WO2020067159A1

WO2020067159A1 - Cable device and manufacturing method thereof

Info

Publication number: WO2020067159A1
Application number: PCT/JP2019/037605
Authority: WO
Inventors: 啓太浅野; 恵美小野口
Original assignee: やまと興業株式会社
Priority date: 2018-09-26
Filing date: 2019-09-25
Publication date: 2020-04-02
Also published as: JP2020051505A

Abstract

In this cable device, an outer cable of a Bowden cable is provided with a liner that slides and guides an inner wire, a hollow metal-made shield that stores and holds the liner, and a synthetic resin-made outer skin that coats the outer periphery of the shield. The cable device is provided with a synthetic resin–made cap (C) that is obtained by insert molding so as to coat and fix the outer periphery of an end part of an outer cable (2) and that is fitted to the inner peripheral part of an end piece (E) so as to be relatively rotatable. The cap has, at a fitting surface to the end piece of the cap, an engaged part (Cg) that is engaged with an engagement part (21c) subjected to caulking at the end piece so as to be relatively rotatable and not to be relatively movable in the axial direction. A retaining locking part (43) configured to expose the end part of a metal member (41) serving as the shield from an outer skin (5) is subjected to insert molding and is embedded in the resin that constitutes the cap. Accordingly, even if the outer cable has a small diameter, joining strength between the end piece and the end part of the outer cable can be effectively increased, and the outer cable end part is unlikely to fall out of the end piece.

Description

Cable device and manufacturing method thereof

The present invention provides a cable device, particularly an inner wire, and an outer cable through which the inner wire is slidably inserted. The present invention relates to a cable device in which certain cylindrical end pieces are connected, and a method for manufacturing the cable device.

The cable device is already known as disclosed in Patent Document 1.

Japanese Patent Application Laid-Open No. 2016-183745

In the cable device described in Patent Document 1, a cylindrical metal stopper ring fitted around the outer end of the outer cable is fixed to the end of the outer cable by caulking, and the end of the outer cable including the stopper ring is fixed. By crimping the end of the end piece in a state of being inserted into the end piece, the stopper ring (and thus the end of the outer cable) is engaged with the end of the end piece so as to be relatively rotatable and immovable relative to the axial direction. I have to.

In recent years, there has been an increasing demand for reducing the diameter of the outer cable, and with the reduction in diameter, the rigidity of the metal shield of the outer cable has been reduced, and the thickness of the synthetic resin sheath covering the outer periphery of the shield has also been reduced. Accordingly, the crimping strength of the stopper ring to the end of the outer cable becomes lower as the diameter of the outer cable is reduced, and the stopper ring and the end of the outer cable are easily detached from the end piece. There is a problem that the part easily comes off.

Further, the stopper ring is basically cylindrical, and has a problem that the degree of freedom of the shape is narrow and the shape cannot be easily changed.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a cable device and a method of manufacturing the same that can solve the above-described various problems at once with a simple structure.

In order to achieve the above object, the present invention provides a flexible Bowden cable having an inner wire and an outer cable through which the inner wire is slidably inserted, at least one end of the outer cable having at least one end. Wherein the outer cable is a synthetic resin liner that directly guides the sliding of the inner wire, and a hollow metal line that houses and holds the liner. A shield comprising a shield and a synthetic resin sheath covering the outer periphery of the shield, wherein the outer cable is insert-molded so as to cover and fix the outer periphery of the end portion, and is relatively rotated around the inner periphery of the end piece. A cap made of synthetic resin which is fitted so that the end piece can be formed by caulking. An engaging portion engaged with the engaging portion so as to be rotatable relative to the axial direction and immovable relative to the axial direction, and for preventing the metal member constituting the shield from being exposed from the outer cover; A first feature is that the locking portion is embedded in the constituent resin material of the cap together with the insert molding.

In the present invention and the present specification, “relative movement in the axial direction” means that the relative movement in the axial direction is not possible in a strict sense (that is, there is no backlash in the axial direction). This concept includes a case where relative movement is allowed within a certain play range (that is, there is some play in the axial direction).

The present invention is characterized in that, in addition to the first feature, a second feature is that a part of the cap is exposed from the end piece.

According to the present invention, in addition to the second aspect, one end of a reinforcing boot for increasing a bending rigidity of a portion of the outer cable extending from the cap is provided on an exposed portion of the cap exposed from the end piece. A third feature is that a locking portion for a boot that can lock the portion is integrally formed, and the other end of the boot is supported by the portion of the outer cable.

According to the present invention, in addition to the second feature, a cable connecting member for connecting an end of the outer cable to another member via the cap is provided on an exposed portion of the cap exposed from the end piece. A fourth feature is that they are integrally formed.

Further, according to the present invention, in addition to any one of the first to fourth features, a bent tube portion that covers and supports an intermediate bent portion that is continuous with the end portion of the outer cable is integrally connected to the cap. A fifth feature is that the bent tube portion is insert-molded together with the cap.

The present invention is also a method for manufacturing a cable device having any one of the first to fifth features, wherein the shield is formed such that a plurality of metal wires as the metal member are closely attached to each other around the liner. Before the insert molding, the ends of the hollow strands are exposed from the outer cover and the diameter thereof is increased, so that the metal strands are discrete and the retaining members are formed before the insert molding. A sixth feature is that the cap is insert-molded so as to surround the first flare portion, and a resin material of the cap is inserted between the metal wires. I do.

In addition to the sixth feature, in addition to the sixth feature, the end of the liner is enlarged before the insert molding to form a second flare portion adjacent to the first flare portion with a gap therebetween, A seventh feature is that the cap is insert-molded so as to also cover the second flare portion.

According to a first feature of the present invention, a cable device includes a synthetic resin cap that is insert-molded so as to cover and fix an end portion of an outer cable and that is relatively rotatably fitted to an inner peripheral portion of an end piece. The cap has an engaging portion that is caulked to the end piece and an engaged portion that is engaged with the end portion so as to be relatively rotatable and axially relatively immovable. The cap and outer cable are provided because the retaining portion, which is constructed by exposing it from the synthetic resin outer shell, is embedded in the constituent resin material of the cap together with insert molding and cuts into the resin material to exert an anchoring effect. The end portion can be firmly connected. Thus, even when the outer cable has a small diameter, the connection strength between the end piece and the end of the outer cable via the cap is effectively increased, so that the end of the outer cable from the end piece can be prevented from easily coming off. . In addition, the insert molded cap not only has a high degree of freedom in selecting the constituent material (synthetic resin), but also has a high degree of freedom in selecting the shape of each part including the engaged part. Accordingly, it is possible to easily design an optimum material and shape structure, and the degree of design freedom can be increased.

According to the second feature, in particular, since a part of the cap is exposed from the end piece, the color tone of the exposed portion can be easily changed by selecting the material of the cap. Thereby, for example, the type of the Bowden cable, the installation destination, and the like can be easily determined by the operator from the color tone of the cap, which can contribute to the prevention of erroneous assembly and the improvement of the assembly workability.

According to the third feature, in particular, the integration of the boot mounting locking portion with the cap improves the formability and workability of the locking portion. Moreover, since the cap to be crimped to the end piece also serves as the boot locking means, it can contribute to the simplification of the structure.

According to the fourth feature, in particular, the cable connecting member for connecting the outer cable to another member via the cap is integrated with the cap, so that the formability and workability of the cable connecting member are improved. In addition, since the cap to be crimped to the end piece also serves as a support base for the cable connecting member, it is possible to contribute to the simplification of the structure.

According to the fifth feature, in particular, the bent tube portion covering and supporting the intermediate bent portion continuous to the end of the outer cable can be insert-molded together with the cap, and can be integrated with the cap. Formability and mountability can be improved. In addition, the cap to be crimped and connected to the end piece and the bent pipe portion supporting the intermediate bent portion of the outer cable can be made into a single component, and the handling is simplified.

According to the sixth feature, in particular, the shield is constituted by a hollow strand formed by arranging and twisting a plurality of metal wires so as to be in close contact with each other around the liner. As a result, a high-quality outer cable having higher tensile / compression strength and stiffness than the shielded structure and easily reducing the diameter can be obtained. In addition, before the cap is insert-molded, the end of the hollow strand is exposed from the outer skin and the diameter thereof is enlarged to form a first flare portion in which each metal element wire is discrete and constitutes a retaining portion for retaining. Since the cap is insert-molded so as to enclose the part and the resin material of the cap is inserted between the metal wires, the first flare portion (the end of each metal wire) can deeply bite into the cap and exert the anchor effect As a result, the coupling strength of the cap to the outer cable end can be further increased.

According to the seventh feature, in particular, the end of the liner is enlarged before insert-molding the cap to form a second flare adjacent to the first flare with a gap therebetween. Since the cap is insert-molded so as to enclose the cap, the first and second flared portions can independently exert an anchoring effect of deeply penetrating into the cap, whereby the end piece is further raised to the outer cable end portion via the cap. The connection can be performed with the bonding strength.

FIG. 1 is a partially broken whole view of an operation system showing a Bowden cable according to a first embodiment of the present invention and an example of its use (that is, an example of application to a throttle valve operation system of a motorcycle engine). FIG. 2 is an enlarged cross-sectional view of the part viewed from the arrow 2 in FIG. FIG. 3 is a cross-sectional view (an enlarged cross-sectional view taken along line 3-3 in FIG. 2) showing a design example of a Bowden cable. FIG. 4 is a longitudinal sectional view more specifically showing the coupling structure between the cap and the end of the outer cable. 5A and 5B show an end structure of the outer cable immediately before insert molding, in which FIG. 5A is a side view in which a part of the outer cover is cut away, and FIG. FIG. 6 shows a reference embodiment of the outer cable, FIG. 6 (A) is a corresponding side view of FIG. 5 (A), and FIG. 6 (B) is a cross section taken along line BB of FIG. 6 (A). FIG. FIG. 7A is a sectional view corresponding to FIG. 2 showing the second embodiment, and FIG. 7B is a sectional view corresponding to FIG. 7A showing a modification of the second embodiment. FIG. 8 shows the third embodiment, and is a longitudinal sectional view of a joint between a cap and an outer cable. FIG. 9 shows a fourth embodiment. FIG. 9 (A) is a longitudinal sectional view of a coupling portion between a cap and an outer cable, and FIG. 9 (B) is BB of FIG. 9 (A). It is a line sectional view. FIG. 10 shows a fifth embodiment, in which FIG. 10 (A) is a longitudinal sectional view of a coupling portion between a cap and an outer cable, and FIG. 10 (B) is a BB line of FIG. 10 (A). It is a line sectional view. FIG. 11 shows a sixth embodiment, in which FIG. 11 (A) is a longitudinal sectional view of a coupling portion between a cap and an outer cable, and FIG. 11 (B) is a view taken along line BB of FIG. 11 (A). It is a line sectional view. FIG. 12 shows a seventh embodiment, in which FIG. 12 (A) is a longitudinal sectional view of a coupling portion between a cap and an outer cable, and FIG. 12 (B) is a view BB of FIG. 12 (A). It is a line sectional view. FIG. 13 shows the eighth embodiment, and is a longitudinal sectional view of a coupling structure between an outer cable, a cap, an end piece, and a bent pipe portion. FIG. 14 shows the ninth embodiment, and is a longitudinal sectional view of a coupling structure between two sets of outer cables, caps and end piece coupling bodies. FIG. 15 is a vertical cross-sectional view (corresponding to FIG. 2) of a connecting portion between a cap and an outer cable, showing a modification of each embodiment.

BO: Bowden cable C: Cap Cg: Engaging groove (engaged part)
Co... Cap exposed portion Coa... Boot locking groove (boot locking part)
Ct ····· Circular projection (engaged part)
E1 ······ First end piece (end piece)
1 ... inner wire 2 ... outer cable (other members)
2a ······ End of the outer cable on the operated side (end)
2c... Middle bent portion 2m... Extended portion 3... Liner 4... Shield 4m... Metal strip (metal member)
5 ... Outer skin 21c ... Reduced diameter part (engagement part)
41 ... Metal wire (metal member)
42 ···· Hollow strand 43 ···· First flared part (locking part for retaining)
44 second flares 35, 35 'support stays (other members)
38 Metal plate (other members)
...

Reinforcement boots

50a, 50b One end and other end 60 of reinforcement boot Bend tube portion 64 Spacer member (cable connecting member)
65, 66 · · · support plate (cable connecting member)
67 Grommet member (cable connecting member)

First, a first embodiment in which the Bowden cable BO in the cable device of the present invention is used in a throttle valve operation system of a motorcycle engine will be described with reference to FIGS. In the illustrated example, two Bowden cables BO are separately used for the valve opening operation and the valve closing operation.

As illustrated in FIGS. 1 and 2, the two Bowden cables BO for the valve opening operation and the valve closing operation have the same structure, each of which has a flexible inner wire 1 and a flexible inner wire 1. A flexible outer cable 2 that is inserted and guides its sliding, a first end piece E1 connected to an operated end 2a of the outer cable 2, and an operating end 2b of the outer cable 2. And a second end piece E2 connected to the second end piece E2. And the 1st end piece E1 is an example of the end piece of the present invention.

Each outer cable 2 has a liner 3 made of a synthetic resin for directly guiding the sliding of the inner wire 1, a hollow metal shield 4 for housing and holding the liner 3, and a synthetic resin for covering the outer periphery of the shield 4. And an outer skin 5 made of the same. A more specific structure of the outer cable 2 will be described later. In addition,

connection terminals

9a and 9b are fixed to the ends of both ends of the inner wire 1 extending outside the outer cable 2 by retrofitting, respectively.

An accelerator grip G is rotatably mounted on the steering handle pipe H of the motorcycle, and a drive drum 7 is fixed and connected to a base of the accelerator grip G. The operation side connection terminals 9b of the inner wires 1 of the two Bowden cables BO are connected to the drive drum 7 so as to apply two different rotational operating forces from the drive drum 7 to the inner wires 1. You. A drum cover 8 that covers the drive drum 7 and the connection terminals 9b is fixed to the handle pipe H.

A slot drum 30, which rotates in conjunction with a throttle valve (not shown), is supported on a throttle body T provided in the intake system of the engine. The connection terminal 9 a on the operated side of both inner wires 1 is connected to the throttle drum 30 so that two different rotational operating forces can be applied to the throttle drum 30 from both inner wires 1.

When the inner wire 1 of one Bowden cable BO is pulled by rotating the accelerator grip G, the throttle valve is opened via the driving drum 7 which rotates in one direction in conjunction with the pulling. If the inner wire 1 of the other Bowden cable BO is pulled, the throttle valve can be closed via the drive drum 7 which rotates in the other direction in conjunction with the pull. A return spring (not shown) for driving the throttle drum 30 in the valve closing direction is connected to the throttle drum 30. Therefore, when the throttle valve is opened, the driver releases his / her hand from the accelerator grip G. For example, the throttle drum 30 rotates in the valve closing direction by the elastic force of the return spring, and the accelerator grip G returns to the initial position in conjunction with the rotation.

Next, the structure of the first and second end pieces E1 and E2 connected to the operated side end 2a and the operated side end 2b of the outer cable 2 in each Bowden cable BO will be described.

The second end piece E2 on the operation side includes a metal end piece body 10 in the form of a bent pipe having a curved middle portion, and a metal mounting pipe portion 11 press-fitted and fixed to the outer periphery of the base of the end piece body 10. Be composed. Then, a male screw portion 10s provided on the outer periphery of the end portion of the end piece body 10 is screwed to the inner circumference of the boss portion 8b of the drum cover 8, and the screwing position is fixed by a lock nut n.

操作 The operation side end 2 b of the outer cable 2 is inserted into the base of the end piece main body 10 and the inside of the mounting pipe 11. Then, by caulking a small-diameter cylindrical portion 11a extending from the end piece main body 10 of the mounting pipe 11, a part of the inner circumference of the mounting pipe 11 is crimped and fixed to the outer circumference of the end 2b of the outer cable 2. You. A flexible synthetic resin pipe inner 12 is inserted into the end piece main body 10, and the inner wire 1 pulled out from the end 2 b of the outer cable 2 is slidable in the pipe inner 12. Is inserted through. A seal cap 13 made of rubber is detachably fitted and locked to the tip of the end piece body 10.

Next, the connection structure between the operated first end piece E1 and the outer cable 2 will be described with reference to FIGS.

The first end piece E1 includes a large-diameter rectangular tube portion 20 having a plurality of engaging surfaces 20a on its outer periphery with which a tool (for example, a spanner, pliers, etc.) can be relatively non-rotatably engaged, and an outer cable of the rectangular tube portion 20. It is constituted by a metal tubular body integrally having a first small-diameter tube portion 21 connected to the two sides and a second small-diameter tube portion 22 connected to the throttle drum 30 side of the square tube portion 20. An external thread portion 22s is engraved on the outer peripheral surface of the second small diameter cylindrical portion 22.

On the other hand, a cap C made of synthetic resin is joined to and integrated with the end 2a of the outer cable 2 on the operated side. The cap C is insert-molded so as to cover and fix the outer periphery of the end 2a of the outer cable 2, and is fitted to the first end piece E1 so as to be relatively rotatable. In the present embodiment, the cap C of the cap C on the outer cable 2 side is formed in a tapered, substantially shell shape, and the base Cb fitted into the first end piece E1 is formed in a cylindrical shape. An annular engagement groove Cg is formed on the fitting surface of the cap C with the first end piece E1 (that is, the outer peripheral surface) at an intermediate position in the axial direction of the cap C simultaneously with the insert molding of the cap C.

The engagement groove Cg is an example of an engaged portion. The engagement groove Cg is formed by caulking the outer peripheral portion of the first small-diameter cylindrical portion 21 radially inward. The reduced diameter portion 21c is engaged. By the engagement between the engagement groove Cg and the reduced diameter portion 21c, the first end piece E1 and the cap C (therefore, the outer cable end 2a fixed to the cap C) can rotate relative to each other and cannot move relative to each other in the axial direction. Linked to Thus, the reduced diameter portion 21c is an example of an engagement portion.

Further, the cap C is partially exposed (in the embodiment, a tapered tip), and is exposed so as to protrude from the first end piece E1, specifically, the outer end of the first small-diameter cylindrical portion 21. The operator can visually recognize the exposed portion Co.

By the way, in the Bowden cable BO of the present embodiment, the shield 4 of the outer cable 2 is constituted by a hollow strand 42 formed by twisting a plurality of

metal wires

41, 41, ... arranged in close contact with each other around the liner 3. You. That is, the metal element wire 41 is an example of the metal member of the present invention that forms the shield 4.

FIG. 3 shows a design example of the Bowden cable BO when the inner wire 1 having a diameter of 1.0 mm is used. For example, the diameter of the

metal wires

41, 41 is 0.4 mm, the number of the

metal wires

41, 41 is 18, the twist pitch of the

metal wires

41, 41 is 47 to 53 mm, and the

metal wires

41, 41 are formed. The twisting method is S-twisting, the outer diameter of the shield 4 is 2.6 mm, the outer diameter of the outer cover 5 (therefore, the outer diameter of the outer cable 2) is 3.0 mm, and the weight is 21 g / m. is there.

FIG. 6 shows a design example of the Bowden cable BO of the reference embodiment using the inner wire 1 having a diameter of 1.0 mm in the same manner as described above. In this case, the thickness of the metal strip 4m as a metal member that is closely wound in a coil shape to form the shield 4 is 0.5 mm, the outer diameter of the shield 4 is 4.0 mm, and the outer diameter of the outer skin 5 ( Accordingly, the outer cable 2 has an outer diameter of 5.0 mm and a weight of 62 g / m. In this case, it should be noted that the shield 4 of the present embodiment has a thickness of 0.4 mm (= the diameter of the metal element wire), an outer diameter of 2.6 mm, and a thickness of the shield 4 of the reference embodiment of 0.5 mm. (= The thickness of the metal strip 4 m) and the same outer diameter of 4.0 mm.

Thus, the outer diameter of the shield 4 of the reference embodiment is 4.0 mm, which is the limit in forming a metal strip 4 m having a thickness of 0.5 mm in close contact with a coil, and the outer diameter is less than 4.0 mm. In order to reduce the thickness, the thickness of the metal strip 4m must be less than 0.5 mm, but the strength of the shield 4 becomes insufficient. On the other hand, the fact that the outer diameter of the shield 4 of the present embodiment can be significantly reduced from the outer diameter of the shield 4 of the reference embodiment means that the plurality of

metal wires

41, 41. This is because the hollow strands 42 are formed in such a manner that they are arranged close to each other around the liner 3 and twisted to form a hollow strand 42, which is used as the shield 4.

As described above, according to the reduction in the diameter of the shield 4 of the present embodiment (about 1 / 1.5 of the reference embodiment), the diameter of the Bowden cable BO is reduced (for example, the outer diameter is 3.0 mm or less), and the weight is reduced. (The weight is about の of the reference embodiment). Moreover, the shield 4 composed of the hollow strands 42 has a higher tensile and compressive strength and a higher rigidity than the shield 4 of the reference embodiment in which the metal strip 4m is wound tightly in a coil shape. It can withstand not only force but also push operation force, can increase the transmission efficiency of any operation force, and is also excellent in flexibility, and its use is extremely wide.

Next, the connection structure between the end 2a of the outer cable 2 and the cap C will be described more specifically with reference to FIGS.

First, as shown in FIG. 5, before the injection molding of the cap C with the synthetic resin, the outer skin 5 is removed from the outer end of the end 2a of the outer cable 2 to expose the end of the hollow strand 42 from the outer skin 5. At the same time, by expanding the diameter of the end of the hollow strand 42, a first flare portion 43 in which the metal wires 41 are discrete is formed. The first flare portion 43 is an example of the retaining portion of the present invention. Furthermore, the diameter of the end portion of the liner 3 is also enlarged, and a second flare portion 44 adjacent to the first flare portion 43 is formed. The second flare portion 44 is formed to have a smaller diameter than the first flare portion 43, and a gap is provided between the second flare portion 44 and the first flare portion 43.

Then, as shown in FIG. 4, the cap C surrounds the first and

second flare portions

43 and 44 and the end of the outer cover 5 (that is, a mold having a cavity for forming the cap C (not shown)). After the end 2a of the outer cable 2 is set to face the cavity, injection molding, that is, insert molding is performed. At that time, the synthetic resin as the molding material enters the gap between the plurality of metal wires 41 constituting the first flare section 43 and the gap between the first and

second flare sections

43 and 44.

When the cap C is insert-molded in this manner, a large number of discrete metal strands 41 of the first flare portion 43 and the first flare portion 43 formed of the end of the liner 3 become resin material of the cap C. The anchor cable is deeply engaged to exert a strong anchor effect, and the coupling strength between the cap C and the end 2a of the outer cable 2 is increased. Further, by providing a gap between the first and

second flare portions

43 and 44 for the synthetic resin to enter, the first and

second flare portions

43 and 44 independently and deeply penetrate the constituent resin material of the cap C. Thus, a strong anchor effect is exhibited, and the bonding strength between the cap C and the end 2a of the outer cable 2 is further increased. Moreover, since the second flare portion 44 is formed to have a smaller diameter than the first flare portion 43, during the above-mentioned injection molding, between the metal materials 41 of the first flare portion 43, and between the first and second flare portions 43, The penetration of the synthetic resin between the spaces 44 becomes good, and the anchor effect of the first and

second flare portions

43 and 44 on the cap C is further enhanced.

By the way, a mounting stay 31 as a support member is fixed to the throttle body T around the throttle drum 30. The mounting stay 31 has a pair of mountings through which the second small-diameter cylindrical portion 22 is loosely penetrated. A hole 31h is formed. Then, the second small-diameter cylindrical portion 22 (accordingly, the end piece E1) is mounted by a pair of

nuts

32, 32 screwed into the male screw portions 22s on both sides of each of the mounting holes 31h and sandwiching the mounting stay 31 therebetween. It is fastened to the stay 31 so that the position can be adjusted.

Thus, the extension end 1e of the inner wire 1 extending from the outer cable end 2a (cap C) in the first end piece E1 is drawn out through the second small-diameter cylindrical portion 22 to the outside.

Connection terminals

9a, 9a fixed to those terminals are connected to the throttle drum 30.

作用 The operation of the following embodiment will be described.

When connecting the end 2a of each Bowden cable BO on the operated side of the outer cable 2 to the first end piece E1, first the outer cable 2 is manufactured, and then the cable end 2a is attached to the cable end 2a as described above. The synthetic resin cap C, which is insert-molded in a suitable molding mode, is combined and integrated. According to this insert molding, the outer cover 5 of the cable end 2a and the first and

second flare portions

43 and 44 are integrally embedded in the synthetic resin material of the cap C.

Next, the base portion Cb of the cap C integrated with the cable end 2a is fitted into the first end piece E1, and the first small-diameter cylindrical portion 21 corresponds to the engaging groove Cg of the cap C in the fitted state. Becomes In this state, the outer peripheral portion of the first small-diameter cylindrical portion 21 is caulked to form a reduced-diameter portion 21c, and the reduced-diameter portion 21c and the engaging groove Cg are engaged with each other. Due to the engagement, the first end piece E1 and the cap C (therefore, the outer cable end 2a fixed to the cap C) are connected to each other so as to be rotatable relative to each other but not to move relative to each other in the axial direction.

As described above, the cable device of the present embodiment is a synthetic resin cap that is insert-molded so as to cover and fix the end 2a of the outer cable 2 and is relatively rotatably fitted to the inner peripheral portion of the first end piece E1. C, and the cap C is engaged with the reduced diameter portion 21c (i.e., the engagement portion) formed by caulking the first end piece E1 so as to be rotatable relative to each other and immovable relative to the axial direction. Joint portion) on the outer peripheral surface. The retaining portion (i.e., the first flare portion 43) configured by exposing the ends of the plurality of metal members (i.e., the metal wires 41) serving as the shields 4 of the outer cable 2 from the outer cover 5 is provided. Since the cap C is embedded and integrated into the resin material of the cap C together with the insert molding to exhibit the effect of preventing the cap C from coming off from the resin material, the cap C and the cable end 2a can be firmly connected.

As a result, even if the outer cable 2 has a small diameter (for example, 3 mm or less), the connection strength between the first end piece E1 and the cable end 2a via the cap C is effectively increased. It becomes difficult for the cable end 2a to escape from E1. In addition, the insert molded cap C not only has a high degree of freedom in selecting the constituent material (synthetic resin), but also has a high degree of freedom in selecting the shape of each part including the engagement groove Cg (that is, the engaged part). In addition, it is possible to easily design an optimum material and shape structure in accordance with the installation mode and the use condition of the Bowden cable BO, and the degree of design freedom is increased.

Further, the cap C is partially exposed (in the embodiment, a tapered tip) so as to protrude from the first end piece E1, and the color tone of the exposed portion Co is determined by appropriately selecting the material of the cap C. It can be easily changed just by doing. Thus, for example, in the process of assembling the Bowden cable BO, the operator can easily determine the type, the assembly destination, and the like of the Bowden cable BO based on the difference in the color tone of the cap C (that is, the exposed portion Co). In addition, erroneous assembly can be prevented and assembly workability can be improved.

If a synthetic resin having good slipperiness is selected as a constituent material of the cap C, the relative rotation between the cap C and the first end piece E1 becomes smoother. As a result, the ease of assembling the cable device to the motorcycle is improved, and there is no possibility that the Bowden cable BO is forcibly twisted in the assembling process or in the assembling completed state.

In particular, in the outer cable 2 of the present embodiment, the shield 4 is formed of hollow strands in which a plurality of metal wires 41 are arranged so as to be in close contact with each other around the synthetic resin liner 3 and twisted. As compared with the shield structure of the reference embodiment in which the metal strip 4m is closely wound in a coil shape as illustrated in FIG. 6, a high-quality outer cable 2 having high tensile / compression strength and rigidity and easy to reduce the diameter can be obtained. .

In addition, in the present embodiment, before the cap C is insert-molded, the end of the shield 4 (that is, the hollow strand) is exposed from the outer skin and the diameter thereof is enlarged to form the first flare portion 43 in which the metal wires 41 are separated. Since the cap C is insert-molded so as to surround the first flare portion 43 and the constituent resin material of the cap C is inserted between the plurality of metal strands 41, the first flare portion 43 (ie, The locking portion for retaining) deeply penetrates into the cap C to exert an anchoring effect, and the coupling strength of the cap C to the cable end 2a is further increased. In addition, before the cap C is insert-molded, the end of the liner 3 is enlarged to form a second flare section 44 adjacent to the first flare section 43 with a gap therebetween. Since the cap C is insert-molded so as to be wrapped, the first and

second flare portions

43 and 44 independently exert an anchor effect of deeply penetrating the cap C, and the coupling strength of the cap C to the cable end 2a is more effective. To be strengthened.

Next, a second embodiment of the present invention will be described with reference to FIG.

In the second embodiment shown in FIG. 7A, an annular boot locking groove Coa as a boot locking portion is inserted into the cap C on the outer periphery of the exposed portion Co exposed from the first end piece E1 of the cap C. It is formed simultaneously with molding. One end 50a of a tapered cylindrical reinforcing boot 50 surrounding the extended portion 2m extending from the cap C of the outer cable 2 and the tip Ca of the cap C is engageable with the boot locking groove Coa. Is fitted and locked. The other end 50b of the boot 50 is fitted and supported in the extended portion 2m of the outer cable 2 in a light press-fit state.

The reinforcing boot 50 is for increasing the bending rigidity of the extended portion 2m of the outer cable 2, and is made of, for example, a synthetic resin material or a rubber material having higher flexibility and elasticity than the constituent resin material of the cap C. You. Other configurations are the same as those of the first embodiment, and therefore, the same functions and effects as those of the first embodiment can be achieved.

Furthermore, in the second embodiment, the special provision of the reinforcing boots 50 can prevent the bent portion 2m of the outer cable 2 extending from the cap C from being excessively bent or broken, and furthermore, the one end 50a of the outer cable 2 is engaged with the boot engaging groove Coa. By stopping, the bonding step for preventing the boot from coming off is not required. In addition, the boot locking groove Coa (the locking portion for the boot) is formed simultaneously with the insert molding of the cap C to be crimped to the end piece E1, so that the formability and workability of the boot locking groove Coa are increased. Is enhanced. Further, since the cap C also serves as the boot locking means, it can contribute to the simplification of the structure.

Also, in the above-described second embodiment, the cap C is provided with the boot locking groove Coa as the boot locking portion recessed in the exposed portion Co. However, FIG. 7B shows the second embodiment. Modifications of the form are shown. In this modified example, an annular locking protrusion Cot is formed on the outer periphery of the exposed portion Co of the cap C at the same time as the insert molding of the cap C, instead of the locking groove Coa, as the boot locking portion.

In the second embodiment described above, the reinforcing boot 50 manufactured in advance on a different manufacturing line from the cap C is attached to the cap C and the outer cable 2 by retrofitting. After the cap C is insert-molded (i.e., primary molding) on the end 2a of the outer cable 2, the reinforcing boot 50 is insert-molded (i.e., secondary molding) on the molded product, so that the reinforcing boot 50 is formed with the cap C. And may be combined with and integrated with the outer cable 2.

Next, a third embodiment of the present invention will be described with reference to FIG.

In the third embodiment, a bent pipe portion 60 that covers and supports the intermediate bent portion 2c that is continuous with the end 2a of the outer cable 2 is integrally connected to the cap C. The bent tube portion 60 has a structure in which a reinforcing rib 60a is integrally provided on one side of the outer periphery, and can exhibit high bending rigidity.

Then, the bent tube portion 60 is insert-molded together with the cap C, and is connected to and integrated with the intermediate bent portion 2c of the outer cable 2. Other configurations are the same as those of the first embodiment, and therefore, the same functions and effects as those of the first embodiment can be achieved.

Further, in the third embodiment, the bent tube portion 60 that covers and supports the intermediate bent portion 2c of the outer cable 2 is formed at the same time as the insert molding of the cap C to which the end piece E1 is to be crimped. The moldability and processability of No. 60 are improved. In addition, the cap C and the bent tube portion 60 that supports the intermediate bent portion 2c of the outer cable 2 can be made into a single component, so that handling is simplified.

Next, fourth to seventh embodiments of the present invention will be described in order with reference to FIGS.

In the fourth to seventh embodiments, the cable connecting member 64 for connecting the end 2a of the outer cable 2 to another member via the cap C to the exposed portion Co of the cap C exposed from the first end piece E1. To 67 are formed simultaneously with the insert molding of the cap C.

For example, in the fourth embodiment shown in FIG. 9, caps C are insert-molded at ends 2a of the outer cables 2 of a pair of Bowden cables BO arranged in parallel with each other. A spacer member 64, which is an example of a cable connecting member, is integrally provided so as to protrude outward in the radial direction of the cap (in a direction approaching each other). Then, the distal ends of the spacer members 64 of the two caps C are integrally joined by an appropriate connecting means (for example, adhesion). Other configurations are the same as those of the first embodiment, and therefore, the same functions and effects as those of the first embodiment can be achieved.

Furthermore, in the fourth embodiment, since the ends 2a of the two outer cables 2 arranged in parallel are connected to each other while maintaining a constant interval via the cap C and the spacer member 64, the pair of Bowden cables BO are arranged in the course of routing. The ends 2a of the two outer cables 2 can be always held at a constant interval, which is advantageous in improving the workability of assembly. By integrating such a spacer member 64 with the cap C, moldability and workability of the spacer member 64 can be improved. Moreover, since the cap C also serves as a support base for the spacer member 64, the structure can be simplified accordingly.

Thus, in the fourth embodiment, the other outer cable 2, which is connected and held at a fixed interval to one outer cable 2 via the

spacer members

64, 64 and the cap C, is different from that of the present invention. It is an example of a member.

In the fifth embodiment shown in FIG. 10, a support plate 65, which is an example of a cable connecting member, protrudes outward in the cap radial direction on an exposed portion Co of a cap C insert-molded at the end 2a of the outer cable 2. In addition, they are integrally protruded so that the plate surface is perpendicular to the cable axis. A support hole 65h is formed at the front end of the support plate 65, and a bolt 36 inserted into the support hole 65h has a support surface that is orthogonal to the cable axis and is fixed to, for example, the vehicle body side. That is, the support plate 65 (accordingly, the cap C) is fastened to the support stay 35 by the bolt 36. Thus, in the fifth embodiment, the support stay 35 is an example of another member of the present invention.

On the other hand, the end piece E1 having the reduced diameter portion 21c in the small diameter cylindrical portion 21 which is crimped to the cap C has not only the rectangular cylindrical portion 20 as in the first embodiment but also a large diameter continuous with the small diameter cylindrical portion 21. The cylindrical portion 22 'also has no male screw portion. The end piece E1 has its large-diameter cylindrical portion 22 'inserted and supported in a support hole 37h1 formed in a support 37 (ie, a second support member) fixed to the vehicle body side. The support 37 has an inner wire guide hole 37h2 which is opened at the bottom of the support hole 37h1 and through which the inner wire 1 is slidably inserted. Other configurations are the same as those of the first embodiment, and therefore, the same functions and effects as those of the first embodiment can be achieved.

In the fifth embodiment, the end 2 a of the outer cable 2 is fastened to the support stay 35 via the cap C and the support plate 65. By integrating such a support plate 65 with the cap C, the formability and workability of the support plate 65 can be improved. Moreover, since the cap C also serves as a support base for the support plate 65, the structure can be simplified accordingly.

In the sixth embodiment shown in FIG. 11, a pair of upper and lower support plates 66, which are an example of a cable connecting member, are provided on the exposed portion Co of the cap C which is insert-molded at the end 2a of the outer cable 2 upward and downward. Each of them protrudes and is integrally formed so that the plate surface is aligned with the cable axis. A support hole 66h is formed at the front end of each support plate 66, and a bolt 36 inserted into the support hole 66h has a support stay 35 'having a support surface along the cable axis and fixed to the vehicle body (that is, a support stay 35'). Each support plate 66 (accordingly, the cap C) is fastened to the support stay 35 'by the bolt 36.

Thus, in the sixth embodiment, the support stay 35 'is an example of another member of the present invention.

On the other hand, similarly to the fifth embodiment, the end piece E1 having the reduced-diameter portion 21c which is crimped to the cap C and having the reduced-diameter portion 21c does not have the rectangular cylindrical portion 20 but also has the large-diameter portion connected to the small-diameter cylindrical portion 21. The cylindrical portion 22 'also has no male screw portion, and the large-diameter cylindrical portion 22' is fitted and supported in a support hole 37h1 of a support body 37 (ie, a second support member) fixed to the vehicle body. . The support 37 has an inner wire guide hole 37h2.

Other configurations are the same as those of the fifth embodiment, and therefore, the same functions and effects as those of the fifth embodiment can be achieved. For example, the end 2a of the outer cable 2 is fastened to the support stay 35 'via the cap C and the support plate 66, and the support plate 66 is integrated with the cap C, so that the formability of the support plate 66 is improved. And workability are enhanced. Moreover, since the cap C also serves as a support base for the support plate 66, the structure can be simplified accordingly.

In the seventh embodiment shown in FIG. 12, a grommet member 67, which is an example of a cable connecting member, is formed integrally with an exposed portion Co of a cap C insert-molded at the end 2a of the outer cable 2. The grommet member 67 includes a cylindrical portion 67m that covers the end 2a of the outer cable 2, and a pair of

flange portions

67a and 67b that project radially outward from outer circumferences of both ends in the axial direction of the cylindrical portion 67m. On the other hand, a base portion of a flexible band-shaped metal plate 38 (that is, a first support member) is fixed to the vehicle body, and a front portion 38 a of the metal plate 38 is connected to a pair of grommet members 67. It is wound around and connected to the cylindrical portion 67m between the

flange portions

67a and 67b. Thus, the cap C (and thus the cable end 2 a) integrated with the grommet member 67 is fixed and supported on the vehicle body side via the metal plate 38.

Thus, in the seventh embodiment, the metal plate 38 is an example of another member of the present invention.

On the other hand, similarly to the fifth embodiment, the end piece E1 having the reduced-diameter portion 21c which is crimped to the cap C and having the reduced-diameter portion 21c does not have the rectangular cylindrical portion 20 but also has the large-diameter portion connected to the small-diameter cylindrical portion 21. The cylindrical portion 22 'also has no male screw portion, and the large-diameter cylindrical portion 22' is fitted and supported in the support hole 37h1 of the support 37 (that is, the second support member). The support 37 has an inner wire guide hole 37h2.

Other configurations are the same as those of the fifth and sixth embodiments, and therefore, the same functions and effects as those of the fifth and sixth embodiments can be achieved. For example, the end 2a of the outer cable 2 is fastened to the metal plate 38 fixed to the vehicle body via the grommet member 67 and the cap C, and the grommet 67 is integrated with the grommet member 67 to form the grommet. The formability and workability of the member 67 are improved. Moreover, since the cap C also serves as a support base for the grommet member 67, the structure can be simplified accordingly.

In the eighth and ninth embodiments shown in FIGS. 13 and 14, the cap C is attached to the other end (the large-diameter cylindrical portion 22 ″) of the end piece E <b> 1 which is crimped to one end (the small-diameter cylindrical portion 21). A combination of the other functional components 70 and E1 'is shown.

For example, in the eighth embodiment shown in FIG. 13, a bent metal pipe portion 70 having a curved middle portion is screwed into the large-diameter cylindrical portion 22 ″ of the end piece E1, and the screwing position is locked. A flexible synthetic resin pipe inner 71 is fitted into the bent pipe portion 70, and is pulled out from the end 2a of the outer cable 2 into the pipe inner 71. The inner wire 1 is slidably inserted into the inner wire 1. The bent tube portion 70 is appropriately fixed and supported on a support stay (not shown) fixed to the vehicle body side, and the other configurations are the same as those of the first embodiment. Therefore, the same operation and effect as the first embodiment can be achieved.

As a modification of the eighth embodiment, a metal bent tube portion 70 may be fixed to the large-diameter cylindrical portion 22 ″ of the end piece E1 by press-fitting (not shown).

In the ninth embodiment shown in FIG. 14, a pair of end pieces E1 and E1 'in which a cap C is crimped to each end (small-diameter cylindrical portion 21) are manufactured and arranged in tandem. The other ends of E1 and E1 'are screwed together, and the screwing position is fixed with a lock nut n. Then, the inner wire 1 is formed such that the end 2a is covered and integrated with one cap C, the end 2a is covered and integrated, and both the end pieces E1 and E1 'are covered and integrated with the other cap C. The other outer cable 2 'is sequentially inserted.

Other configurations are the same as those of the first embodiment, and therefore, the same functions and effects as those of the first embodiment can be achieved. Furthermore, in the ninth embodiment, the overall length of the outer cables 2, 2 'can be arbitrarily adjusted by adjusting the mutual screwing positions of both end pieces E1, E1'.

Incidentally, in the first to ninth embodiments, the annular engagement groove Cg is exemplified as the engaged portion to be provided on the cap C. However, as a modification of the first to ninth embodiments, the engagement of the outer periphery of the cap C is performed. An annular projection Ct instead of the groove Cg may be formed simultaneously with the insert molding of the cap C, and the annular projection Ct may be used as the engaged portion of the present invention.

For example, FIG. 15 shows an example in which an annular protrusion Ct is formed on the outer periphery of the cap C in place of the engaging groove Cg in the first embodiment. Then, the reduced diameter portion 21c formed by caulking the first small-diameter cylindrical portion 21 of the first end piece E1 is engaged so as to be relatively rotatable and relatively immovable in the axial direction. Although not shown, an annular projection Ct may be formed on the outer periphery of the cap C instead of the engagement groove Cg in the second to ninth embodiments in the same manner as described above.

Therefore, the same operation and effects as those of the first to ninth embodiments can be achieved by the respective modifications of the first to ninth embodiments.

In the first to ninth embodiments and their modifications, as shown in FIGS. 2 to 5, the metal shield 4 of the outer cable 2 is provided with a plurality of metal elements arranged in close contact with each other around the liner 3. Although it is composed of the hollow strands 42 formed by twisting the wires 41, the structure of the metal shield 4 in each of the first to fifth features of the present invention is not limited to the above embodiment. For example, instead of the metal shield 4 including the hollow strands 42 in the first to ninth embodiments, a metal strip 4m (metal member) as in the reference embodiment illustrated in FIG. The metal shield 4 may be used as the metal shield 4 in each of the first to fifth features of the present invention. In this case, a portion of the end portion of the metal strip 4m (metal member) which is protruded and exposed from the outer cover 5 serves as a retaining portion of the present invention.

Although the embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various design changes can be made without departing from the gist of the present invention.

For example, in the above-described embodiment, the Bowden cable BO is applied to the throttle valve operation system of the motorcycle engine. However, the Bowden cable of the present invention is applied to an operation system other than the throttle valve operation system of the vehicle, such as a clutch, The present invention is applicable to an operation system such as a brake, and may be applied to various operation systems other than the vehicle.

Further, in the above embodiment, the terminal structure of the Bowden cable according to the present invention is applied only to the terminal structure of the operated side Bowden cable. A similar terminal structure may be applied.

In the above-described embodiment, the first end piece E1, which is an example of the end piece, is entirely made of metal. However, in the present invention, a part of the first end piece E1, including a portion to be crimped. May be made of metal, and the other parts may be made of nonmetal (for example, made of synthetic resin).

Claims

At least one end (2a) of the outer cable (2) in the flexible Bowden cable (BO) including the inner wire (1) and the outer cable (2) through which the inner wire (1) is slidably inserted. ) Is connected to a tubular end piece (E1) at least partially made of metal,
An outer cable (2) for directly guiding the sliding of the inner wire (1); a synthetic resin liner (3); a hollow metal shield (4) for housing and holding the liner (3); A synthetic resin outer skin (5) covering the outer periphery of the shield (4);
A cap made of synthetic resin which is insert-molded so as to cover and fix the outer periphery of the end portion (2a) of the outer cable (2) and is relatively rotatably fitted to the inner peripheral portion of the end piece (E1). C)
The cap (C) has an engaged portion (Cg, Ct) that engages with an engaging portion (21c) formed by caulking on the end piece (E1) so as to be relatively rotatable and immovable relative to the axial direction. And
A retaining locking portion (43) formed by exposing an end of a metal member (41, 4m) constituting the shield (4) from the outer cover (5) is provided together with the insert molding with the cap (C). A cable device, wherein the cable device is embedded in a resin material according to the item (1).
The cable device according to claim 1, wherein a part of the cap (C) is exposed from the end piece (E1).
The outer cable (2) has an exposed portion (Co) exposed from the end piece (E1) of the cap (C) for increasing a bending rigidity of a portion (2m) of the outer cable (2) extending from the cap (C). An engaging portion (Coa) for a boot capable of engaging one end (50a) of the reinforcing boot (50) is integrally formed, and the other end (50b) of the boot (50) is connected to the outer cable (2). 3. The cable device according to claim 2, wherein the cable device is supported by the extension portion (2 m). 4.
The end (2a) of the outer cable (2) is connected to the exposed portion (Co) of the cap (C) exposed from the end piece (E1) via the cap (C) by another member (2, 35). Cable device according to claim 2, characterized in that the cable connecting members (64-67) for connecting to the cable devices (35, 38) are integrally formed.
The cap (C) is integrally connected with a bent pipe portion (60) for covering and supporting an intermediate bent portion (2c) continuous to the end portion (2a) of the outer cable (2). The cable device according to any one of claims 1 to 4, wherein the pipe (60) is insert-molded together with the cap (C).
A method for manufacturing a cable device according to any one of claims 1 to 5,
The shield (4) is constituted by a hollow strand (42) formed by arranging and twisting a plurality of metal wires (41) as the metal member so as to be in close contact with each other around the liner (3), Before the insert molding, the ends of the hollow strands (42) are exposed from the outer cover (5) and the diameter thereof is enlarged, so that the metal wires (41) are discrete to form the retaining portions for retaining. The cap (C) is insert-molded so as to surround the first flare part (43), and the resin material of the cap (C) is interposed between the metal wires (41). A method for manufacturing a cable device, characterized in that the cable device is inserted into the cable device.
Before the insert molding, the end of the liner (3) is enlarged to form a second flare portion (44) adjacent to the first flare portion (43) with a gap therebetween, and the second flare portion is formed. The method for manufacturing a cable device according to claim 6, wherein the cap (C) is insert-molded so as to also cover (44).