JPH05166415A - Flat insulated wire and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide an insulated wire which is usable in the case of a large current flow and capable of securing a space sufficient to install wiring and also easily applicable to a nonlinear wiring route, and to dispense with a member exclusively used for keeping wiring positions. CONSTITUTION:A plurality of parallel arranged conductors 52 are formed by molding after a wiring route and the conductors 52 formed by molding are covered with insulating materials 53 such that they are put between the insulating materials 53 at the upper and lower sides. It is thereby possible to simply lay an insulated wire 50 along a nonlinear wiring route as the wire is finished in advance in a form corresponding to the wiring route, and also it is possible to omit members exclusively used for keeping wiring positions such as a protector, etc. Moreover, as the plurality of conductors 52 are arranged in parallel, they can secure a large cross sectional area of conductor for a large current flow and also easily secure a space for installation of wiring by flattening the form of the sectional area.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flat insulated wire attached along a predetermined wiring path and a method for manufacturing the flat insulated wire.

[0002]

2. Description of the Related Art Electric wires used for in-vehicle wiring are
Generally, an insulated wire 10 having a circular cross section as shown in FIG. 16 is used. The insulated wire 10 is formed by covering a conductor 12 formed by twisting a plurality of element wires 11 made of a copper wire or the like into a substantially circular cross section with an insulating material 13.

In such an insulated wire 10, terminal processing is performed before wiring work. Insulated wire 10 for terminal treatment
A predetermined amount of the insulating material 13 at the end of the conductor 12 is stripped to expose the end of the conductor 12, and a terminal or the like is crimped to the exposed portion. Then, after that, at the wiring work site, the insulated electric wire 10 is bent along the wiring route in the vehicle, and the required portions are fixed by a clamp or the like. In some cases, the insulated wire 10 is preliminarily formed along the wiring path and is held in a forming posture by a protector or the like in the electric wire manufacturing stage. Then, the insulated electric wire 20 held in the molding posture is attached at the wiring work site.

On the other hand, in recent years, a flat insulated wire 20 as shown in FIG. 17 has also been proposed. This insulated wire 2
0 is formed by arranging a plurality of (four) conductors 22 in parallel and covering the outer circumference with an insulating material 23.

[0005]

A drive motor for mobile equipment such as an electric vehicle has a large load and requires a large current. Fig. 1 shows the wiring for such a drive motor.
When the insulated wire 10 shown in FIG. 6 is used, it is necessary to make the cross section of the conductor 12 large so as to cope with a large current, and naturally the diameter dimension of the insulated wire 10 also becomes large. For this reason, it is necessary to secure a wiring mounting space having a large cross-section that spreads in the radial direction along the wiring path, and the wiring for the drive motor of the electric vehicle that requires the wiring for the large current in the limited space. There is a problem that it is not suitable in such cases.

In addition, in the wiring work, the insulated electric wire 10 must be bent along the wiring path, and there is a problem that the work is complicated. In addition, when the shape of the electric wire 10 is held in advance so as to conform to the wiring path, a member such as a protector for holding the electric wire 10 in the molding posture is separately required, and the number of parts is increased accordingly. However, there is a problem in that the cost increases and the wiring mounting space also increases. In addition, the terminal treatment requires a work of peeling off the insulating material 13 at the end portion of the insulated wire 10, and thus has a problem that the terminal treatment work is complicated.

On the other hand, in the flat insulated wire 20 shown in FIG. 17, since a plurality of conductors 22 are arranged in parallel, the cross-sectional shape is substantially rectangular while securing a large conductor cross-sectional area for a large current. With the flat shape, it is easy to secure a space for wiring installation. However, when the wiring is attached along the non-linear wiring route so as to sew a gap between required portions like the wiring in the vehicle, the insulated wire 20 is connected to the conductor 22.
Is also required to be bent in the arrangement direction (the left-right direction in FIG. 17), and it is extremely difficult to bend the insulated wire 20 in the same direction. Therefore, it is practically impossible to use the insulated wire 20 for in-vehicle wiring. there were.

A first object of the present invention is that it can be used even under a large current, can secure a sufficient wiring mounting space, and can easily deal with a non-linear wiring path such as in-vehicle wiring. It is an object of the present invention to provide an insulated wire that does not particularly require a dedicated member for maintaining the wiring posture.

A second object of the present invention is to provide a method for manufacturing a flat insulated wire which can achieve the first object.

A third object of the present invention is to provide a method for manufacturing a flat insulated wire which can be used even under a large current, can secure a sufficient wiring mounting space, and can easily carry out a terminal treatment operation. ..

[0011]

The invention according to claim 1 is
A flat insulated wire attached along a non-linear wiring path, in order to achieve the above-mentioned first object, the wires are arranged in parallel in contact with each other, and follow the wiring path in the direction of the arrangement. A plurality of conductors formed by bending are provided, and an insulating material that covers the plurality of conductors so as to sandwich the conductors in a direction orthogonal to the arrangement direction.

According to a second aspect of the present invention, there is provided a method of manufacturing a flat insulated wire which is attached along a non-linear wiring path, and in order to achieve the second object, the parallel insulated wires are in contact with each other. A forming step of forming a plurality of conductors arranged in a line so as to bend in the direction of the arrangement along the wiring path, and after the forming step is completed, the plurality of conductors are orthogonal to the direction of the arrangement. And a covering step of covering the insulating material from the direction.

According to a third aspect of the present invention, there is provided a method of manufacturing an insulated wire, which comprises the step of arranging a plurality of conductors in parallel while making contact with each other and the parallel formation of the plurality of conductors in order to achieve the third object. And a step of covering the central region of each of the plurality of arranged conductors excluding the ends thereof with an insulating material so as to sandwich the central region from a direction orthogonal to the direction of the arrangement.

[0014]

According to the flat insulated wire of the first aspect, the plurality of conductors arranged in parallel are preformed so as to be bent in the arrangement direction following the non-linear wiring path. Also, it is possible to easily deal with a non-linear wiring path, and a dedicated member such as a protector for maintaining the wiring posture can be omitted. Furthermore, since a plurality of conductors are arranged in parallel, it is easy to secure a wiring mounting space by making the cross-sectional shape flat while securing a large conductor cross-sectional area for a large current.

According to the method for producing a flat insulated wire of the second aspect, a plurality of conductors arranged in parallel are formed along a non-linear wiring path, and then coated with an insulating material. Therefore, it is possible to manufacture a flat insulated wire finished in a shape suitable for a non-linear wiring path.

According to the third aspect of the present invention, the plurality of conductors are arranged in parallel, and the central region of each of the plurality of conductors except the end portions is covered with the insulating material. Therefore, it is possible to manufacture a flat insulated wire in which the conductor end portion is exposed, and the terminal treatment work can be simplified. Moreover, since the manufactured insulated wire has a plurality of conductors arranged in parallel, it is easy to secure a wiring mounting space as a flat shape while securing a large conductor cross-sectional area for a large current.

[0017]

1 to 9 are views for explaining a first embodiment of the present invention. In the following examples, claim 1
According to the inventions described in (3) to (3), a flat insulated wire that is used under a large current for a drive motor of an electric vehicle or the like and that is attached along a non-linear wiring path so as to sew between required parts is manufactured. The case will be described.

As shown in FIGS. 1 and 2, first, a flat insulated wire is manufactured by twisting a plurality of (seven) wires 51 made of aluminum wire or annealed copper wire into a substantially circular cross section. 52 is formed.

Next, as shown in FIGS. 3 and 4, the four conductors 52 are arranged in parallel while being in contact with each other.
In this case, the adjacent conductors 52 may be welded to each other,
You don't have to.

Subsequently, as shown in FIG. 5, the conductors 52 arranged in parallel are modeled according to the shape of the above-mentioned wiring path to form the conductors 5.
Molding is performed so as to be bent in the arrangement direction of 2 (arrangement direction of FIG. 5).

Next, as shown in FIGS. 6 and 7, two insulating plastic sheets made of polyvinyl chloride (PVC) or the like and formed in correspondence with the planar shape of the above-mentioned molded conductor 52 ( The insulating materials 53, 53 are superposed on the central region of the conductor 52 excluding the end portion 52a so as to be sandwiched from the direction orthogonal to the arrangement direction of the conductors 52 (the direction perpendicular to the paper surface of FIG. 6).

Subsequently, the insulating materials 53, 53 are welded to each other by heat treatment (heat sealing treatment), and the ears 53a, 53a (see FIG. 7) are cut off.

As a result, as shown in FIGS. 8 and 9,
The flat insulated wire 50 in which the end portion 52a of the conductor 52 is exposed is formed.

As shown in FIGS. 10 and 11, the end treatment of the insulated electric wire 50 is performed by twisting the exposed end portions 52a of the four conductors 52 into a substantially circular shape and connecting the terminals (not shown) to the twisted portions. ) Is attached by crimping or welding and, if necessary, connectors and the like.

The insulated wire 50 that has been subjected to the terminal treatment is transported to the wiring work site and used for the wiring work. That is, the insulated wire 50 is arranged along the above wiring path, and a required portion is fixed by using a fixture such as a clamp. In this case, since the insulated electric wire 50 is finished by following the wiring route in advance, the wiring work is completed simply by arranging the insulated electric wire 50 along the wiring route in that state and fixing it with a clamp. For example, the work of bending the insulated wire 50 in the conductor arrangement direction can be omitted, and the work of wiring can be performed easily. Further, since a dedicated member such as a protector for holding the wiring posture is not used, the number of parts can be reduced accordingly, the cost can be reduced, and the wiring mounting space can be reduced.

In the step of coating the insulating material 53, the conductor 5
Since the central region excluding the second end 52a is covered, the insulated wire 50 in which the end 52a of the conductor 52 is exposed is formed. Therefore, it is not necessary to newly peel off the end portion of the insulating material 53 to expose the end portion 52a, which simplifies the terminal treatment. Furthermore, since the end portion 52a of the conductor 52 is laid in a substantially circular shape in the terminal treatment, the end portion 52 is
a has substantially the same shape as the conductor 52 of the insulated wire 10 shown in FIG. 16, and the terminal crimping can be performed without any trouble using the conventional device.

Further, since a plurality of conductors 52 are used, a large total cross section of the conductor 52 can be secured and it can be used even under a large current. Moreover, since the conductors 52 are arranged in parallel, the cross section becomes a flat shape having a substantially rectangular shape, and it becomes easy to secure a wiring mounting space. For reference, while setting the thickness of the insulating material to 4.5 mm, the conductor cross-sectional area is 100 mm.
^{2 is} secured, the conventional insulated wire 10 having a circular cross section shown in FIG. 16 has a diameter L1 (see FIG. 16) of 23.6 mm, but the flat insulated wire 50 of this embodiment has a thickness L2.
(See FIG. 8) becomes 16.5 mm. Further, generally, as the number of twisted strands increases, it takes more time to manufacture the conductor. Therefore, the manufacturing time can be shortened by using a plurality of conductors 52 as in the insulated wire 50 of this embodiment, as compared with the case of using the single conductor 12 having a large diameter as in the conventional insulated wire 10.

If the conductors 52 are merely contacted with each other without being welded to each other, the insulated wire 50 is easily bent, and a laying error at the time of laying the wire can be easily absorbed.

Further, by appropriately changing the material of the insulating material 53, the hardness and heat resistance of the insulated wire 50 can be arbitrarily set.

12 and 13 are views for explaining a method of manufacturing a flat insulated wire according to a second embodiment of the present invention, and particularly relate to the invention of claim 3.

In the method of manufacturing the insulated wire 150, the three conductors 53 in which the plurality of element wires 51 are twisted are arranged in parallel. And the insulating material 5 made of an insulating plastic sheet
3, 53 in the central region excluding the end portion 52a of the conductor 52,
The conductors 52 are stacked so as to be sandwiched from a direction orthogonal to the arrangement direction of the conductors 52 (vertical direction in FIG. 13), and are welded to each other by heat sealing. This allows the conductor 52
A straight insulated wire 150 having an exposed end 52a is formed.

As shown in FIGS. 14 and 15, the wire end treatment is performed by twisting the exposed end portions 52a of the three conductors 52 into a substantially circular shape and attaching the terminals to the twisted portions by crimping or welding. Further, a connector or the like is attached if necessary.

According to this insulated wire 150, since the central region of the conductor 52 excluding the end portion 52a is covered, the insulated wire 150 having the exposed end portion 52a can be manufactured. Therefore, the insulating material 5 for exposing the end portion 52a
The end stripping work of 3 can be omitted, and the terminal processing becomes simple.

In the above embodiment, the insulating material is covered by the heat-sealing process of the plastic sheet, but it may be formed by vacuum forming.

Further, the number of conductors 52 is not limited to three or four, and may be plural.

[0036]

According to the flat insulated wire of claim 1,
Since multiple conductors arranged in parallel are pre-molded so as to bend in parallel following the non-linear wiring path, it is easy to arrange non-linear wiring simply by arranging in that state. It can be laid along the route, and a dedicated member such as a protector for maintaining the wiring posture can be omitted. Furthermore, since a plurality of conductors are arranged in parallel, the first effect is obtained in which the cross-sectional shape is flat and the wiring mounting space is easily secured while securing a large conductor cross-sectional area for a large current. ..

According to the method for producing a flat insulated wire of the second aspect, a plurality of conductors arranged in parallel are formed along a non-linear wiring path, and then covered with an insulating material. Therefore, the second effect is obtained in that the flat insulated wire according to the first aspect can be manufactured in a shape suitable for the non-linear wiring path.

According to the method for producing a flat insulated wire of the third aspect, a plurality of conductors are arranged in parallel, and the central region of each of the plurality of conductors except the end portions is covered with an insulating material. Therefore, it is possible to manufacture a flat insulated wire in which the conductor ends are exposed, and it is not necessary to carry out the work of stripping the end of the insulating material again, which simplifies the terminal treatment. Moreover, since the manufactured insulated wire has a plurality of conductors arranged in parallel, it is possible to secure a large conductor cross-sectional area for a large current.
The third effect is obtained in that the cross-sectional shape is flat and it is easy to secure a wiring mounting space.

[Brief description of drawings]

FIG. 1 is a sectional view for explaining a method for manufacturing a flat insulated wire according to a first embodiment of the present invention.

FIG. 2 is a plan view for explaining the manufacturing method according to the first embodiment.

FIG. 3 is a plan view for explaining the manufacturing method according to the first embodiment.

FIG. 4 is a cross-sectional view for explaining the manufacturing method according to the first embodiment.

FIG. 5 is a plan view for explaining the manufacturing method according to the first embodiment.

FIG. 6 is a plan view for explaining the manufacturing method according to the first embodiment.

FIG. 7 is a cross-sectional view for explaining the manufacturing method according to the first embodiment.

FIG. 8 is a cross-sectional view of a flat insulated wire manufactured by the manufacturing method according to the first embodiment.

FIG. 9 is a plan view of a flat insulated wire manufactured by the manufacturing method according to the first embodiment.

FIG. 10 is a plan view for explaining an electric wire end treatment in the first embodiment.

FIG. 11 is a front view for explaining the electric wire end treatment in the first embodiment.

FIG. 12 is a plan view for explaining the method for manufacturing the flat insulated wire according to the second embodiment of the present invention.

FIG. 13 is a front view for explaining the manufacturing method according to the second embodiment.

FIG. 14 is a plan view for explaining an electric wire end treatment in the second embodiment.

FIG. 15 is a front view for explaining an electric wire end treatment in the second embodiment.

FIG. 16 is a cross-sectional view showing a conventional insulated wire.

FIG. 17 is a cross-sectional view showing an insulated electric wire as a conventional proposal example.

[Explanation of symbols]

 50,150 Insulated wire 52 Conductor 52a End portion 53 Insulation material

Claims (3)

[Claims] 1. A flat insulated wire which is mounted along a non-linear wiring path, arranged in parallel in contact with each other, and bent along the wiring path in the direction of the arrangement. A flat insulated wire comprising: a plurality of molded conductors; and an insulating material that covers the plurality of conductors so as to sandwich the conductors in a direction orthogonal to the array direction. 2. A method of manufacturing a flat insulated wire which is attached along a non-linear wiring path, wherein a plurality of conductors arranged in parallel while being in contact with each other are provided.
A forming step of forming the wire along the wiring path so as to be bent in the direction of the array; and, after the forming step is completed, sandwiching the plurality of conductors with an insulating material from a direction orthogonal to the direction of the array. A method of manufacturing a flat insulated wire, including a covering step of covering. 3. A step of arranging a plurality of conductors in parallel while making contact with each other, and a direction in which the central regions of the plurality of conductors arranged in parallel except for respective end portions are arranged by an insulating material. And a step of covering so as to be sandwiched from a direction orthogonal to the flat insulated wire.