JP7488196B2 - Composite cable, wiring harness arrangement structure, and manufacturing method of composite cable - Google Patents

Description

The present invention relates to a composite cable, a wiring harness arrangement structure, and a manufacturing method for a composite cable, for example, a composite cable for use in a vehicle, a wiring harness arrangement structure, and a manufacturing method for a composite cable.

2. Description of the Related Art Wiring systems for automobiles and the like use wire harnesses in which communication cables and power cables that are manufactured independently are bundled together, as necessary, with tape or the like.
In recent years, the number of on-board wire harnesses using composite cables capable of transmitting both electrical and optical signals has been increasing. For example, Patent Document 1 discloses an on-board composite cable in which a group of tensile strength fibers having a conductive material layer formed on the surface by plating or the like is filled between optical fibers and their coating. Patent Document 2 discloses an indoor composite cable in which a power line and a communication line are combined.

Japanese Patent No. 5920283 JP 2003-86028 A

However, it is difficult to say that conventional composite cables have sufficient performance for use as in-vehicle wire harnesses.

For example, the conductive tensile fibers constituting the composite cable disclosed in Patent Document 1 are formed by plating the surface of tensile fibers such as aramid with a conductive metal such as copper. Therefore, in order to ensure sufficient conductive performance (electrical resistance) required for an in-vehicle wire harness, a conductor cross-sectional area equivalent to that of a conventional insulated wire is required, and the bending performance is also thought to be equivalent to that of a conventional insulated wire. In other words, in the technology described in Patent Document 1, in order to satisfy the conductive performance required for an in-vehicle wire harness, the diameter of the composite cable is larger than when a conventional insulated wire is used. As a result, the bending performance of the composite cable may decrease and the weight of the composite cable may increase.

In addition, in the composite cable disclosed in Patent Document 2, the hollow tube is located at the end of the cross section of the composite cable, and only the hollow tube may be affected by external forces. In addition, the hollow tube may be locally deformed by the effect of external forces and press the optical cord, which may increase the transmission loss of the optical cord or cause the optical cord to break. In particular, when the composite cable is used as a wire harness, when wiring along a vehicle body, the number of bends with small bending radii increases, making the above-mentioned hollow tube more likely to be locally deformed (buckled, etc.). For this reason, it is difficult to say that the bending performance is high.
Thus, it is difficult to say that the conventional composite cable has sufficient performance as a wire harness.

The present invention has been made in consideration of the above-mentioned problems, and aims to provide a composite cable that has sufficient performance as a wire harness.

A composite cable according to a representative embodiment of the present invention comprises at least one first linear body including a conductor formed of a conductive material, a tubular body extending in the extension direction of the first linear body, at least one second linear body housed in an unconstrained state inside the tubular body, and an outer sheath made of an insulating material that covers the outer surfaces of the first linear body and the tubular body, the first linear body and the tubular body being arranged side by side in an arrangement direction that is one direction of a cross section perpendicular to the extension direction of the first linear body, and the first linear body and the outer sheath being configured to suppress local deformation of the tubular body due to the influence of an external force.

The composite cable of the present invention makes it possible to provide a composite cable that has sufficient performance as a wire harness.

1 is a cross-sectional view of a composite cable according to a first embodiment. FIG. 2 is a cross-sectional view of an optical fiber core as a signal line. FIG. 11 is a cross-sectional view of a composite cable according to a second embodiment. FIG. 11 is a cross-sectional view of a composite cable according to a third embodiment. FIG. 11 is a cross-sectional view of a composite cable according to a fourth embodiment. A cross-sectional view of a composite cable according to embodiment 5. A cross-sectional view of a composite cable according to a sixth embodiment. A cross-sectional view of a composite cable according to embodiment 7. A cross-sectional view of a composite cable according to embodiment 8. A cross-sectional view of a composite cable according to embodiment 9. A cross-sectional view of a composite cable according to embodiment 10. A cross-sectional view of a composite cable according to embodiment 11. A cross-sectional view of a composite cable relating to embodiment 12. A cross-sectional view of a composite cable relating to embodiment 13. A cross-sectional view of a composite cable relating to embodiment 14. A cross-sectional view of a composite cable relating to embodiment 15. A cross-sectional view of a composite cable relating to embodiment 16. A cross-sectional view of a composite cable relating to embodiment 17. A cross-sectional view of a composite cable relating to embodiment 18. A cross-sectional view of a composite cable relating to embodiment 19. A cross-sectional view of a composite cable relating to embodiment 20. 1 is a diagram showing a configuration in which an external terminal is connected to an end of a composite cable according to an embodiment of the present invention; 1 is a flow chart showing a flow of a method for manufacturing a composite cable according to an embodiment of the present invention. 1 is a plan view of a wiring harness arrangement structure using a composite cable according to an embodiment; FIG. 25 is a perspective view of a main part showing the wiring structure of the wire harness shown in FIG. 24 . 4 is a cross-sectional view showing another aspect of the composite cable of embodiment 1. FIG. 4 is a cross-sectional view showing yet another aspect of the composite cable of embodiment 1. FIG. 11 is a cross-sectional view showing another aspect of the composite cable of embodiment 2. FIG. A cross-sectional view showing another aspect of the composite cable of embodiment 5. 4 is a cross-sectional view showing yet another aspect of the composite cable of embodiment 1. FIG.

1. Overview of the embodiment First, an overview of a representative embodiment of the invention disclosed in this application will be described. Note that in the following description, as an example, reference numerals in the drawings corresponding to components of the invention are given in parentheses.

[1] A composite cable (1A to 1T) according to a representative embodiment of the present invention comprises at least one first linear body (2A to 2T) including a conductor made of a conductive material, a tubular body (31A to 31T) extending in the extension direction of the first linear body, at least one second linear body (3A to 3T) housed in an unconstrained state inside the tubular body, and an outer sheath (4A to 4T) made of an insulating material that covers the outer surfaces of the first linear body and the tubular body, the first linear body and the tubular body being arranged side by side in an arrangement direction that is one direction of a cross section perpendicular to the extension direction of the first linear body, and the first linear body and the outer sheath being configured to be capable of suppressing local deformation of the tubular body due to the influence of an external force.

In addition, in the composite cable described in [1] above, a plurality of the first linear bodies may be provided, and the tubular body may be arranged adjacent to the plurality of first linear bodies along the arrangement direction.

In addition, in the composite cable described in [1] above, a space (30) may be formed between the inner surface of the tubular body and the linear body.

In addition, in the composite cable (1C) described in [1] above, the tubular body may be a conductor (31C).

In addition, in the composite cable (1A, 1B, 1D to 1T) described in [1] above, the tubular body may be an insulator (31A, 31B, 31D to 31T).

In addition, in the composite cable (1A, 1D-1G, 1I-1R) described in [1] above, the first linear body may be a solid wire (2A, 2D-2G, 2I-2R) composed of a single metal wire.

In addition, in the composite cable (1B, 1C, 1H, 1T) described in [1] above, the first linear body may be a twisted wire (2B, 2C, 2H, 2T) made by twisting together multiple metal wires.

In addition, the composite cable (1C) described in [1] above may have an insulating coating (25C) made of an insulating material that contacts the inner surface of the outer sheath and covers the outer surface of the first linear body.

In addition, in the composite cable (1A-1C, 1E, 1G, 1I-1K, 1M, 1O-1T) described in [1] above, the tubular body may be circular in cross section.

In addition, in the composite cable (1D, 1F, 1H, 1L to 1N) described in [1] above, the tubular body may be rectangular in cross section.

In addition, in the composite cable (1A, 1F, 1I, 1J, 1L, 1O to 1T) described in [1] above, the first linear body may be circular in cross section.

In addition, in the composite cable (1D, 1E, 1G, 1H, 1K, 1M, 1N) described in [1] above, the first linear body may have a cross-sectional visual shape.

In addition, in the composite cable (1D, 1E, 1H, 1M, 1N) described in [1] above, the first linear body may be rectangular in cross section.

In addition, the composite cable (1A to 1T) described in [1] above may further have a first external terminal (8) connected to the end of the first linear body in the extension direction.

In addition, in the composite cable (1C) described in [1] above, the second linear body may include a metal wire (3C) that transmits an electrical signal.

[2] In the composite cable (1A to 1T) described in [1] above, the rigidity of the tubular body is lower than both the rigidity of the first linear body and the rigidity of the outer sheath.

[3] The composite cable (1A to 1T) described in [2] above is characterized in that it has a portion in which the outer surface of the cylindrical body and the inner surface of the outer sheath are in close contact with each other.

[4] The composite cable (1A to 1T) described in [1] above is characterized in that the cylindrical body is movable relative to the outer sheath.

[5] The composite cable (1B to 1T) described in [1] above is characterized in that the first linear body is arranged at both ends of the arrangement in the arrangement direction.

[6] The composite cable (1A to 1T) described in [1] above is characterized in that the first linear body is arranged on both sides of the tubular body in the arrangement direction.

[7] The composite cable (1A to 1T) described in [1] above is characterized in that the dimension of the tubular body in the cable thickness direction is smaller than the dimension of the first linear body in the cable thickness direction.

[8] In the composite cable (1A to 1T) described in [1] above, the dimension of the tubular body in the cable thickness direction is smaller than the dimension of the conductor portion of the first linear body in the cable thickness direction.

[9] In the composite cable (1A to 1T) described in [1] above, the second linear body is characterized in that it includes at least one of a metal wire (3C) which is a transmission line for an electric signal, an optical fiber (3A, 3B, 3D to 3T) which is a transmission line for an optical signal, and a thread member which does not function as a transmission line.

[10] The composite cable (1A to 1T) described in [1] above is characterized in that it further has at least one of a first external terminal (8) connected to an end of the first linear body in the extension direction and a second external terminal (9) connected to an end of the second linear body in the extension direction.

[11] In the composite cable (1A, 1I to 1T) described in [1] above, the outer sheath (4A, 4I to 4T) is characterized in having a slit portion (41A, 41I to 41T) extending from the outer peripheral surface toward the cylindrical body (31A, 31I to 31T).

[12] In the composite cable (1A, 1I to 1T) described in [11] above, the slit portion (41A, 41I to 41T) is characterized in that it reaches the cylindrical body (31A, 31I to 31T).

[13] In the composite cable (1A, 1I to 1T) described in [11] above, the slit portion (41A, 41I to 41T) is provided on the outer peripheral surface of the outer sheath (4A, 4I to 4T) and is provided with a closing member (6A, 6I to 6T) that closes the slit portion (41A, 41I to 41T).

[14] A wiring harness arrangement structure (500) according to a representative embodiment of the present invention has a trunk line (12a-12d, 22a-22c) including a power line and a communication line, and branch lines (13, 15) branching off from the trunk line, and is characterized in that at least a portion of the trunk line or the branch lines is a composite cable (1A-1T) described in any one of [1] to [13] above.

[15] The wiring harness arrangement structure (500) described in [14] above is characterized in that at least a portion of the main wires (12a-12d, 22a-22c) or the branch wires (13, 15) has a bent portion (BP) that conforms to the object to be routed.

[16] The wiring harness arrangement structure described in [14] or [15] above is characterized in that it further has an earth wire.

[17] A method for manufacturing a composite cable according to a representative embodiment of the present invention includes a first step (S101) of forming at least one first linear body made of a conductive material, a second step (S102) of forming a tubular body (31A), and a third step (S103) of forming by extrusion molding an outer sheath (4A) made of an insulating material that covers the outer surfaces of the first linear body formed in the first step and the tubular body formed in the second step.

[18] The method for manufacturing a composite cable described in [17] above is characterized in that it includes a fourth step (S104) of inserting a second linear body (3A) into the inside of the tubular body on which the outer sheath is formed in the third step.

[19] The manufacturing method for a composite cable described in [17] or [18] above is characterized in that it includes a fifth step (S105) of connecting a first external terminal (8) to the end in the extension direction of the first linear body on which the outer sheath is formed in the third step.

[20] The manufacturing method for the composite cable described in [18] above is characterized in that it includes a sixth step (S106) of connecting a second external terminal (9) to the end of the second linear body in the extension direction.

2. Specific examples of embodiments of the present invention will be described below with reference to the drawings. In the following description, components common to each embodiment are given the same reference numerals, and repeated description will be omitted. It should be noted that the drawings are schematic, and the dimensional relationship of each element, the ratio of each element, etc. may differ from reality. There may also be parts in which the dimensional relationship and ratio differ between the drawings.

First Embodiment
FIG. 1 is a cross-sectional view of a composite cable according to a first embodiment.
A composite cable 1A shown in FIG. 1 is, for example, a cable capable of transmitting power and optical signals.

As shown in FIG. 1, the composite cable 1A has a first linear body 2A, a tubular body 31A, a signal line 3A, and an outer sheath 4A.

The first linear body 2A is made of a conductive material. When the composite cable 1A is used as a main or branch line of a wire harness, the first linear body 2A can function, for example, as a power line for power transmission.

Specifically, the first linear body 2A is a solid single wire (metal wire) made of a metal material. The first linear body 2A is, for example, circular in cross section. The first linear body 2A may be made of any metal material having conductive properties, such as aluminum, aluminum alloy, copper, copper alloy, tin-plated wire, iron, and nickel.

The cylindrical body 31A is disposed adjacent to the first linear body 2A in a direction perpendicular to the extending direction (hereinafter referred to as "cross-sectional direction"). The cylindrical body 31A is made of an insulating material. The cylindrical body 31A is a hollow tube made of an insulating material and has a space 30. The cylindrical body 31A is, for example, circular in cross section. The cylindrical body 31A may be made of any insulating material, such as polyethylene, PVC (polyvinyl chloride), nylon, and silicone resin. Of these, with regard to the metal material used for the power line, a highly conductive material, such as a copper-based (pure copper-based) or aluminum-based (pure aluminum-based: so-called 1000-based) material with a small amount of impurities or additives, is preferred. With regard to the power line through which a particularly large current flows, it is expected that the cross-sectional area will be, for example, about 5 to 200 mm ^2. Therefore, from the viewpoint of ensuring the bendability of the composite cable, a relatively flexible material, such as a copper-based or aluminum-based material with a small amount of the above-mentioned impurities or additives, is preferred. This viewpoint is the same for each of the following embodiments.
The cylindrical body 31A is formed, for example, by extrusion molding. The outer dimension (outer diameter D2) of the cylindrical body 31A in the cross-sectional direction is the same as or smaller than the outer dimension (outer diameter D1) of the first linear body 2A in the cross-sectional direction. In Fig. 1, the outer diameter D2 of the cylindrical body 31A is the same as the outer diameter D1 of the first linear body 2A. In this specification, the outer dimensions of the first linear body and the cylindrical body are described in terms of the dimensions in the thickness direction of the composite cable unless otherwise specified.

The signal line 3A is a second linear body. The signal line 3A is, for example, an optical fiber core. When the composite cable 1A is used as a main line or a branch line of a wire harness, the signal line 3A can function, for example, as a linear body (signal line) for signal transmission.

1 illustrates an example in which two optical fiber cores are housed inside the cylindrical body 31A as the signal lines 3A, but the number of signal lines 3A housed inside the cylindrical body 31A is not particularly limited. In other words, the number of signal lines 3A housed inside the cylindrical body 31A may be one, or three or more.

FIG. 2 is a cross-sectional view of an optical fiber core serving as the signal line 3A.
As shown in Fig. 2, the optical fiber core as the signal line 3A has a core 101, a clad 102, a fiber bare wire coating 103, a buffer material 104, and an outer jacket 105. The core 101 and the clad 102 are made of, for example, quartz glass, resin, or the like. The outer diameter of the clad 102 can be equal to or smaller than 125 micrometers that is normally used for communication applications, and can be, for example, 80 micrometers (including an error of ±5%). By reducing the outer diameter of the clad 102, the bending strain of the optical fiber is reduced, and the probability of breakage can be reduced. However, if the outer diameter of the clad 102 is made too small, it becomes necessary to reduce the core size, and the connection loss tends to increase.

The fiber core coating 103 is made of, for example, silicone acrylate. However, depending on the purpose, it may be made of other resin materials (polyimide, acrylate, silicone resin, fluororesin, etc.).

The buffer material 104 is a member arranged around the fiber wire coating 103 to increase the strength against the tensile force applied in the longitudinal direction of the optical fiber. The buffer material 104 is, for example, made of a plurality of fibers and arranged around the entire circumference of the fiber wire coating 103. Examples of the above-mentioned fibers include aramid fibers. The outer jacket 105 is preferably made of, for example, nylon or fluororesin (for example, ETFE). The outer diameter of the outer jacket 105 is preferably 1 millimeter or less, for example, 800 to 900 micrometers, and is configured to an appropriate desired value. By reducing the outer diameter of the outer jacket 105 (i.e., making the outer jacket 105 thinner), the optical fiber core wire becomes easier to bend, leading to improved routing. However, if the outer diameter of the outer jacket 105 is made too small (i.e., making the outer jacket 105 too thin), protection from external forces becomes insufficient and transmission loss tends to increase.

The signal lines 3A are housed in an unconstrained state inside the cylindrical body 31A. Specifically, a space 30 is formed between the inner circumferential surface 33A of the cylindrical body 31A and the signal lines 3A. For example, the space 30 is filled with air, and each signal line 3A is arranged in a movable state in the space 30 of the cylindrical body 31A.

The outer jacket 4A is composed of an insulating material that covers the outer peripheral surface 29A of the first linear body 2A and the outer peripheral surface 32A of the tubular body 31A. Examples of insulating materials include polyethylene, PVC, nylon, and silicone resin. For example, the outer jacket 4A is formed by extrusion molding. The outer jacket 4A has a shape that can integrally cover the outer peripheral surface 29A of the first linear body 2A and the outer peripheral surface 32A of the tubular body 31A that are adjacent to each other in the cross-sectional direction of the composite cable 1A, for example, an elliptical or oval shape in cross section.

The composite cable 1A having the above-described configuration has a first linear body 2A having electrical conductivity and at least one signal line 3A housed inside a tubular body 31A arranged adjacent to the first linear body 2A, so that the transmission of power via the first linear body 2A and the transmission of an optical signal via the optical fiber serving as the signal line 3A can be achieved with a single cable using the minimum necessary configuration.

In addition, since the signal line 3A is housed inside the cylindrical body 31A, even if an external force is applied to the outer sheath 4A of the composite cable 1A, the external force is unlikely to act directly on the signal line 3A. In particular, since the outer dimensions of the cylindrical body 31A are set to be equal to or smaller than the outer dimensions of the first linear body 2A, even if an external force is applied to the outer sheath 4A of the composite cable 1A, the external force is applied to the first linear body 2A first and then to the cylindrical body 31A, so that the external force is unlikely to act directly on the signal line 3A. This makes it possible to suppress adverse effects on signal transmission through the signal line 3A due to the application of an external force to the signal line 3A. From this viewpoint, it is preferable that the outer dimensions of the cylindrical body 31A are set to be smaller than the outer dimensions of the first linear body 2A.
In addition, from the viewpoint of being able to suppress local deformation such as buckling of the tubular body 31A when an external force is applied to the jacket 4A of the composite cable 1A, it is also preferable to adopt the following configurations (1) to (5). Here, the following configurations (1) to (5) may be appropriately combined, but either of the configurations (2) and (3) is adopted. This point is similar to the other embodiments.
(1) The rigidity (difficulty in bending: load/deformation amount) of the tubular body 31 is lower than both the rigidity of the first linear body 2 and the rigidity of the outer jacket 4 .
(2) There is a portion where the outer surface of the cylindrical body 31 and the inner surface of the outer jacket 4 are in close contact with each other.
(3) The cylindrical body 31 is movable relative to the outer cover 4 .
(4) The first linear body 2 is arranged at both ends of the arrangement direction of the components of the composite cable 1 (suppressing the influence of external forces on the tubular body 31 from the arrangement direction of the components of the composite cable 1).
(5) The first linear body 2 is arranged on both sides of the tubular body 31 in the arrangement direction of the components of the composite cable 1 (suppressing local deformation of the tubular body 31 in the arrangement direction of the components of the composite cable 1).

In addition, the signal line 3A is accommodated in an unconstrained state inside the cylindrical body 31A, that is, the signal line 3A is arranged in a movable state in the space 30 between the inner circumferential surface 33A of the cylindrical body 31A and the signal line 3A. Even if the cylindrical body 31A is deformed in response to bending of the composite cable 1A due to the influence of an external force, the signal line 3A moves inside the cylindrical body 31A, and it is possible to prevent the signal line 3A from being subjected to an external force. Note that the composite cable 1A is assumed to be configured to have a minimum necessary size in order to be mounted on a vehicle or the like. In this case, both the cylindrical body 31A and the space 30 are of a minimum necessary size. Therefore, in this embodiment, from the viewpoint of being able to suppress local deformation of the cylindrical body 31A, the adhesion between the outer surface of the cylindrical body 31A and the inner surface of the outer jacket 4A is taken into consideration, and it is possible to prevent the signal line 3A from being subjected to an external force.

In addition, according to the composite cable 1A, the tubular body 31A is formed of a flexible insulating material, so that the rigidity of the tubular body 31A can be made lower than both the rigidity of the first linear body 2A and the rigidity of the outer jacket 4A, which allows the tubular body 31A to plastically deform when the composite cable 1A is curved, thereby improving the bending performance of the composite cable 1A. In addition, since the cross-sectional shape of the composite cable 1A is flat, such as an ellipse or oval, the flexibility and bendability in the short axis direction (thickness direction of the cable) are improved compared to a circular cable of the same material and equivalent cross-sectional area, and the ease of installation in a vehicle is improved.

Furthermore, because the first linear body 2A is a single wire of metal that can be plastically deformed, when the composite cable 1A is locked with a locking part, springback does not occur in the composite cable 1A, and the locking part is less likely to be subjected to force due to the springiness of the composite cable 1A. This makes it possible to improve the holding performance of the composite cable 1A by the locking part.

In addition, by using optical fiber as the signal line 3A, signal transmission in the signal line 3A is less susceptible to adverse effects from the first linear body 2A acting as a power line or from electromagnetic waves generated externally.

As described above, according to the composite cable 1A of embodiment 1, when an external force is applied to the outer sheath 4A of the composite cable 1A, local deformation of the tubular body 31A is suppressed, making it possible to provide a cable having sufficient performance as a wire harness.

Second Embodiment
FIG. 3 is a cross-sectional view of a composite cable according to the second embodiment.

The composite cable 1B of embodiment 2 differs from the composite cable 1A of embodiment 1 in that it has multiple first linear bodies 2B, and that these first linear bodies 2B are twisted wires made up of multiple metal wires twisted together, but is otherwise similar to the composite cable 1A of embodiment 1.

As shown in FIG. 3, in the composite cable 1B, the first linear body 2B is formed by twisting together a plurality of, for example, seven, metal wires 200B to function as one linear body. The first linear body 2B is a so-called bare stranded wire in which no covering is provided on the outer surface 29B other than the outer sheath 4B. A plurality of, for example, two, first linear bodies 2B are provided in the composite cable 1B, and are arranged along the direction of a virtual axis X (meaning the arrangement direction; the same applies below) provided in the cross-sectional direction that is perpendicular to the axis AX indicating the extension direction. Specifically, the first linear body 2B is arranged to sandwich the cylindrical body 31B in the cross-sectional direction that is perpendicular to the extension direction of the composite cable 1B. In other words, the cylindrical body 31B is arranged adjacent to both of the two first linear bodies 2B. In addition, the first linear bodies 2B are arranged at both ends of the arrangement direction of the components of the composite cable 1B.

The cylindrical body 31B is a tube formed of an insulating material having a circular cross-sectional shape, similar to the cylindrical body 31A according to embodiment 1. The outer diameter D2 in the cross-sectional direction of the cylindrical body 31B is smaller than the outer diameter D1 in the cross-sectional direction of the first linear body 2B. The outer peripheral surface 32B of the cylindrical body 31B is covered by an outer jacket 4B. The outer jacket 4B is formed of the same material as the outer jacket 4A according to embodiment 1. Like the outer jacket 4A, the outer jacket 4B is also formed in an elliptical cross-sectional shape corresponding to the cylindrical body 31B.

It is preferable that each communication line 3B is movably arranged in the space 30 defined by the inner surface 28B of the cylindrical body 31B.

In the composite cable 1B according to the second embodiment, in addition to the effects of the composite cable 1A according to the first embodiment, the outer diameter of the tubular body 31B is smaller than the outer diameter of the first linear body 2B. In addition, in the composite cable 1B according to the second embodiment, the tubular body 31B is arranged in a row along the virtual axis X adjacent to a plurality of first linear bodies 2B. Therefore, according to the composite cable 1B according to the second embodiment, even if a lateral pressure is applied to the composite cable 1B, an external force acts on the first linear body 2B first, and it is possible to suppress the external force from acting on the tubular body 31B. Therefore, according to the composite cable 1B according to the second embodiment, when an external force is applied to the outer sheath 4B of the composite cable 1A, local deformation of the tubular body 31B is suppressed, and the occurrence of signal failure can be suppressed.

In addition, according to the composite cable 1B of the second embodiment, by adopting a plurality of first linear bodies 2B, the surface area can be made larger than that of a single first linear body 2A having a cross-sectional area equal to the sum of the cross-sectional areas of the plurality of first linear bodies 2B, thereby improving heat dissipation. In addition, according to the composite cable 1B of the second embodiment, by sandwiching the insulating tubular body 31B between the plurality of first linear bodies 2B, two power supply systems can be arranged. Furthermore, according to the composite cable 1B of the second embodiment, the first linear body 2B is, for example, a bare twisted wire made of the same material as the first linear body 2A, so that the adhesion between the outer jacket 4B and the first linear body 2B is good and no misalignment occurs within the composite cable 1B.

Third Embodiment
FIG. 4 is a cross-sectional view of a composite cable 1C according to the third embodiment.

The composite cable 1C of embodiment 3 differs from the composite cable 1B of embodiment 2 in that the configuration of the first linear body 2C, the configuration of the tubular body 31C, and the type of signal line 3C are different, but in other respects it is similar to the composite cable 1B of embodiment 2.

Specifically, as shown in Fig. 4, the tubular body 31C in the composite cable 1C is formed into a tubular shape from a conductive material, i.e., a non-insulating material, such as the metal wire (copper wire) used in the first linear body 2A of the composite cable 1A according to embodiment 1. The tubular body 31C is formed, for example, by extrusion molding.

The first linear body 2C in the composite cable 1C is similar to the first linear body 2B in the second embodiment in that multiple, for example, seven metal wires 200C are twisted together to form one linear body, and the outer circumferential surface 29C of the first linear body 2C is covered with an insulating coating 5 made of an insulating material. Therefore, the outer circumferential surface of the insulating coating 5 of the first linear body 2C is covered with an outer jacket 4C.

The insulating coating 5 is made of, for example, the same insulating material as the outer coating 4D (outer coating 4A). The insulating coating 5 is formed, for example, by extrusion molding.

In the composite cable 1C, the signal wire 3C is, for example, a metal wire. The signal wire 3C includes, for example, a twisted wire 301 and a jacket 302 that covers the outer circumference of the twisted wire 301. The twisted wire 301 is made by twisting together a plurality of coated electric wires 311. While FIG. 4 shows an example in which two coated electric wires 311 are twisted together, the number of coated electric wires 311 is not particularly limited.

Each coated electric wire 311 includes a conductor 3110 made of, for example, a metal, and an insulating layer 3111 made of an insulating material that coats the outer circumference of the conductor 3110. The conductor 3110 can be made of, for example, the same material as the first linear body 2A. The insulating layer 3111 can be made of, for example, the same material as the outer sheath 4A. The jacket 302 can be made of, for example, the same material as the outer sheath 4A. The conductor 3110 may be a solid wire or a twisted wire.

In the composite cable 1C according to the third embodiment, the cylindrical body 31C is formed of a non-insulating material. Therefore, according to the composite cable 1C according to the third embodiment, in addition to the effect of the composite cable 1B according to the second embodiment, the electromagnetic waves generated from the first linear body 2C or other devices do not interfere with the second linear body 3C, which is a signal line formed of a metal wire inside the cylindrical body 31C, and the occurrence of signal interference can be suppressed. In addition, in order to suppress local deformation of the cylindrical body 31C when an external force is applied to the outer sheath 4C of the composite cable 1C, the rigidity of the cylindrical body 31C may be configured to be lower than the rigidity of the first linear body 2C or the outer sheath 4C, as in the above-mentioned embodiments. In addition, the outer diameter of the cylindrical body 31C may be configured to be smaller than the inner diameter of the insulating coating 5 of the first linear body 2C, the rigidity of the cylindrical body 31C may be configured to be lower than the rigidity of the insulating coating 5 of the first linear body 2C, etc.

Fourth Embodiment
FIG. 5 is a perspective view of a composite cable 1D according to the fourth embodiment.
The composite cable 1D of embodiment 4 differs from the composite cable 1B of embodiment 2 in that the configuration of the first linear body 2D and the shape of the tubular body 31D are different, but in other respects is similar to the composite cable 1B of embodiment 2.

As shown in Figure 5, in the composite cable 1D, the first linear body 2D is a solid single wire (metal wire) made of a metal material, like the first linear body 2A in the composite cable 1A according to embodiment 1. Unlike the first linear body 2A, the first linear body 2D has a rectangular shape in cross section. The first linear body 2D may be made of any metal material having conductive properties, and examples of such metal materials include aluminum, copper, copper alloy, tin-plated wire, iron, and nickel.

The cylindrical body 31D is made of an insulating material and is arranged adjacent to the first linear body 2D in the cross-sectional direction, similar to the cylindrical body 31A. Unlike the cylindrical body 31A, the cylindrical body 31D has a rectangular shape in cross section.

In the composite cable 1D according to the fourth embodiment, in addition to the effects of the composite cable 1B according to the second embodiment, the first linear body 2D and the tubular body 3D are both rectangular, so that they are easily aligned when they are collectively covered with the outer jacket 4D during manufacturing. In other words, the composite cable 1D according to the fourth embodiment can facilitate the work during manufacturing.

Fifth Embodiment
FIG. 6 is a cross-sectional view of a composite cable 1E according to the fifth embodiment.
The composite cable 1E of the fifth embodiment differs from the composite cable 1D of the fourth embodiment in that the shape of the tubular body 31E is different, but in other respects is similar to the composite cable 1D of the fourth embodiment.

As shown in FIG. 6, in the composite cable 1E, the tubular body 31E has a circular cross-sectional shape like the tubular body 31A of the composite cable 1A of embodiment 1, unlike the tubular body 31D of the composite cable 1D of embodiment 4.

According to the composite cable 1E of embodiment 5, the same effect as that of the composite cable 1D of embodiment 4 described above can be obtained.

Sixth Embodiment
FIG. 7 is a diagram showing the configuration of a composite cable 1F according to the sixth embodiment.
The composite cable 1F of the sixth embodiment differs from the composite cable 1B of the second embodiment in that the shape of the tubular body 31F is different, but in other respects is similar to the composite cable 1B of the second embodiment.

As shown in FIG. 7, in the composite cable 1F, the tubular body 31F is rectangular in cross section, unlike the tubular body 31B of the composite cable 1B of embodiment 2, like the tubular body 31D of the composite cable 1D of embodiment 4.

According to the composite cable 1F of embodiment 6, the same effect as that of the composite cable 1B of embodiment 2 described above can be obtained.

Seventh embodiment
FIG. 8 is a diagram showing the configuration of a composite cable 1G according to the seventh embodiment.
The composite cable 1G of embodiment 7 differs from the composite cable 1B of embodiment 2 in that the shape of the first linear body 2G is different, but in other respects is similar to the composite cable 1B of embodiment 2.

As shown in Fig. 8, in the composite cable 1G, the first linear body 2G has a triangular cross-sectional shape, unlike the first linear body 2B of the composite cable 1B according to embodiment 2. Note that the cross-sectional shape of the first linear body 2G is not limited to the example shown in Fig. 8, and various angular shapes such as a hexagon can be adopted.

According to the composite cable 1G of embodiment 7, the same effect as that of the composite cable 1B of embodiment 2 described above can be obtained.

Eighth embodiment
FIG. 9 is a cross-sectional view of a composite cable according to an eighth embodiment.
As shown in Figure 9, the composite cable 1H of embodiment 8 differs from the composite cable 1D of embodiment 4 in that the shape of the first linear body 2H is rectangular in cross section, the structure of the first linear body 2H is a flat twisted wire, and the number of first linear bodies 2H is increased from two to six, but in other respects is similar to the composite cable 1D of embodiment 4.

9, in the composite cable 1H, the first linear body 2H is a flat twisted wire having a rectangular (e.g., rectangular) cross-sectional shape in order to arrange the first linear body 2H in a space having the same cross-sectional area as the first linear body 2D while increasing the number of first linear bodies 2H from two in the first linear body 2D in the composite cable 1D to six. The flat twisted wire structure in the first linear body 2D is formed by twisting together a plurality of metal wires 200H, as in the first linear body 2B in the composite cable 1B according to embodiment 2. In the composite cable 1H, the first linear bodies 2H are arranged so that their short sides face the longitudinal direction in the cross-sectional view, so that three first linear bodies 2H are arranged on each side of the tubular body 31H.

According to the composite cable 1H of the eighth embodiment, by arranging a plurality of first linear bodies 2H, which are flat stranded wires having a rectangular cross section, on both sides of the tubular body 31H, it is possible to obtain the same effect as the composite cable 1B of the second embodiment described above. The first linear body 2H may be a plate-shaped conductor having a rectangular cross section, a plate-shaped coated conductor coated therewith, or a flat coated stranded wire coated on the first linear body 2H. Furthermore, the rigidity of the tubular body 31H is lower than both the rigidity of the first linear body 2H and the rigidity of the outer jacket 4H, so that local deformation of the tubular body 31H due to bending of the composite cable 1H can be suppressed.

Ninth Embodiment
FIG. 10 is a perspective view of a composite cable 1I according to a tenth embodiment.
The composite cable 1I of embodiment 10 differs from the composite cable 1B of embodiment 2 in that it has the configuration of a first linear body 2I, a slit portion 41I, and a closing member 6I, but is similar to the composite cable 1B of embodiment 2 in other respects.

As shown in FIG. 10, in the composite cable 1I, the first linear body 2I is a solid single wire (metal wire) made of a metal material, similar to the first linear body 2A in the composite cable 1A according to the first embodiment. Note that the first linear body 2I shown in FIG. 10 is not limited to a solid single wire (metal wire) and may be a twisted wire. A plurality of first linear bodies 2I, for example, two, are provided in the composite cable 1I, and are arranged along the direction of a virtual axis X provided in the cross-sectional direction that is perpendicular to the axis AX indicating the extension direction. Specifically, the first linear body 2I is arranged to sandwich the cylindrical body 31I in the cross-sectional direction that is perpendicular to the extension direction of the composite cable 1I. In other words, the cylindrical body 31I is arranged adjacent to both of the two first linear bodies 2I.

The slit portion 41I is provided, for example, between the outer surface of the jacket 4I and the inner surface of the tubular body 31I. The slit portion 41I can separate the jacket 4I and the tubular body 31I at one location in the cross-sectional direction of the composite cable 1I, and communicate the outside of the composite cable 1I with the space on the inner surface of the tubular body 31I. Therefore, in the composite cable 1I, the second linear body 3I can be inserted into the space inside the tubular body 31I using the slit portion 41I. Note that the slit portion 41I may be a cut, a V-shaped groove, or a thin-walled portion provided in a part between the outside of the composite cable 1I and the tubular body 31I, in which the jacket 4I and the tubular body 31I are divided in the cross-sectional direction during the manufacture of the composite cable 1I described later (i.e., before the insertion of the second linear body 3I). In this case, before the second linear body 3I is inserted, an external force can be applied to the side of the slit portion 41I of the composite cable 1I that opens (including passing a tool or the like through the slit portion 41I), thereby allowing the tubular body 31I to be separated afterwards at the position of the slit portion 41I in the cross-sectional direction of the composite cable 1I, thereby connecting the outside of the composite cable 1I with the space on the inner surface of the tubular body 31I.

The closure member 6I is provided on the outer surface of the portion of the outer sheath 4I where the slit portion 41I is provided. The closure member 6I closes the slit portion 41I, which is open to the outside, and the cylindrical body 31I provided inside the slit portion 41I, from the outside. Specifically, the closure member 6I is formed, for example, by a resin tape attached to the outer sheath 4I, or by welding a part of the outer sheath 4I by laser heating, roller heating, or the like. Note that the specific form of the closure member 6I is not limited to the above example, as long as it can seal the slit portion 41I to close it.

According to the composite cable 1I of the ninth embodiment, in addition to the effects of the composite cable 1B of the second embodiment, the slit portion 41I is provided, so that the second linear body 3I such as a signal line can be easily inserted into the cylindrical body 31I provided inside the slit portion 41I during manufacturing. Also, according to the composite cable 1I, since the closing member 6I for closing the slit portion 41I is provided, the slit portion 41I after the second linear body 3I is inserted can be closed reliably and the second linear body 3I can be held inside the cylindrical body 31I. In other words, according to the composite cable 1I of the ninth embodiment, the work during manufacturing can be simplified. In addition, in order to suppress local deformation of the cylindrical body 31I when an external force is applied to the outer sheath 4I of the composite cable 1I, the rigidity of the cylindrical body 31I can be configured to be lower than the rigidity of the first linear body 2I or the rigidity of the outer sheath 4I, as in the above-mentioned embodiments.

Tenth embodiment
FIG. 11 is a cross-sectional view of a composite cable 1J according to a tenth embodiment.
The composite cable 1J of the tenth embodiment differs from the composite cable 1I of the ninth embodiment in that the shape of the slit portion 41J is different, but in other respects is similar to the composite cable 1I of the ninth embodiment.

As shown in Fig. 11, in the composite cable 1J, the slit portion 41J differs from the slit portion 41I of the composite cable 1I according to embodiment 9 in that the outer sheath 4J and the tubular body 31J are diagonally divided at an angle in the cross-sectional direction to connect the outside of the composite cable 1J to the space on the inner surface of the tubular body 31J. Note that the position at which the slit portion 41J is provided in the composite cable 1J is not limited to this.

According to the composite cable 1J of embodiment 10, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

Eleventh Embodiment
FIG. 12 is a diagram showing the configuration of a composite cable 1K according to an eleventh embodiment.
The composite cable 1K of embodiment 11 differs from the composite cable 1I of embodiment 9 in that the shape of the first linear body 2K is different, but in other respects is similar to the composite cable 1I of embodiment 9.

12, in the composite cable 1K, the first linear body 2K is triangular in cross section like the first linear body 2G of the composite cable 1G of embodiment 7, unlike the first linear body 2I of the composite cable 1I of embodiment 9. Note that the cross-sectional shape of the first linear body 2I is not limited to the example shown in FIG. 12, and various angular shapes such as a hexagon can be adopted.

According to the composite cable 1K of embodiment 11, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

<<Twelfth embodiment>>
FIG. 13 is a diagram showing the configuration of a composite cable 1L according to a twelfth embodiment.
The composite cable 1L of embodiment 12 differs from the composite cable 1I of embodiment 9 in that the shape of the tubular body 31L is different, but in other respects is similar to the composite cable 1I of embodiment 9.

As shown in FIG. 13, in the composite cable 1L, the tubular body 31L has a rectangular cross-sectional shape like the tubular body 31D of the composite cable 1D of embodiment 4, unlike the tubular body 31I of the composite cable 1I of embodiment 9.

According to the composite cable 1L of embodiment 12, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

<<Thirteenth embodiment>>
FIG. 14 is a diagram showing the configuration of a composite cable 1M according to the thirteenth embodiment.
The composite cable 1M of embodiment 13 differs from the composite cable 1I of embodiment 9 in that the shape of the first linear body 2M is different, but in other respects is similar to the composite cable 1I of embodiment 9.

As shown in FIG. 14, in the composite cable 1M, the first linear body 2M is rectangular in cross section, unlike the first linear body 2I of the composite cable 1I of embodiment 9, like the first linear body 2D of the composite cable 1D of embodiment 4.

According to the composite cable 1M of embodiment 13, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

<<Embodiment 14>>
FIG. 15 is a diagram showing the configuration of a composite cable 1N according to a fourteenth embodiment.
The composite cable 1N of embodiment 14 differs from the composite cable 1M of embodiment 13 in that the shape of the tubular body 31N is different, but in other respects is similar to the composite cable 1N of embodiment 14.

As shown in FIG. 15, in the composite cable 1N, the tubular body 31N is rectangular in cross section, unlike the tubular body 31M of the composite cable 1M of embodiment 13, like the tubular body 31D of the composite cable 1D of embodiment 4.

According to the composite cable 1N of embodiment 14, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

<<Fifteenth embodiment>>
FIG. 16 is a cross-sectional view of a composite cable 10 according to a fifteenth embodiment.
The composite cable 1O of embodiment 15 differs from the composite cable 1I of embodiment 9 in that the shape of the outer sheath 4O is different, but in other respects is similar to the composite cable 1I of embodiment 9.

As shown in Figure 16, in the composite cable 1O, unlike the outer sheath 4O of the composite cable 1I according to embodiment 9, the outer sheath 4O is formed in a shape in which two oval shapes are arranged in the cross-sectional direction so as to cover the outside of the two first linear bodies 2O. Also, in the composite cable 1O, the slit portion 41O is formed at a position where the two oval shapes of the outer sheath 4O are joined in the cross-sectional direction. Therefore, in the composite cable 1O, the slit portion 41O can be provided in the thin-walled portion of the outer sheath 4O, which makes it easier to form the slit portion 41O.

According to the composite cable 1O of embodiment 15, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

Sixteenth Embodiment
FIG. 17 is a cross-sectional view of a composite cable 1P according to a sixteenth embodiment.
The composite cable 1P of embodiment 16 differs from the composite cable 1O of embodiment 15 in that the shape of the closing member 6P is different, but in other respects is similar to the composite cable 1O of embodiment 15.

17, in the composite cable 1P, unlike the closing member 6O of the composite cable 1O according to embodiment 15, the closing member 6P is provided in two places so as to linearly connect the vertices of the outer sheath 4P which is formed in a shape like two ellipses arranged side by side in the cross-sectional direction. Also, in the composite cable 1P, the area between the inside of the closing member 6P and the outer sheath 4P has two spaces (linear body arrangement portions 7P) in which the second linear body 3P can be arranged.

According to the composite cable 1P of embodiment 16, in addition to being able to obtain the same effect as the composite cable 1I of embodiment 9 described above, by having a linear body arrangement portion 7P formed by an outer jacket 4P and a closing member 6P, it is possible to arrange even more second linear bodies 3P. In addition, since the second linear bodies 3P can be arranged separately in the tubular body 31P and the linear body arrangement portion 7P, the second linear bodies 3P can be appropriately arranged according to the arrangement form of the composite cable 1P.

<<Embodiment 17>>
FIG. 18 is a cross-sectional view of a composite cable 1Q according to a seventeenth embodiment.
The composite cable 1Q of embodiment 17 differs from the composite cable 1P of embodiment 16 in that it does not have a closing member 6O but instead has a covering member 10Q that covers the outside of the outer sheath 4O, but in other respects is similar to the composite cable 1P of embodiment 16.

As shown in Figure 18, in the composite cable 1Q, unlike the closing member 6P of the composite cable 1P according to embodiment 16, the covering member 10Q is provided to cover from the outside the entire outer sheath 4Q which is formed in a shape like two ellipses arranged side by side in the cross-sectional direction. The covering member 10Q has an elliptical shape in cross section in Figure 18, but it may have an oval shape in cross section, for example. Also, in the composite cable 1Q, a space (linear body arrangement portion 7Q) is formed in the area between the inside of the covering member 10Q and the outer sheath 4Q in which the second linear body 3Q can be arranged.

According to the composite cable 1P of embodiment 17, the same effect as that of the composite cable 1P of embodiment 16 described above can be obtained.

<Embodiment 18>
FIG. 19 is a cross-sectional view of a composite cable 1R according to an eighteenth embodiment.
The composite cable 1R of embodiment 18 differs from the composite cable 1I of embodiment 9 in that the number of first linear bodies 2R, the number of second linear bodies 3R, the number of tubular bodies 31R, the number of slit portions 41R, and the number of closing members 6R are different, but in other respects it is similar to the composite cable 1I of embodiment 9.

As shown in FIG. 19, the composite cable 1R has three first linear bodies 2R, two tubular bodies 31R, and four second linear bodies 3R. In the cross-sectional direction of the composite cable 1R, the tubular bodies 31R are arranged alternately with the first linear bodies 2R. Furthermore, the first linear bodies 2R are arranged at both ends of the arrangement in the arrangement direction of the components of the composite cable 1R. The slit portions 41R and closing members 6R in the cross-sectional direction of the composite cable 1R are provided corresponding to each of the two tubular bodies 31R. Thus, in the composite cable 1R, the number of first linear bodies 2R, the number of second linear bodies 3R, the number of tubular bodies 31R, the number of slit portions 41R, and the number of closing members 6R are not limited.

According to the composite cable 1R of embodiment 18, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

<<Embodiment 19>>
FIG. 20 is a diagram showing the configuration of a composite cable 1S according to the nineteenth embodiment.
The composite cable 1S of embodiment 19 differs from the composite cable 1I of embodiment 9 in that the configuration of the first linear body 2S is different, but in other respects is similar to the composite cable 1I of embodiment 9.

20, in the composite cable 1S, the first linear body 2S is different from the first linear body 2I of the composite cable 1I according to the ninth embodiment in that the outer surface of the metal wire 200S made of a single metal wire is covered with an insulating coating 5 made of an insulating material. Therefore, in the first linear body 2S, the outer surface of the insulating coating 5 is covered with an outer jacket 4S.

According to the composite cable 1S of embodiment 19, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

<<Twentyth embodiment>>
FIG. 21 is a diagram showing the configuration of a composite cable 1T according to embodiment 20.
The composite cable 1T of embodiment 20 differs from the composite cable 1I of embodiment 9 in that the configuration of the first linear body 2T is different, but in other respects is similar to the composite cable 1I of embodiment 9.

21, in the composite cable 1T, unlike the first linear body 2I of the composite cable 1I according to embodiment 9, the first linear body 2T is similar to the first linear body 2B according to embodiment 2 in that a plurality of, for example, seven metal wires 200T are twisted together to form one linear body, the outer circumferential surface of which is covered with an insulating coating 5 made of an insulating material. Therefore, the outer circumferential surface of the insulating coating 5 of the first linear body 2T is covered with an outer jacket 4T.

According to the composite cable 1T of embodiment 20, the same effect as that of the composite cable 1I of embodiment 9 described above can be obtained.

<<Embodiment 21>>
FIG. 22 is a cross-sectional view of a composite cable 1B according to a twenty-first embodiment.
22 is a diagram showing a configuration in which external terminals are connected to the end of a composite cable 1B according to an embodiment of the present invention. In the figure, as an example, a case in which external terminals 8 and 9 are connected to the composite cable 1B according to the second embodiment is shown.

The external terminal 8 (first external terminal) is a simple connection member for facilitating the connection of the first linear body 2B in the composite cable 1B with an external device or other wiring. An example of the external terminal 8 is a crimp terminal. The external terminal 8 is connected to the end of the first linear body 2B in the extension direction.

The external terminal 9 (second external terminal) is a simple connection member for facilitating connection of the signal line 3B in the composite cable 1B with an external device or other wiring. For example, when the signal line 3B is an optical fiber, the external terminal 9 can be, for example, various optical connectors such as FC, SC, and LC. The external terminal 9 is connected to the end of each signal line 3B in the extension direction.

In the present embodiment, the case where separate external terminals 8, 9 are connected to the first linear body 2B and the signal line 3B of the composite cable 1B is illustrated, but this is not limited to the above. For example, a single connector-like simple connection member in which the external terminals 8, 9 are integrally formed may be connected to the end of the composite cable 1B.

In addition, in this embodiment, an example has been given of connecting external terminals 8, 9 to the composite cable 1B of embodiment 2, but external terminals 8, 9 can also be connected to each of the composite cables 1A, 1C to 1T of embodiments 1, 3 to 20 in a similar manner.

<<Embodiment 22>>
Next, a method for manufacturing the above-mentioned composite cables 1A to 1T will be described.
23 is a flow diagram showing the flow of a method for manufacturing a composite cable according to one embodiment of the present invention. Here, the flow of the manufacturing method of the composite cable 1A according to the first embodiment will be described as a representative example, but the composite cables 1B to 1T according to the other embodiments can also be manufactured by substantially the same flow.

First, a conductive first linear body 2A is formed (step S101). For example, as described above, the first linear body 2A is formed by extruding a metal material such as aluminum, copper, copper alloy, tin-plated wire, iron, and nickel. Here, in the case of a power line through which a large current flows, the cross-sectional area of the first linear body 2A is large. Therefore, in order to ensure the bendability of the composite cable, a copper-based or aluminum-based material that is a relatively flexible material and has a small amount of impurities or additives is preferable, as in each of the above-mentioned embodiments.

Next, an insulating cylindrical body 31A is formed (step S102). For example, as described above, the cylindrical body 31A is formed by extruding an insulating material such as polyethylene, PVC, nylon, or silicone resin.

Next, the outer jacket 4A is formed from an insulating material that covers the outer surface 29A of the first linear body 2A and the outer surface 32A of the tubular body 31A formed in steps S101 and S102 (step S103). For example, as described above, the outer jacket 4A is formed by extruding (e.g., one-time extrusion) a material such as polyethylene, PVC, nylon, or silicone resin on the outer surface 29A of the first linear body 2A and the outer surface 29A of the tubular body 31A. In the case of composite cables 1I-1T in which slit portions 41I-41T are provided in the outer jackets 4I-4T and the tubular bodies 31I-31T, after the outer jackets 4I-4T are formed by extrusion molding, a processing process is performed in which the outer jackets 4I-4T are cut open or cut or V-shaped grooves are formed in order to form the slit portions 41I-41T.

Next, the second linear body 3A is inserted into the cylindrical body 31A on which the outer jacket 4A was formed in step S103 (step S104). For example, the subassembly in which the outer jacket 4A is formed on the cylindrical body 31A is cut so that the subassembly has a predetermined length, and an optical fiber as the signal line 3A is inserted from the end of the cut subassembly (the end of the cylindrical body 31A). In the case of a composite cable 1I-1T in which slit portions 41I-41T are provided in the outer jackets 4I-4T and the cylindrical bodies 31I-31T, the slit portions 41I-41T are opened and the second linear body 3I-3T is inserted into the cylindrical body 31I-31T. After the second linear body 3I-3T is inserted into the cylindrical body 31I-31T, in order to close the slit portions 41I-41T, a closing member 6I-6T is provided on the outside of the outer jacket 4I-4T by an appropriate method such as attaching a tape or welding the outer jacket 4I-4T.

Next, if necessary, a simple connection member 8 serving as a first external terminal is connected to the end in the extension direction of the first linear body 2A on which the outer sheath 4A was formed in step S103 (step S105).

Next, if necessary, a simple connection member 9 as a second external terminal is connected to the end in the extension direction of the second linear body 3A inserted inside the cylindrical body 31A in step S104 (step S106). Note that the connection of the simple connection members 8 and 9 in steps S105 and S106 can be realized by using a known method such as a conventional method for connecting crimp terminals.

This makes it possible to manufacture the composite cable 1A of embodiment 1.

In step S104, an example has been given of inserting a signal line (optical fiber) as the second linear body 3A inside the cylindrical body 31A on which the outer sheath 4A was formed in step S103, but the signal line may be a metal wire instead of an optical fiber, and a thread member that does not function as a transmission line (e.g., a drawstring) may be inserted instead of the signal line.

Specifically, in step S104, the pull string as the linear body 3A is inserted in a movable state into the inside of the tubular body 31A. Then, the tubular body 31A on which the outer jacket 4A is formed and the pull string inserted therein may be shipped as a composite cable.

In this case, at the site where the composite cable is to be installed, a signal line such as a metal wire or optical fiber is tied to the pull string, and the pull string is pulled to introduce the signal line into the inside of the cylindrical body 31A. This allows any signal line such as a metal wire or optical fiber to be introduced into the composite cable at the site where the composite cable is to be installed.

In addition, in the case of composite cables 1I-1T, after extrusion molding of the outer sheath 4I-4T, the slit portions 41I-41T provided in the outer sheath 4I-4T and the tubular body 31I-31T are formed, the formed slit portions 41I-41T are opened, the second linear body 3I-3T is inserted into the tubular body 31I-31T, and the slit portions 41I-41T are closed using the closing members 6I-6T. This series of operations can be carried out on a single line.

<<Embodiment 23>>
24 and 25 are diagrams showing an example of wiring when the composite cable according to the embodiment of the present invention is used as an on-vehicle wire harness.
Figure 24 shows a plan view of a wiring harness arrangement structure using any of the composite cables 1A to 1T of the above embodiments, and Figure 25 shows an oblique view of a key portion of the wiring harness arrangement structure.

The wiring harness arrangement structure 500 shown in Figures 24 and 25 is mounted on a vehicle 600. Examples of the vehicle 600 include automobiles including hybrid vehicles, electric vehicles, fuel cell vehicles, etc.

24 and 25, the wiring structure 500 of the wire harness has, as a power supply system, a first power supply trunk 12a connected to a power source 10 mounted on a vehicle 600, a first power supply distributor 11a connected to the first power supply trunk 12a, a second power supply trunk 12b connected to the first power supply distributor 11a and arranged in the fore-and-aft direction of the vehicle, a second power supply distributor 11b connected to the second power supply trunk 12b, a third power supply trunk 12c connected to the second power supply distributor 11b and arranged in the vehicle width direction, a third power supply distributor 11c connected to the third power supply trunk 12c, a fourth power supply trunk 12d connected to the third power supply distributor 11c and arranged in the fore-and-aft direction of the vehicle, and a fourth power supply distributor 11d connected to the fourth power supply trunk 12d. In addition, the wire harness routing structure 500 has, as communication infrastructure, a first communication control unit 21a, a first communication trunk 22a connected to the first communication control unit 21a and routed in the fore-and-aft direction of the vehicle, a second communication control unit 21b connected to the first communication trunk 22a, a second communication trunk 22b connected to the second communication control unit 21b and routed in the vehicle width direction, a third communication control unit 21c connected to the second communication trunk 22b, a third communication trunk 22c connected to the third communication control unit 21c and routed in the fore-and-aft direction of the vehicle, and a fourth communication control unit 21d connected to the third communication trunk 22c. The power supply control unit 21 also has a branch line (communication branch line and power supply branch line) 13 connected to each of the first to fourth power supply distributors 11a to 11d, a first auxiliary 14 connected to each of the branch lines 13, a branch line (communication branch line and power supply branch line) 15 connected to each of the communication control units 21a to 21d, and a second auxiliary 16 connected to each of the branch lines 15. The first power supply distributor 11a and the first communication control unit 21a are housed in a first housing 31 and integrated. Similarly, the second power supply distributor 11b and the first communication control unit 21b are housed in a second housing 32, the third power supply distributor 11c and the third communication control unit 21c are housed in a third housing 33, and the fourth power supply distributor 11d and the fourth communication control unit 21d are housed in a fourth housing 34 and integrated.

In the wiring harness arrangement structure 500, the composite cables 1A to 1T according to any of the above-mentioned embodiments 1 to 8 can be used for at least a portion of the trunk lines including the power lines and the communication lines, i.e., the power supply trunk lines 12a to 12d and the communication trunk lines 22a to 22c. Similarly, in the wiring harness arrangement structure 500, the composite cables 1A to 1T according to any of the above-mentioned embodiments 1 to 21 can be used for at least a portion of the branch lines (power supply branch lines and communication branch lines) 13, 15 branching off from the trunk line.

In this way, by adopting the composite cable 1A-1T according to any one of the above-mentioned embodiments 1 to 20 in the wiring harness arrangement structure 500 for a vehicle, the power line and the communication line can be routed by one cable, so that the wiring of the wire harness in the vehicle can be further improved. In addition, in the wiring harness arrangement structure 500 of FIG. 25, the composite cable 1A-1T has a bent portion BP that follows the shape of the vehicle 600 to be routed. The bent portion BP may have a small bending radius. In the conventional composite cable, the influence of bending on the communication line is a concern, but in the present invention, by applying the composite cable 1A-1T according to any one of the embodiments 1 to 20, local deformation of the tubular body 31A-31T due to the application of an external force to the composite cable is suppressed, and the application of an external force to the second linear body 3A-3T can be avoided.

In addition, in the wiring structure 500 of the wire harness, the power supply trunk lines 12a to 12d and the branch lines 13, 15 (power supply branch lines) may include a signal line to which a power supply voltage is supplied and a signal line (earth line) to which a ground voltage is supplied, or the power supply trunk lines 12a to 12d and the branch lines 13, 15 (power supply branch lines) may be signal lines to which a power supply voltage is supplied, and an earth line to which a ground voltage is supplied may be provided separately from these power supply lines.

<<Extension of the embodiment>>
The invention made by the present inventors has been specifically described above based on an embodiment, but it goes without saying that the invention is not limited thereto and can be modified in various ways without departing from the spirit of the invention.

For example, in the above embodiment, the second linear bodies 3A, 3C are communication lines such as optical fibers or metal wires, but as described above, the second linear bodies 3A, 3C may be thread members (such as pull strings) that do not function as transmission lines.

Figure 26 is a cross-sectional view showing another aspect of the composite cable 1A1 according to embodiment 1. Also, Figure 27 is a cross-sectional view showing yet another aspect of the composite cable 1A2 according to embodiment 1.

26 and 27, the composite cables 1A1 and 1A2 according to the first embodiment may have a slit portion 41A and a closing member 6A. The slit portion 41A and the closing member 6A may be provided on a side surface corresponding to the short direction in the cross section of the outer sheath 4A of the composite cable 1A1 as shown in Fig. 26, or may be provided on an upper surface corresponding to the long direction in the cross section of the outer sheath 4A of the composite cable 1A2 as shown in Fig. 27.

According to the composite cable 1A relating to another aspect of embodiment 1 that is formed as described above, it is possible to obtain the same effect as the composite cable 1I relating to embodiment 9 described above.

In addition, in the above-mentioned second embodiment, the first linear bodies 2B are arranged one at a time on both ends of the arrangement of the components of the composite cable 1B in the arrangement direction so as to sandwich the tubular body 31B, but this is not limited to this, and for example, as shown in Figure 28, the first linear bodies 2B1 may be arranged two at a time so as to sandwich the tubular body 31B1, or three or more may be arranged. In this way, when an external force is applied to the outer sheath 4B1 of the composite cable 1B1, local deformation of the tubular body 31B1 is further suppressed.

In addition, in the above-mentioned embodiment 5, the first linear body 2E of the composite cable 1E is rectangular (square) in cross section, but is not limited thereto. For example, as shown in FIG. 29, the first linear body 2E1 may be rectangular in cross section and flattened in the arrangement direction of the components of the composite cable 1E1. In this way, the composite cable 1E1 becomes easier to bend in the flattened direction, and heat dissipation is improved. In addition, if the dimension of the tubular body 31E1 in the thickness direction of the composite cable 1E1 is made smaller than the dimension of the first linear body 2E1 in the thickness direction of the composite cable 1E1, local deformation of the tubular body 31E1 is further suppressed. In FIG. 29, the first linear body 2E1 and the tubular body 31E1 are arranged side by side through the outer sheath 4E1, but the first linear body 2E1 and the tubular body 31E1 may be adjacent to each other.

In the above embodiment 1, the first linear body 2A of the composite cable 1A is circular in cross section, but this is not limited thereto. For example, as shown in FIG. 30, the first linear body 2A3 may be rectangular in cross section and flattened in the arrangement direction of the components of the composite cable 1A3. In this way, the composite cable 1A3 becomes easier to bend in the flattened direction, and heat dissipation is improved. In addition, if the dimension of the tubular body 31A3 in the thickness direction of the composite cable 1A3 is made smaller than the dimension of the first linear body 2A3 in the thickness direction of the composite cable 1A3, local deformation of the tubular body 31A3 is further suppressed. In FIG. 30, the first linear body 2A3 and the tubular body 31A3 are arranged side by side through the outer sheath 4A3, but the first linear body 2A3 and the tubular body 31A3 may be adjacent to each other.

According to the composite cables 1A3, 1C1, and 1F1 according to other aspects of the first, second, and fifth embodiments formed as described above, it is possible to obtain the same effects as the composite cables 1A, 1C, and 1F according to the first, second, and fifth embodiments described above. The same can also be applied to the other embodiments.

1A to 1T, 1A1 to 1A3, 1B1, 1E1... composite cable, 2A to 2H, 2A1 to 2A3, 2B1, 2E1... first linear body, 3A to 3B, 3D to 3T, 3A1 to 3A3, 3B1, 3E1... second linear body, signal line (optical fiber), 3C... linear body, signal line (metal wire), 4A to 4T, 4A1 to 4A3, 4B1, 4E1... outer sheath, 5... insulating coating, 6A, 6I to 6T... closing member, 7... linear body arrangement portion, 8... first external terminal (easy connection member), 9... second external terminal (easy connection member), 12a to 12d... power supply main line, 13, 15... branch line, 22a to 22c... communication main line, 28A, 28B... inner circumferential surface, 29A, 29B, 29C... outer circumferential surface, 30... Space, 31...first housing, 31A to 31T, 31A1 to 31A3, 31B1, 31E1...cylindrical body, 32...second housing, 32A...outer surface, 32B...outer surface, 33...third housing, 33A...inner surface, 34...fourth housing, 41A, 41I to 41T...slit portion, 101...core, 102...clad, 103...fiber bare wire coating, 104...buffer material, 105...outer jacket, 200B...metal wire, 200C...metal wire, 200H...metal wire, 301...twisted wire, 302...jacket, 311...coated electric wire, 500...wiring structure, 600...vehicle, 1015...outer jacket, 3110...conductor, 3111...insulating layer, BP...bent portion

Claims (17)

At least one first linear body including a conductor formed of a conductive material;
A cylindrical body extending in a direction in which the first linear body extends;
At least one second linear body accommodated in an unconstrained state inside the cylindrical body;
an outer covering made of an insulating material covering the outer circumferential surfaces of the first linear body and the cylindrical body;
the first linear body and the cylindrical body are arranged side by side in an arrangement direction which is one direction of a cross section perpendicular to an extension direction of the first linear body,
the first linear body and the outer jacket are configured to be capable of suppressing local deformation of the cylindrical body due to the influence of an external force ,
The outer cover has a slit portion extending from an outer circumferential surface toward the cylindrical body,
The slit portion is provided on an outer peripheral surface of the outer jacket and includes a closing member that closes the slit portion .
A composite cable characterized by: The composite cable according to claim 1, characterized in that the rigidity of the tubular body is lower than both the rigidity of the first linear body and the rigidity of the outer sheath. 3. The composite cable according to claim 2,
A composite cable comprising: a cylindrical body having an outer surface and an inner surface of the outer sheath in close contact with each other; 2. The composite cable according to claim 1,
The composite cable, wherein the cylindrical body is movable relative to the outer sheath. 2. The composite cable according to claim 1,
A composite cable, characterized in that the first linear members are arranged at both ends of the arrangement in the arrangement direction. 2. The composite cable according to claim 1,
A composite cable, characterized in that the first linear members are arranged on both sides of the cylindrical member in an arrangement direction. 2. The composite cable according to claim 1,
A composite cable, wherein a dimension of the tubular body in a cable thickness direction is smaller than a dimension of the first linear body in the cable thickness direction. 2. The composite cable according to claim 1,
A composite cable, wherein a dimension of the tubular body in a cable thickness direction is smaller than a dimension of a conductor portion of the first linear body in the cable thickness direction. 2. The composite cable according to claim 1,
A composite cable, characterized in that the second linear body includes at least one of a metal wire which is a transmission line for an electric signal, an optical fiber which is a transmission line for an optical signal, and a thread member which does not function as a transmission line. 2. The composite cable according to claim 1,
a first external terminal connected to an end of the first linear body in an extension direction and a second external terminal connected to an end of the second linear body in an extension direction. 2. The composite cable according to claim 1 ,
The composite cable, wherein the slit portion reaches the cylindrical body. A trunk line including a power line and a communication line, and a branch line branching off from the trunk line,
A wiring harness arrangement structure, wherein at least a part of the trunk wire or the branch wire is the composite cable according to claim 1. The wiring harness arrangement structure according to claim 12 ,
a bent portion of at least one of the main wire and the branch wire that is bent along an object to be wired, The wiring harness arrangement structure according to claim 12 ,
The wiring harness arrangement structure further comprises a ground wire. A first step of forming at least one first linear body made of a conductive material;
A second step of forming a cylindrical body;
a third step of forming an outer cover made of an insulating material by extrusion molding, the outer cover covering the outer peripheral surfaces of the first linear body formed in the first step and the cylindrical body formed in the second step, and then performing a processing step of forming a slit portion ;
a fourth step of opening the slit portion and inserting a second linear object into the inside of the tubular body on which the outer sheath is formed in the third step, and then providing a closing member on the outside of the outer sheath . The method for producing a composite cable according to claim 15 ,
At the end of the first linear body on which the jacket is formed in the fourth step,
a fifth step of connecting a first external terminal. The method for producing a composite cable according to claim 16 ,
a sixth step of connecting a second external terminal to an end of the second linear body in an extending direction thereof.

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