configured, and versatility and applications can be expanded.

In addition, compared to the case where at least one of the shield layer and the waterproof layer is individually provided on the outside of each flat electric wire, the wire harness composed of a plurality of flat electric wires is collectively provided with the shield layer and the waterproof layer. Since at least one of them is provided on the outside, it is possible to reduce the cost and trouble of providing the shield layer and the waterproof layer.

Further, according to the present invention, a plurality of strands supplied from a supply bobbin of a twisting machine are twisted together in one direction in a circumferential shape and in a substantially rectangular cross section, and the plurality of strands move relative to each other. In order to make it possible , a flat stranded conductor having a two-layer structure and an uneven outer surface is formed, and the outer surface of the flat stranded conductor is covered with an insulating coating so as to be relatively movable, The inner surface of the insulating coating portion in the front view cross section is a smooth surface that is slightly larger than the profile line that connects the convex portions of the flat stranded conductor having an uneven outer surface and that does not bite into between the plurality of strands that are stranded. and the insulating coating portion is configured in a substantially rectangular shape that covers the flat stranded conductor so as to maintain the cross-sectional shape of the bendable flat stranded conductor, and edgewise along the long side direction of the cross section In a state where the flat stranded conductor is bent, the outer surface of the flat stranded conductor and the inner surface of the insulating coating portion relatively move while maintaining the cross-sectional shape of the flat stranded conductor where the insulating coating portion is bent, and the flat twist The wires constituting the wire conductor move relative to each other and unravel in a fan shape, absorb the path difference between the inside of the bend and the outside of the bend, and maintain a flat state without standing up in the bending direction. It is characterized by being a manufacturing method of the flat electric wire which comprises .
According to the present invention, it is possible to configure a flat electric wire capable of improving edgewise flexibility.

Further, as an aspect of the present invention, a plurality of twisted strands can be compression-molded to form a desired substantially rectangular cross section.
According to the present invention, it is possible to accurately form a desired substantially rectangular cross-section, so that a flat electric wire having desired heat dissipation and flexibility can be reliably constructed.

ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the flat electric wire excellent in edgewise flexibility, a wire harness, and a flat electric wire can be provided.

The perspective view of a flat electric wire. Explanatory drawing about the edgewise bending of a flat electric wire. The block diagram of the manufacturing apparatus of a flat electric wire. The schematic block diagram of the mandrel in a manufacturing apparatus. The perspective view of a rectangular wire harness. The schematic perspective view of a cross-sectional deformation|transformation wire harness. Explanatory drawing of a cross-sectional deformation|transformation wire harness. The perspective view of the rectangular wire harness of another embodiment. FIG. 2 is a perspective view of a conventional flat electric wire composed of a braided conductor obtained by covering a flat braided wire with an insulating coating. The perspective view of the conventional wire harness bent edgewise.

One embodiment of the present invention will be described below with reference to the drawings.
FIG. 1 shows a perspective view of a flat electric wire 1, and FIG. 2 shows an explanatory diagram of edgewise bending of the flat electric wire 1. As shown in FIG. Specifically, FIG. 2A shows a cross-sectional view of the flat electric wire 1, and FIG. FIG. 2(c) shows a plan view of a flat stranded conductor 2 bent edgewise.

1 shows the insulation coating portion 4 in a transparent state, and FIG. Illustrated. 2(b) and 2(c), illustration of the insulation coating portion 4 is omitted.
3 shows a configuration diagram of a manufacturing apparatus 100 for the flat electric wire 1, and FIG. 4 shows a schematic configuration diagram of a mandrel 120 in the manufacturing apparatus 100. As shown in FIG.

FIG. 5 shows a perspective view of the rectangular wire harness 10, FIG. 6 shows a schematic perspective view of the cross-sectionally deformed wire harness 20, and FIG. More specifically, FIG. 6 also shows cross-sectional views of the circular cross-sectional portion 20a and the flat cross-sectional portion 20b in the schematic perspective view of the cross-sectionally deformed wire harness 20. As shown in FIG. 7A shows a cross-sectional view of a circular cross-sectional portion 20a in the cross-sectionally deformed wire harness 20, FIG. 7B shows a cross-sectional view of a flat cross-sectional portion 20b in the cross-sectionally deformed wire harness 20, and FIG. 3 is a schematic plan view for explaining the positions of the circular cross-sectional portion 20a and the flat cross-sectional portion 20b in the cross-sectionally deformed wire harness 20. FIG.

A flat electric wire 1 is composed of a flat stranded conductor 2 in which a plurality of strands 3 are twisted together in one direction in a circumferential shape, and an insulating coating portion 4 that covers the outer side of the flat stranded conductor 2 .
The flat stranded conductor 2 is formed by twisting a plurality of strands 3 so as to be relatively movable by a manufacturing method using a manufacturing apparatus 100, which will be described later, and has a generally rectangular cross section when viewed from the front.

The insulating coating portion 4 is formed by extrusion molding, and is a coating made of a crosslinked polyethylene resin in which the outer surface 2a of the flat stranded conductor 2 and the inner surface 4a of the insulating coating portion 4 are configured to be relatively movable. Here, in order to maintain the cross-sectional shape of the flat stranded conductor 2 when the flat electric wire 1 is bent, the insulation coating portion 4 covering the flat stranded conductor 2 has a substantially rectangular cross section in a front view.

Specifically, the outer surface 2a of the flat stranded conductor 2 formed by twisting together a plurality of strands 3 having a circular cross section in one direction and in a circumferential shape to form a substantially rectangular cross section has the outer surface 2a of the strand 3. However, the inner surface 4a of the insulating coating portion 4 is composed of a smooth surface slightly larger than the outline line L (see FIG. 2A) connecting the convex portions of the flat stranded conductor 2 having the uneven shape. there is

In addition, the flat stranded conductor 2 is produced by the manufacturing apparatus 100 by collectively twisting a plurality of strands 3 made of tough-pitch copper with a circular cross-section into a generally rectangular cross-section at a twisting pitch p in one direction and circumferentially. , and formed into a desired substantially rectangular cross section by compression molding. In FIGS. 1 and 2, the flat stranded conductor 2 has a two-layer structure, and R is a set edgewise bending radius.

More specifically, about 20 to 500 wires 3 having a diameter of about 0.1 to 2.0 mm are twisted in one direction at a twist pitch p of 30 mm to 500 mm to obtain a flat cross-sectional shape. constitutes the flat twisted wire conductor 2 of. In addition, the flat stranded wire conductor 2 has a flatness (width/thickness of the wire) of about 8 to 15 and a cross-sectional area of 8 mm ² to 12 mm ² is desirable.

As shown in FIG. 3, the manufacturing apparatus 100 for manufacturing the flat stranded conductor 2 includes a twisting machine 110 that twists the strands 3 in one direction to form the twisted strands 3a, and the twisted strands 3a. It is composed of a compression roll part 130 for compression molding and a capstan 140 for winding the flat stranded conductor 2 .

The twisting machine 110 includes a supply bobbin 111 that supplies the wire 3 and a mandrel 120 that twists the wire 3 supplied from the supply bobbin 111 . The number of supply bobbins 111 corresponding to the number of strands 3 constituting the flat stranded conductor 2 is provided.

The mandrel 120, as shown in FIG. A number of passage holes 121 a corresponding to the number of strands 3 forming the flat stranded conductor 2 are arranged in the perimeter of the perforated plate 121 near the outer periphery at regular intervals.
The twisting main shaft 122 is arranged downstream of the manufacturing apparatus 100 from the center of the batten plate 121, and has a circular cross section on the base end side, but gradually becomes flattened toward the tip end flat portion 122a. is changing.

The compression roll section 130 is composed of two rollers 131 arranged opposite to each other so as to sandwich the twisted strand 3a twisted by the twisting machine 110 .
The capstan 140 is composed of large and small feeding rollers 141 and 142 for feeding the flat stranded conductor 2 compression-molded by the compression roll section 130 to the downstream side, and a winding bobbin 150 arranged downstream.

In the manufacturing apparatus 100 configured as described above, the strands 3 are supplied to the mandrel 120 from the supply bobbins 111 rotating together with the mandrel 120, and the supplied strands 3 pass through the passage holes 121a of the battens 121 and are twisted. The strands are wound around the main shaft 122 and twisted together, and fed downstream as the twisted strand 3a from the flat end portion 122a. At this time, since the tip flat portion 122a of the twisting main shaft 122 has a flat cross section, the twisted wire 3a also has a substantially flat cross section.

The twisted strands 3a having a substantially flat cross section and fed downstream are compression-molded by passing between the rollers 131 in the compression roll section 130 to form the flat stranded conductor 2 having a desired flat cross-sectional shape. becomes.
The flat stranded conductor 2 processed into a desired cross-sectional shape by the compression roll section 130 is delivered by the capstan 140 and wound on the rotating winding bobbin 150 . Then, the flat wire 1 can be manufactured by extruding the above-described insulation coating portion 4 onto the flat stranded conductor 2 unwound from the winding bobbin 150 .

As described above, the manufacturing apparatus 100 performs a twisting molding process for twisting a plurality of wires 3 to form a twisted wire 3a, and a flat twisted wire conductor 2 by compression molding the twisted wires 3a. The compression molding process can be performed in a continuous flow.

Although the compression roll unit 130 has been described as compression molding means for compression-molding the flat stranded conductor 2 into a desired flat shape, for example, the flat stranded conductor 2 is formed by passing the twisted strands 3a through a die. may be manufactured.

As described above, the inner surface 4a of the insulating coating portion 4 is formed larger than the outer surface 2a of the flat stranded conductor 2 manufactured by the manufacturing apparatus 100, and the insulating coating portion 4 does not bite into between the twisted wires 3. The electric wire 1 has excellent heat dissipation properties and can improve edgewise flexibility (indicated by an arrow Ew in FIG. 2).

More specifically, when the flat electric wire 1 is bent edgewise, a path difference occurs between the inside of the bend and the outside of the bend. Since the wires 3 are relatively movable, and the inner surface 4a of the insulation coating portion 4 covering the flat stranded conductor 2 and the outer surface 2a of the flat stranded conductor 2 are relatively movable, FIG. 2, the strands 3 of the flat stranded conductor 2 move relative to each other and unwind in a fan shape, thereby absorbing the path difference described above and improving edgewise flexibility.

Therefore, as shown in FIG. 9, when a conventional flat electric wire is bent edgewise, it does not stand up in the bending direction and can be bent while maintaining a flat state, and the space in the thickness direction is narrow. Even if it is a wiring path, it can be wired without damaging the wire 3 . That is, the flat electric wire 1 can realize space saving of the wiring space and improvement of wiring performance.

In addition, since the flat stranded conductor 2 is formed by twisting together a plurality of strands 3 in one direction and in a circumferential shape at the twist pitch p, the flat electric wire 1 can be bent at the set edgewise bending. It is possible to achieve both excellent flexibility for the flat stranded wire conductor 2 and retention of the cross-sectional shape of the flat stranded conductor 2 .

Note that connection terminals (not shown) may be connected to both ends of the flat electric wire 1 configured in this manner. Specifically, a connection terminal (not shown) is composed of a connection portion connected to another terminal and a wire connection portion connected to the flat electric wire 1, and the wire connection portion connects the flat stranded conductor 2 of the flat electric wire 1. It has conductor connections for connection.
Here, the wire connecting portion may include a covering fixing portion for compressing and fixing the insulating covering portion 4 of the flat electric wire. Moreover, the connection between the connection terminal and the flat electric wire 1 can be applied by crimping, welding, or other techniques according to the required performance.

Thus, the flat electric wire 1 having connection terminals at both ends can be connected to an electric circuit via the connection terminals.
In the flat electric wire 1 to which the connection terminal is attached, since the flat stranded conductor 2 is fixed by the connection terminal, edgewise flexibility is more significantly reduced due to the path difference between the outer side and the inner side of the bend. However, the plurality of strands 3 that are twisted in a substantially rectangular cross section to form the flat stranded conductor 2 move relative to each other, and the inner surface 4 a of the insulating coating portion 4 that covers the flat stranded conductor 2 and the flat stranded wire Due to the relative movement with the outer surface 2a of the conductor 2, deterioration of edgewise flexibility can be suppressed. In addition, the flat electric wire 1 has a larger surface area than an electric wire having a circular cross-section with the same conductor cross-sectional area, and has high heat dissipation, so that it can be used as a high-voltage power line or a wiring electric wire.

Further, a shield layer 5 and a waterproof protector layer 6, which will be described later, may be provided outside the insulating coating portion 4 of the flat electric wire 1. FIG. In this way, by providing the shield layer 5 and the waterproof protector layer 6, which will be described later, on the outside of the insulating coating portion 4 in the flat electric wire 1, it has excellent edgewise flexibility and at least shielding and waterproofing properties. The flat electric wire 1 having one side can be configured, and the versatility and applications of the flat electric wire 1 can be expanded. In addition, the shield layer 5 and the waterproof protector layer 6 may be integrally formed outside the insulating coating portion 4 of the flat electric wire 1 .

Next, a wire harness configured by bundling the flat electric wires 1 will be described.
As shown in FIG. 5, the rectangular wire harness 10 includes two stacked flat electric wires 1, a shield layer 5 surrounding the two flat electric wires 1 together, and a waterproof protector surrounding the outer side of the shield layer 5. It is a wire harness with a flat cross-section formed with a layer 6.

The shield layer 5 is formed by winding a metal foil, a metal sheet, a metal braid, or the like, and the waterproof protector layer 6 is made of a waterproof resin and is attached to the outside of the shield layer 5 by an appropriate method.
The flat electric wire 1 constituting the square wire harness 10 may have the above-described structure, but the diameter of the wire 3 is reduced to about 0.1 mm to 0.3 mm, and the number of twists is 20 to 40. By reducing it to this level, the flexibility of the wire harness can be further improved. In addition, the shield layer 5 may be composed of a conductive material, and depending on the required characteristics, placement of a conductive resin sheet, placement of a metal layer by plating or thermal spraying on a flat wire, placement of a carbon coat, etc. It can be performed.

In addition, by providing the interval c between the flat electric wires 1, the heat dissipation of the rectangular wire harness 10 can be improved. Specifically, when a direct current of 130 A is applied to two flat stranded conductors ² equivalent to 12 mm 2 (thickness 1 mm × width 12 mm), 2 mm or more between the flat stranded conductors 2 of the flat electric wire 1 It is more preferable to provide an interval c of

Thus, the rectangular wire harness 10 configured by laminating two flat electric wires 1 exhibits the effects of the flat electric wire 1 including the improvement in edgewise flexibility as described above, and also provides shielding. effect and waterproof effect can be exhibited.

In addition, since the flat electric wire 1 itself has excellent flexibility, for example, it is possible to combine excellent flexibility and shielding properties without using an expensive shielding material woven like a braided wire. can be done. Moreover, since the waterproof protector layer 6 is provided, it is not necessary to attach a separate protector to the flat electric wire 1 .

In addition, compared to the case where the shield layer 5 and the waterproof protector layer 6 are individually provided for each flat electric wire 1, the shield layer 5 and the waterproof protector layer are collectively applied to the wire harness 10 composed of a plurality of flat electric wires 1. 6, the cost and labor can be reduced.
Furthermore, since the rectangular wire harness 10 has excellent heat dissipation properties, it can be used as a high-voltage wire harness or wiring electric wire for connecting between a three-phase AC motor and an inverter, for example.

In the above description, the shield layer 5 and the waterproof protector layer 6 are provided separately, but a shield waterproof layer having both shielding and waterproofing properties may be provided, or a plurality of flat layers arranged in the thickness direction may be provided. A shield layer 5 may be provided outside the waterproof protector layer 6 that surrounds the wires 1 together.

Next, a cross-sectionally deformed wire harness 20 including a plurality of flat electric wires 1 and having a circular and flat cross-section will be described with reference to FIGS. 6 and 7. FIG.
As shown in FIGS. 6 and 7, the cross-sectionally deformed wire harness 20 includes three flat electric wires 1, and is composed of a circular section 20a with a circular section and a flat section 20b with a flat section.

The circular cross section 20a has three flat wires 1 arranged in the thickness direction, the three flat wires 1 are collectively surrounded by the shield layer 5, and the waterproof protector layer 6 is arranged outside the shield layer 5. It consists of

The flat cross-sectional portion 20b has three flat electric wires 1 arranged in the width direction, the arranged three flat electric wires 1 are collectively surrounded by a shield layer 5, and a waterproof protector layer 6 is provided outside the shield layer 5. placed and configured.

In the circular cross-section portion 20a, three flat wires 1 are arranged in the thickness direction with an interval c of about 2 mm in order to ensure heat dissipation. , three flat electric wires 1 are arranged in the width direction.

In addition, the cross-sectionally deformed wire harness 20 having the circular cross-section portion 20a and the flat cross-section portion 20b in this manner gradually changes from the circular cross-section portion 20a to the flat cross-section portion 20b, and conversely, from the flat cross-section portion 20b to the circular cross-section portion 20a. It is configured so that the cross section changes. More specifically, for example, regarding the transition from the circular cross-section portion 20a to the flat cross-section portion 20b, the flat electric wires 1 arranged in the thickness direction gradually move in the width direction toward the flat cross-section portion 20b, and three of flat electric wires 1 are arranged in the width direction.

As described above, the cross-sectionally deformed wire harness 20 having the circular cross-section portion 20a and the flat cross-section portion 20b has the advantages of the flat electric wire 1 including the improvement in edgewise flexibility as described above, and the rectangular wire harness. In addition to the shield effect and waterproof effect in 10, it can be configured in various modes according to the application and specifications.

For example, as shown in FIG. 7(c), the straight portion of the wiring route is configured with the flat cross-section portion 20b, and the curved portion is configured with the circular cross-section portion 20a. The flat cross-section portion 20b to be routed can save space in the height direction of the wire, and the circular cross-section portion 20a to be routed at the bent portion can maintain the strength to withstand bending plastic working.

Furthermore, it is also possible to wire the flat cross-section portion 20b in a wiring space narrow in the height direction, such as a gap with an exhaust pipe under the floor, and to wire the circular cross-section portion 20a in another wiring space without restrictions. . In this case, the flat cross-sectional portion 20b, in which the flat electric wires 1 having high edgewise flexibility are arranged in the width direction, can be twisted and rise against bending, as in the case of edgewise bending of a conventional flat electric wire. Therefore, even if the wiring space is narrow in the height direction, the wires 3 constituting the flat electric wire 1 are not damaged, and a desired wiring route can be used.

Therefore, the cross-sectionally deformed wire harness 20 excellent in heat dissipation is configured in a manner corresponding to each of various wiring paths, and is used for high-voltage applications such as connecting between a three-phase AC motor and an inverter, for example. It can also be used as a wire harness or an electric wire for wiring.

In correspondence with the configuration of this invention and the above-described embodiments,
The wire harness of the present invention corresponds to the rectangular wire harnesses 10 and 10a and the cross-sectionally deformed wire harness 20,
The short side direction of the cross section of the flat wire corresponds to the thickness direction,
The long side direction of the cross section of the flat electric wire corresponds to the width direction,
The present invention is not limited to the configurations of the above-described embodiments, and many embodiments can be obtained.

For example, although a two-layer structure is shown as an example of the flat stranded conductor 2, the structure is not limited to the two-layer structure as long as it has edgewise flexibility.
Further, for example, as shown in FIG. 8, a surrounding foil 7 functioning as a surrounding body is provided to cover the outside of the flat stranded conductor 2 so that the insulating coating portion 4 does not bite into the outer surface 2a of the flat stranded conductor 2. The rectangular wire harness 10a may be configured using the flat electric wire 1a. As a result, the insulating coating portion 4 does not bite into the outer surface 2a of the flat stranded conductor 2 configured by twisting a plurality of strands 3 together in one direction and in a circumferential shape. and the insulating coating portion 4 are separated, relative movement between the strands 3 and relative movement between the flat stranded conductor 2 and the insulating coating portion 4 can be ensured.

Further, for example, even if the insulating coating portion 4 is formed on the outside of the flat stranded conductor 2 by a method such as vapor deposition or thermal spraying, the flat stranded conductor 2 and the insulating coating portion 4 are cut off by the surrounding foil 7, The relative movement between the strands 3 and the relative movement between the flat stranded conductor 2 and the insulating coating 4 can be ensured without the insulating coating 4 biting into the outer surface 2 a of the flat stranded conductor 2 . In other words, the surrounding foil 7 can expand options for forming the insulation coating portion 4 that can ensure relative movement between the wires 3 and relative movement between the flat stranded conductor 2 and the insulation coating portion 4 .

DESCRIPTION OF SYMBOLS 1... Flat electric wire 2... Flat twisted wire conductor 2a... Outer surface 3... Wire 4... Insulating coating part 4a... Inner surface 5... Shield layer 6... Waterproof protector layer 7... Surrounding foils 10, 10a... Rectangular wire harness 20... Cross-sectional deformation Wire harness 110 Twisting machine 111 Supply bobbin p Twisting pitch R Set bending radius

Claims (11)

It consists of a flat stranded wire conductor having a substantially rectangular cross section, in which a plurality of strands are twisted together in one direction in a circumferential shape to form an uneven outer surface, and an insulating coating that covers the flat stranded wire conductor. ,
The flat stranded conductor has a two-layer structure, and the plurality of strands constituting the flat stranded conductor are twisted to have a substantially flat cross section so that they can move relative to each other,
The insulating coating portion in the front view cross section,
configured in a substantially rectangular shape covering the flat stranded conductor so as to maintain the cross-sectional shape of the flat stranded conductor to be bent,
The inner surface of the insulating coating portion in the front view cross section is
The outer surface is slightly larger than the contour line connecting the convex portions of the flat stranded conductor having an uneven shape, and is composed of a smooth surface that does not bite into between the plurality of strands that are twisted together,
With the cross section bent edgewise along the long side,
The outer surface of the flat stranded conductor and the inner surface of the insulating coating portion relatively move while maintaining the cross-sectional shape of the flat stranded conductor to which the insulating coating portion is bent,
The strands constituting the flat stranded conductor move relative to each other to unwind in a fan shape, absorb the path difference between the inside of the bend and the outside of the bend, and maintain a flat state without standing up in the bending direction. flat electric wire. The flat stranded conductor,
2. The flat electric wire according to claim 1, which has an oblateness (width/thickness) of 8 to 15. The flat stranded conductor,
The flat according to claim 1 or claim 2, wherein 20 to 500 strands having a diameter of 0.1 to 2.0 mm are twisted in one direction at a twist pitch of 30 mm to 500 mm. Electrical wire. The flat electric wire according to any one of claims 1 to 3, wherein connection terminals are attached to the ends of the flat stranded conductors. 5. The flat electric wire according to any one of claims 1 to 4, wherein at least one of a shield layer and a waterproof layer is provided outside the insulating coating. A wire harness in which the flat electric wires according to any one of claims 1 to 5 are bundled. 7. The wire harness according to claim 6, wherein the plurality of flat electric wires are arranged in the long side direction of the cross section in at least part of the longitudinal direction. 7. The wire harness according to claim 6, wherein the plurality of flat electric wires are arranged in the short side direction of the cross section in at least part of the longitudinal direction. In a part of the longitudinal direction, the plurality of flat wires are arranged in the long side direction of the cross section,
7. The wire harness according to claim 6, wherein the plurality of flat wires are arranged in the short side direction of the cross section in a portion different from the one portion in the longitudinal direction. A plurality of strands supplied from a supply bobbin of a twisting machine are twisted together in one direction in a circumferential shape and with a substantially rectangular cross section so that the plurality of strands can move relative to each other. , forming a flat stranded conductor having a two-layer structure and an uneven outer surface ;
Covering the outer surface of the flat stranded conductor with an insulating coating part so as to be relatively movable,
The inner surface of the insulating coating portion in the front view cross section is a smooth surface that is slightly larger than the profile line that connects the convex portions of the flat stranded conductor having an uneven outer surface and that does not bite into between the plurality of strands that are stranded. consists of
the insulating coating,
configured in a substantially rectangular shape covering the flat stranded conductor so as to maintain the cross-sectional shape of the bendable flat stranded conductor;
With the cross section bent edgewise along the long side,
The outer surface of the flat stranded conductor and the inner surface of the insulating coating portion relatively move while maintaining the cross-sectional shape of the flat stranded conductor to which the insulating coating portion is bent ,
The strands constituting the flat stranded conductor move relative to each other to unwind in a fan shape, absorb the path difference between the inside of the bend and the outside of the bend, and maintain a flat state without standing up in the bending direction. configure as
A method for manufacturing a flat electric wire. 11. The method of manufacturing a flat electric wire according to claim 10, wherein a plurality of twisted strands are compression-molded to form a desired substantially rectangular cross-section.

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