WO2022210684A1 - 絶縁電線およびワイヤーハーネス - Google Patents
絶縁電線およびワイヤーハーネス Download PDFInfo
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- WO2022210684A1 WO2022210684A1 PCT/JP2022/015370 JP2022015370W WO2022210684A1 WO 2022210684 A1 WO2022210684 A1 WO 2022210684A1 JP 2022015370 W JP2022015370 W JP 2022015370W WO 2022210684 A1 WO2022210684 A1 WO 2022210684A1
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- Prior art keywords
- bending
- conductor
- insulated wire
- wire
- height direction
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- 238000005452 bending Methods 0.000 claims abstract description 187
- 239000004020 conductor Substances 0.000 claims abstract description 114
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
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- 229910000881 Cu alloy Inorganic materials 0.000 description 3
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- 230000000996 additive effect Effects 0.000 description 2
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/08—Flat or ribbon cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/08—Several wires or the like stranded in the form of a rope
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0045—Cable-harnesses
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0006—Apparatus or processes specially adapted for manufacturing conductors or cables for reducing the size of conductors or cables
Definitions
- the present disclosure relates to insulated wires and wire harnesses.
- a flat cable configured using flat conductors is known. By using a flat cable, it is possible to reduce the space occupied during wiring as compared with the case of using a general electric wire having a conductor with a substantially circular cross section.
- Patent Documents 1 and 2 In conventional general flat cables, rectangular conductors are often used as conductors, as disclosed in Patent Documents 1 and 2. A rectangular conductor is formed by forming a metal single wire into a rectangular cross section.
- Patent Documents 3 and 4 filed by the applicants disclose electric wire conductors in which a twisted wire obtained by twisting a plurality of strands is formed into a flat shape from the viewpoint of achieving both flexibility and space saving. there is
- an insulated wire having a conductor with a flattened cross section and having excellent selectivity of bending in the height direction of the flattened insulated wire, and a wire harness having such an insulated wire are provided. is the subject.
- An insulated wire of the present disclosure is an insulated wire having a conductor and an insulating coating that covers the outer periphery of the conductor, wherein the conductor has a cross section perpendicular to the axial direction, the dimension in the width direction is the height direction. It has a flat portion larger than the dimension, and in the flat portion, the bending rigidity of the insulated wire in the width direction is 2.6 times or more the bending rigidity in the height direction.
- the wire harness of the present disclosure includes the insulated wire.
- An insulated wire and a wire harness according to the present disclosure are an insulated wire in which a conductor has a flattened cross section, and an insulated wire excellent in the selectivity of bending in the height direction of the flattened shape, and such an insulated wire. It becomes a wire harness with
- FIG. 1 is a cross-sectional view showing an insulated wire according to an embodiment of the present disclosure
- FIG. 2 is a side view for explaining a method of measuring bending stiffness.
- FIG. 3 is a diagram showing the relationship between deflection and bending load obtained in measurement of bending stiffness.
- FIG. 4 is a side view for explaining a method of measuring bending stress.
- An insulated wire according to the present disclosure is an insulated wire that includes a conductor and an insulating coating that covers the outer periphery of the conductor, wherein the conductor has a cross section perpendicular to the axial direction and a dimension in the width direction in the height direction.
- the bending rigidity of the insulated wire in the width direction is 2.6 times or more the bending rigidity in the height direction.
- the bending rigidity in the width direction of the flat shape is 2.6 times or more of the bending rigidity in the height direction. It is difficult to cause bending to. That is, the selectivity of bending in the height direction is high. Therefore, when routing the insulated wire, it becomes easier to perform the work of bending in the height direction while avoiding unintended bending in the width direction.
- the conductor is configured as a twisted wire obtained by twisting a plurality of strands.
- the bending flexibility of the conductor increases, and the wiring of the insulated wire becomes easier with bending in the height direction of the flat shape.
- the flexibility in the width direction of the flat shape is also higher, but as described above, the bending rigidity in the width direction is 2.6 times the bending rigidity in the height direction. By doing so, it is possible to sufficiently suppress the occurrence of unintended bending in the width direction.
- the dimension in the width direction is preferably at least 3.0 times the dimension in the height direction.
- the outer diameter of the wire is preferably 0.32 mm or less.
- the bendability is not improved as much as in the height direction due to the influence of the frictional force between the strands. Therefore, in the insulated wire, it becomes easier to increase the selectivity of bending in the height direction.
- the cross-sectional area of the conductor is 100 mm 2 or more. Insulated wires with a large conductor cross-sectional area may be difficult to route while being flexibly bent. Therefore, routing can be performed easily.
- the bending rigidity in the width direction is preferably 0.5 N ⁇ m 2 or more. Then, unintended bending of the insulated wire in the width direction can be effectively suppressed.
- the bending rigidity in the height direction is preferably less than 0.3 N ⁇ m 2 . Then, bending of the insulated wire in the height direction can be effectively promoted.
- the conductor is preferably made of aluminum or an aluminum alloy. Since aluminum and aluminum alloys have lower conductivity than copper and copper alloys, insulated wires are often designed with a large conductor cross-sectional area, but in the insulated wire of the present disclosure, the flat shape height By using the ease of selective bending in a direction, routing can be performed easily even when the conductor cross-sectional area is large.
- a wire harness according to the present disclosure includes the insulated wire. Since this wire harness includes the above-described insulated wire, it is excellent in selectivity of bending in the height direction of the flat shape of the conductor. Therefore, when routing the insulated wire in the form of a wire harness in a predetermined space, it is easy to perform routing involving bending in the height direction while suppressing the influence of bending in the width direction.
- Insulated wires and wire harnesses according to embodiments of the present disclosure will be described in detail below with reference to the drawings.
- the concept of the shape and arrangement of the member such as straight, parallel, and vertical, is approximately ⁇ 15% in length and approximately ⁇ 15° in angle. Errors from the geometrical concept are included within the allowable range for this type of insulated wire, such as deviation of
- the cross section of a conductor or an insulated wire indicates a cross section taken perpendicularly to the axial direction (longitudinal direction).
- Various characteristics are values evaluated at room temperature in the atmosphere.
- FIG. 1 shows a cross-sectional view of an insulated wire 1 according to an embodiment of the present disclosure.
- An insulated wire 1 according to this embodiment has a conductor 10 and an insulating coating 20 .
- the insulating coating 20 covers the entire circumference of the conductor 10 .
- the conductor 10 may have a single-wire structure made of a metal material such as a metal foil or a metal plate that is integrally continuous as a whole, or may be configured as a stranded wire in which a plurality of strands 15 are mutually twisted. . In the illustrated form, the conductor 10 is configured as a stranded wire.
- the conductor 10 has a flat outer shape at least partially along the axial direction. That is, the conductor 10 has a flattened portion in which a cross section perpendicular to the axial direction has a flattened shape. In this embodiment, the entire axial direction of the conductor 10 is such a flat portion.
- the fact that the cross section of the conductor 10 has a flat shape means that the width w, which is the dimension of the longest straight line among the straight lines that cross the cross section parallel to the sides that make up the cross section and cover the entire cross section, is , is larger than the height h, which is the dimension of a straight line perpendicular to the straight line and covering the entire cross section.
- the cross section of the conductor 10 may have any specific shape as long as it has a flat shape, but in the present embodiment, the cross section of the conductor 10 approximates a rectangle.
- the fact that the cross-sectional shape of the conductor 10 is rectangular means that the circumscribed figure of the conductor 10 indicated by the dashed lines in the figure can be approximated to a rectangle within an error range of about ⁇ 15° in the mutual relationship of each side.
- flat shapes other than rectangular include elliptical, oval, oval (rectangular with semicircles at both ends), parallelogram, trapezoid, and the like.
- the conductor 10 can be formed, for example, by rolling a raw material stranded wire in which a plurality of strands 15 are twisted together to have a substantially circular cross section. At least a part of each wire 15 constituting the conductor 10 may have a cross-sectional shape deformed from a circular shape due to the flattening. However, from the viewpoint of ensuring high flexibility in the conductor 10, the deformation rate from the circular shape of the wire 15 is preferably smaller in the outer peripheral portion of the cross section of the conductor 10 than in the inner portion. Moreover, in the cross section of the conductor 10 , it is preferable that a gap is left between each strand 15 to accommodate one or more strands 15 , or two or more strands 15 .
- the insulated wire 1 has a conductor 10 with a flat cross section, so that the space required for wiring is smaller than that of a wire having a substantially circular cross section with the same conductor cross section. can be made smaller. That is, it is possible to reduce the space around a certain wire in which other wires or other members cannot be arranged. In particular, the space occupied by the electric wires can be reduced along the height direction (y direction), making it easy to achieve space saving. In addition, since the conductor 10 has a flat shape and a small dimension in the height direction, the insulated wire 1 exhibits high flexibility in the height direction.
- the conductor 10 when the conductor 10 is composed of a stranded wire, the conductor 10 is configured as an assembly of a plurality of small-diameter strands 15, thereby obtaining particularly high flexibility.
- the conductor 10 in the insulated wire 1 according to the present embodiment, has a flat shape, thereby achieving both high space saving and flexibility.
- a material constituting the conductor 10 is not particularly limited, and various metal materials can be applied.
- Typical metal materials that make up the conductor 10 include copper and copper alloys, and aluminum and aluminum alloys.
- the conductor cross-sectional area tends to be large in order to ensure the necessary electrical conductivity. Therefore, the effects of flattening the conductor 10 and enhancing the space-saving property and bending flexibility in the height direction are enhanced.
- the conductor 10 is preferably made of aluminum or an aluminum alloy.
- the cross-sectional area of the conductor is preferably 100 mm 2 or more, more preferably 120 mm 2 or more. Although there is no particular upper limit to the cross-sectional area of the conductor, it is preferable to keep the cross-sectional area to 300 mm 2 or less, for example, from the viewpoint of ensuring bending flexibility.
- the material constituting the insulating coating 20 is not particularly limited as long as it is an insulating material, but it is preferably based on an organic polymer.
- organic polymers include olefin polymers such as polyolefins and olefin copolymers, halogen polymers such as polyvinyl chloride, various elastomers, and rubbers.
- the organic polymer may be crosslinked or foamed.
- the insulating coating 20 may contain various additives such as a flame retardant in addition to the organic polymer.
- the insulation coating 20 has a considerably higher degree of flexibility than the conductor 10, so the degree of flexibility of the insulated wire 1 as a whole is substantially defined by the degree of flexibility of the conductor 10. However, if the insulation coating 20 also has high flexibility, the flexibility of the insulated wire 1 as a whole tends to be increased. From that point of view, the flexural modulus of the constituent material of the insulating coating 20 is preferably 30 MPa or less, more preferably 20 MPa or less.
- the insulated wire 1 according to the present embodiment may be used alone or may be used as a constituent member of the wire harness according to the embodiment of the present disclosure.
- a wire harness according to an embodiment of the present disclosure includes the insulated wire 1 according to the above embodiment.
- the wire harness may include a plurality of the insulated wires 1 described above, or may include other types of insulated wires in addition to the insulated wires 1 described above.
- Preferably, a plurality of the insulated wires 1 are arranged in the width direction (x direction) and/or the height direction (y direction).
- the specific arrangement structure of the plurality of insulated wires 1 is not particularly limited, but as a preferred form, the plurality of insulated wires 1 are arranged in the width direction, and on a common sheet material, A form of fixing by fusion or the like can be exemplified. In this case, it is particularly preferable that the heights of the plurality of insulated wires 1 arranged are uniform.
- the conductor 10 is configured as a stranded wire of aluminum or an aluminum alloy.
- the conductor 10 may be either a stranded wire or a single wire, and the type of metal material that constitutes the conductor 10 is not particularly limited. , and each configuration described below applies regardless of the form and metal type of the conductor 10 .
- Specific upper and lower limit values of each parameter may differ depending on whether the conductor 10 is a stranded wire or a single wire, and also depending on the type of metal. The relation with the effect does not depend on the form of the conductor 10 and the metal type.
- the conductor 10 has a flat shape, so that the bending rigidity in the width direction (edge direction; x direction) is increased in the height direction (flat direction; y direction). is greater than the bending stiffness of
- the bending rigidity ratio defined as the ratio of the bending rigidity in the width direction to the bending rigidity in the height direction, as in the following formula (1) is 2.6 or more. It is preferable that That is, it is preferable that the bending rigidity in the width direction is 2.6 times or more the bending rigidity in the height direction.
- [Bending stiffness ratio] [Bending stiffness in the width direction]/[Bending stiffness in the height direction] (1)
- the bending rigidity of the insulated wire 1 can be evaluated by, for example, a three-point bending test conforming to JIS K 7171. That is, as shown in FIG. 2, the insulated wire 1 is supported with two cylinders T1, T1 as fulcrums, and the cylinder T2 is pushed in from the direction opposite to the support direction at the intermediate point between the cylinders T1, T1, A bending load F is applied to the insulated wire 1 . At this time, the insulated wire 1 is flexed by the pushing amount of the cylinder T2. Based on this measurement result, the flexural rigidity can be obtained by the following formula (2).
- [Bending stiffness] ([Bending load F] ⁇ [Distance between fulcrums L] 3 )/(48 ⁇ [Deflection]) (2)
- the above three-point bending test is performed for bending the flat insulated wire 1 in the height direction and in the width direction. That is, the measurement is performed with the height direction of the insulated wire 1 directed to the load application direction corresponding to the vertical direction in FIG. 2, and the measurement is performed with the width direction directed. Then, the flexural rigidity ratio can be obtained from the above equation (1).
- the insulated wire 1 Because the bending rigidity ratio of the insulated wire 1 is increased to 2.6 or more, the insulated wire 1 is flexible and easy to bend in the height direction, but difficult to bend in the width direction. That is, the insulated wire 1 has excellent selectivity for bending in the height direction. As a result, when routing the insulated wire 1, it is possible to route the insulated wire 1 along a predetermined path by utilizing the bending in the height direction while suppressing the occurrence of unintended bending in the width direction. In the insulated wire 1, since the conductor 10 has a flat shape, the conductor 10 and the insulation coating 20 are more likely to be bent in the height direction, which has a smaller dimension, than in the width direction, which has a larger dimension. Small load.
- the insulated wire 1 has a high space-saving property in the height direction due to the flat shape of the conductor 10, and by performing wiring while bending in the height direction, the wiring route can be saved. Space can be effectively used.
- the bending rigidity ratio of the insulated wire 1 is more preferably 3.0 or more, or 3.5 or more. Although there is no particular upper limit for the bending rigidity ratio, it is preferable to set it to about 20.0 or less from the viewpoint of avoiding excessive restriction on bending in the width direction.
- the bending rigidity of the conductor 10 predominantly contributes to the bending rigidity of the insulated wire 1 as a whole. Therefore, the bending rigidity ratio of the insulated wire 1 can be adjusted by the specific configuration of the conductor 10 such as the diameter of the wire 15 constituting the stranded wire, the flatness ratio of the conductor 10 , and the like. As will be described later, the smaller the diameter of the wire 15 and the larger the flatness ratio, the greater the flexural rigidity ratio. Although the insulating coating 20 does not affect the bending stiffness of the insulated wire 1 in each direction, its contribution is limited compared to the contribution of the wire conductor 10 .
- the bending rigidity in the height direction and the bending rigidity in the width direction are not particularly limited.
- the higher the bending rigidity in the width direction and the lower the bending rigidity in the height direction the higher the bending rigidity ratio and the higher the selectivity of bending in the height direction.
- the bending rigidity in the width direction is 0.3 N ⁇ m 2 or more, further 0.5 N ⁇ m 2 or more, or 0.8 N ⁇ m 2 or more, the bending of the insulated wire 1 in the width direction is can be effectively suppressed.
- the bending rigidity in the height direction is less than 0.3 N ⁇ m 2 , and further less than 0.25 N ⁇ m 2 , the bending of the insulated wire 1 in the height direction can be effectively promoted. can be done.
- the flatness ratio of the conductor 10 that is, the ratio of the width to the height of the conductor 10 (w/h) is preferably 2.0 or more.
- the flatness ratio of the cross-sectional shape of the insulated wire 1 increases, the area occupied by the conductor 10 in the width direction becomes larger than in the height direction, making it difficult to bend the conductor 10 in the width direction. That is, the bending rigidity ratio of the insulated wire 1 is increased, and the selectivity of bending in the height direction is likely to be enhanced.
- the flatness ratio of the conductor 10 is 3.0 or more. There is no particular upper limit for the flatness ratio of the conductor 10, but from the viewpoint of avoiding excessive flatness, for example, it may be set to 6.0 or less.
- the outer diameter of the wire 15 that constitutes the stranded wire is preferably 0.40 mm or less.
- the cross-sectional area of the conductor is the same, the finer the wire 15 constituting the stranded wire, the higher the flexibility of the conductor 10 as a whole.
- the bending of the flat shape in the height direction reflects well the effect of improving the flexibility due to the thinning of the wires 15, making it easier to bend.
- the total frictional force acting between the strands 15 when bending is applied increases.
- the outer diameter of the wire 15 is preferably 0.32 mm or less, more preferably 0.30 mm or less.
- the lower limit of the outer diameter of the wire 15 is not particularly specified, but from the viewpoint of maintaining the strength of the wire 15, for example, it is preferably 0.1 mm or more.
- the selectivity of bending in the height direction improves. Bending selectivity can be evaluated, for example, by bending stress when the insulated wire 1 is bent. In terms of the ratio of the bending stress when bending the insulated wire 1 in the height direction, it can be said that the higher the bending stress when bending the insulated wire 1 in the width direction, the higher the selectivity of bending in the height direction.
- the insulated wire 1 is gripped at two points separated by 200 mm and bent to 60° with a bending radius (r) of 150 mm.
- the ratio of the stress when bending in the width direction to the stress when bending in the direction is defined as the bending stress ratio (formula (3) below), and if the bending rigidity ratio is set to 2.6 or more, the bending stress ratio is 4.0 That's it.
- [Bending stress ratio] [Bending stress in width direction]/[Bending stress in height direction] (3)
- a bending stress ratio of 4.0 or more means that bending the insulated wire 1 in the width direction requires four times the force required to bend it in the height direction. When a force is applied to bend the insulated wire 1 in the longitudinal direction, it is considerably less likely that the insulated wire 1 is unintentionally bent in the width direction.
- the bending stress ratio is 4.0 or more
- the height The selectivity of bending in direction can be significantly increased. It is more preferable if the bending stress ratio is 4.5 or more, or 5.0 or more.
- An insulating coating having a thickness of 1.6 mm was formed on the outer circumference of each conductor by extrusion molding.
- the coating material the following two types were used. ⁇ Coating material 1-organic polymer: silane cross-linked polyethylene (100 parts by mass), additive: magnesium hydroxide (70 parts by mass), flexural modulus: 35 MPa ⁇ Coating material 2-organic polymer: silane cross-linked polyethylene (100 parts by mass), additive: brominated flame retardant (30 parts by mass) and antimony trioxide (10 parts by mass), flexural modulus: 15 MPa
- the bending rigidity in the width direction and the height direction was measured by a three-point bending test conforming to JIS K 7171. That is, as shown in FIG. 2, the insulated wire 1 is supported with two cylinders T1, T1 as fulcrums, and the cylinder T2 is pushed in from the direction opposite to the support direction at the intermediate point between the cylinders T1, T1, A bending load F was applied to the insulated wire 1 . Then, the relationship with the deflection of the insulated wire 1, which is shown as the pushing amount of the cylinder T2, was recorded.
- the distance L between fulcrums was 100 mm, and the length of the insulated wire 1 used as a sample was 150 mm.
- the cylinders T1 and T2 used for supporting the insulated wire 1 and applying a bending load had a diameter of 5 mm.
- the pressing speed when applying the bending load F was 100 mm/min.
- Measurements were taken for the bending in the height direction and the bending in the width direction of the flat shape. Measurements provide the relationship between deflection and bending load, as illustrated in FIG. Using the values of the deflection and the bending load in the region of small deflection, the bending stiffness in bending in each direction was calculated from the above formula (2). Then, using the obtained values, a bending stiffness ratio was obtained as a ratio of the bending stiffness in the width direction to the bending stiffness in the height direction, as in Equation (1). In addition, FIG. 3 shows the measurement results when the sample A1 in Table 1 is bent in the width direction.
- each insulated wire 1 was cut to a length of 200 mm, and both ends were gripped by grippers T3, T3, respectively, and the insulated wire 1 was bent.
- a load F' applied to the end of the insulated wire 1 was measured by a load cell attached to a gripper while the insulated wire 1 was bent at a predetermined bending radius. Then, of the load F', a component orthogonal to the axial direction of the insulated wire 1 was obtained and used as the bending stress f.
- Table 1 summarizes the configuration of the insulated wires and the evaluation results for the samples A1 to A8 in which the conductors are composed of stranded wires.
- samples A7 and A8 have bending rigidity ratios of less than 2.6.
- the bending stress ratio is less than 4.0, and the selectivity of bending in the height direction is low. From the above results, it can be seen that the bending stiffness ratio is a good index indicating the selectivity of the bending direction in an insulated wire having a flat conductor. By setting the bending rigidity ratio to 2.6 or more, the insulated wire has high selectivity for bending in the height direction.
- Samples A1, A5, A7, and A8 differ in the flatness ratio of the conductor.
- Sample A5, sample A1, sample A8, and sample A7 have the largest flatness ratio.
- Sample A5, sample A1, sample A8, and sample A7 are arranged in descending order of flexural rigidity ratio, and the flatness ratio and the size relationship match. From this, it can be seen that by increasing the flatness ratio of the conductor, the flexural rigidity ratio of the insulation coating can be increased and the selectivity of bending in the height direction can be enhanced.
- Samples A1, A2, and A6 are different in wire diameter.
- Sample A6, Sample A1, and Sample A2 have wire diameters in descending order.
- the flexural rigidity ratios are sample A2, sample A1, and sample A6 in descending order, and the size relationship with the wire diameter is reversed. From this, it can be seen that by reducing the outer diameter of the wire constituting the conductor, the bending rigidity ratio of the insulation coating can be increased, and the selectivity of bending in the height direction can be enhanced.
- the set of samples A1 and A3 and the set of samples A2 and A4 each differ in the type of covering material.
- the flexural rigidity values in the width direction and the height direction were higher when using the coating material 1 with a high elastic modulus (Samples A1 and A2) than when using the coating material 2 with a low elastic modulus. It is larger than when using (Samples A3 and A4).
- the difference due to the different types of covering materials is small.
- the values of the flexural rigidity ratios are the same regardless of the type of covering material. It can be said that the effect of the type of insulation coating on the bending stiffness ratio of an insulated wire is limited, and the effect of the configuration of the conductor is dominant.
- sample A1 and sample A2 sample A2 has a larger bending stiffness ratio
- the ratio is higher for sample A1, inverting the relationship.
- Table 2 shows the electric wire configuration and bending rigidity evaluation results for samples B1 to B5 in which the conductor is formed in a single-wire structure.
- the flexural rigidity ratio is 2.6 by flattening the conductor as in samples B2 to B5, as in the case of stranded wires. It can be as above. Furthermore, when the flatness ratio is increased from sample B2 to sample B5, the flexural rigidity ratio is also increased accordingly.
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Abstract
Description
最初に本開示の実施形態を列記して説明する。
本開示にかかる絶縁電線は、導体と、前記導体の外周を被覆する絶縁被覆と、を有する絶縁電線であって、前記導体は、軸線方向に直交する断面が、幅方向の寸法が高さ方向の寸法よりも大きい扁平部を有しており、前記扁平部において、前記絶縁電線の前記幅方向への曲げ剛性が、前記高さ方向への曲げ剛性の2.6倍以上である。
以下に、本開示の実施形態にかかる絶縁電線およびワイヤーハーネスについて、図面を用いて詳細に説明する。本明細書において、絶縁電線の各部の形状に関して、直線、平行、垂直等、部材の形状や配置を示す概念には、長さにして概ね±15%程度、また角度にして概ね±15°程度のずれ等、この種の絶縁電線において許容される範囲で、幾何的な概念からの誤差を含むものとする。本明細書において、導体や絶縁電線の断面とは、特記しない限り、軸線方向(長手方向)に垂直に切断した断面を示すものとする。また、各種特性は、室温、大気中にて評価される値とする。
図1に、本開示の一実施形態にかかる絶縁電線1の断面図を示す。本実施形態にかかる絶縁電線1は、導体10と、絶縁被覆20とを有している。絶縁被覆20は、導体10の外周を、全周にわたって被覆している。
以下、絶縁電線1の構造および特性の詳細について説明する。以下では、導体10が、アルミニウムまたはアルミニウム合金の撚線として構成される形態を主に想定して、説明を行う。しかし、上記のように、本開示の実施形態にかかる絶縁電線1においては、導体10が撚線と単線のいずれの形態をとってもよく、また導体10を構成する金属材料の種類も特に限定されないものであり、以下に示す各構成は、導体10の形態および金属種を問わずに当てはまる。各パラメータの具体的な上下限値は、導体10が撚線であるか単線であるか、また金属種によって異なる可能性はあるが、各パラメータがとる値の大小と、発生する現象や得られる効果との関係は、導体10の形態および金属種によらない。
[曲げ剛性比]=[幅方向への曲げ剛性]/[高さ方向への曲げ剛性] (1)
[曲げ剛性]=([曲げ荷重F]×[支点間距離L]3)/(48×[たわみ]) (2)
上記の3点曲げ試験を、絶縁電線1の扁平形状の高さ方向への曲げと、幅方向への曲げについて行う。つまり、図2の縦方向にあたる荷重印加方向に、絶縁電線1の高さ方向を向けた計測と、幅方向を向けた計測をそれぞれ行う。そして、上の式(1)によって曲げ剛性比を求めればよい。
[曲げ応力比]=[幅方向への曲げ応力]/[高さ方向への曲げ応力] (3)
最初に、アルミニウム合金素線を用いて、撚線よりなる導体を作製した。試料A1~A8について、用いた素線の外径および導体構成は、表1に示すとおりとした。導体構成は、「親撚本数/子撚本数/素線径(mm)」の形式で表記している。得られた撚線をローラによって扁平形状に圧延することで、導体を作製した。この際、圧延率を変更することで、扁平比w/hを、表1に記載のとおり設定した。また、別途、試料B1~B5として、アルミニウム合金を用いて、単線構造の導体も準備した。
・被覆材1-有機ポリマー:シラン架橋ポリエチレン(100質量部)、添加剤:水酸化マグネシウム(70質量部)、曲げ弾性率:35MPa
・被覆材2-有機ポリマー:シラン架橋ポリエチレン(100質量部)、添加剤:臭素系難燃剤(30質量部)および三酸化アンチモン(10質量部)、曲げ弾性率:15MPa
上記で得た各絶縁電線に対して、JIS K 7171に準拠した3点曲げ試験によって、幅方向および高さ方向の曲げ剛性を計測した。つまり、図2に示すように、2つの円柱T1,T1を支点として絶縁電線1を支持し、それらの円柱T1,T1の中間の箇所において、支持方向と逆の方向から、円柱T2を押し込み、絶縁電線1に曲げ荷重Fを印加した。そして、円柱T2の押し込み量として示される絶縁電線1のたわみとの関係を記録した。支点間距離Lは100mmとし、試料として用いる絶縁電線1の長さは150mmとした。絶縁電線1の支持および曲げ荷重の印加に用いた円柱T1,T2は、直径5mmであった。曲げ荷重Fを印加する際の押し込みの速度は、100mm/分とした。
上記で作製した、導体が撚線より構成された各絶縁電線について、図4に説明する方法で、曲げ応力を測定した。測定に際し、各絶縁電線1を長さ200mmに切り出し、両端をそれぞれ把持具T3,T3で把持して、絶縁電線1に曲げを加えた。所定の曲げ半径で曲げた状態で、絶縁電線1の端部に印加される荷重F’を、把持具に取り付けたロードセルによって計測した。そして、その荷重F’のうち、絶縁電線1の軸線方向に直交する成分を求めて、曲げ応力fとした。曲げ半径(r)は、150mm、100mm、50mmの3とおりとした。曲げ応力の計測は、扁平形状の高さ方向への曲げと、幅方向への曲げのそれぞれについて行った。そして、上記式(3)のように、高さ方向への曲げ応力に対する幅方向への曲げ応力の比率として、曲げ応力比を求めた。
表1に、導体が撚線より構成された試料A1~A8について、絶縁電線の構成と、各評価結果をまとめる。
10 導体
15 素線
F 曲げ弾性の評価における曲げ荷重
F’ 曲げ応力の評価において測定される荷重
f 曲げ応力
L 支点間距離
r 曲げ半径
T1,T2 円柱
T3 把持具
x 幅方向
y 高さ方向
Claims (9)
- 導体と、
前記導体の外周を被覆する絶縁被覆と、を有する絶縁電線であって、
前記導体は、軸線方向に直交する断面が、幅方向の寸法が高さ方向の寸法よりも大きい扁平形状となった扁平部を有しており、
前記扁平部において、前記絶縁電線の前記幅方向への曲げ剛性が、前記高さ方向への曲げ剛性の2.6倍以上である、絶縁電線。 - 前記導体は、複数の素線を撚り合わせた撚線として構成されている、請求項1に記載の絶縁電線。
- 前記導体の前記断面において、前記幅方向の寸法が、前記高さ方向の寸法の3.0倍以上である、請求項2に記載の絶縁電線。
- 前記素線の外径は、0.32mm以下である、請求項2または請求項3に記載の絶縁電線。
- 導体断面積が100mm2以上である、請求項2から請求項4のいずれか1項に記載の絶縁電線。
- 前記幅方向への曲げ剛性は、0.5N・m2以上である、請求項1から請求項5のいずれか1項に記載の絶縁電線。
- 前記高さ方向への曲げ剛性は、0.3N・m2未満である、請求項1から請求項6のいずれか1項に記載の絶縁電線。
- 前記導体は、アルミニウムまたはアルミニウム合金より構成されている、請求項1から請求項7のいずれか1項に記載の絶縁電線。
- 請求項1から請求項8のいずれか1項に記載の絶縁電線を含む、ワイヤーハーネス。
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