Conductor for busbar wire, and busbar wire

Abstract

A conductor for a bus wire and a bus wire are provided, which are formed by a conductive plate having a substantially rectangular cross-sectional shape, the conductor including: an opening formed on one side along a width direction orthogonal to the longitudinal direction of the plate, the width direction corresponding to the plane direction of the plate.

Description

Technical Field

[0001] The present disclosure relates to a conductor for a busbar wire and a busbar wire. Background Art

[0002] In the prior art, from the perspective of space saving when wiring vehicles, etc., there is a busbar electric wire using a flat conductor with a rectangular (flat) cross-section (see JP2014-238927A, JP2016-076316A, and JP2018-160317A).

[0003] In order to perform wiring according to the vehicle shape, etc., the busbar wires described in JP2014-238927A, JP2016-076316A, and JP2018-160317A need to be bent in the plane direction of the flat conductor. When bending in the plane direction, a bending jig having a predetermined bend R contacts the inside of the bend.

[0004] Therefore, in the busbar wires described in JP2014-238927A, JP2016-076316A, and JP2018-160317A, the metal inside the flat conductor tends to be compressed when bent in the planar direction, which increases the internal plate thickness and causes cracks to occur. The occurrence of cracks unexpectedly changes the electrical characteristics, resulting in a problem of not being able to meet the specifications. Summary of the invention

[0005] The present disclosure provides a conductor for a bus bar electric wire and a bus bar electric wire capable of reducing the possibility of cracks occurring when bent in a planar direction.

[0006] According to an illustrative aspect of the present disclosure, a conductor for a busbar wire, which is formed by a conductive plate having a substantially rectangular cross-sectional shape, includes: an opening formed on one side along a width direction orthogonal to a longitudinal direction of the plate, the width direction corresponding to a plane direction of the plate.

[0007] According to the present disclosure, since an opening is formed on one side in the plane direction of the plate, when the plate is bent so that the one side becomes the inner side, the opening is filled by the compression of the inner side, thereby preventing the plate thickness from increasing. Therefore, the plate thickness can be prevented from increasing on the inner side of the bend when bending in the plane direction, thereby reducing the possibility of cracks. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a first perspective view showing a bus bar wire according to an embodiment of the present disclosure.

[0009] Figure 2 is a second perspective view showing the bus bar wire according to the embodiment of the present disclosure.

[0010] Figure 3 It shows Figure 2 A perspective view of a flat conductor of a busbar wire is shown.

[0011] Figure 4 yes Figure 2 A cross-sectional view of the busbar wires shown.

[0012] Figure 5 is a top view showing the operation of the bus bar wire according to the embodiment.

[0013] Figure 6 2 is a diagram showing the structure of a flat-plate conductor according to Modification 1.

[0014] Figure 7 2 is a diagram showing the structure of a flat conductor according to Modification 2.

[0015] Figure 8 2 is a diagram showing the structure of a flat conductor according to Modification 3. DETAILED DESCRIPTION

[0016] Hereinafter, the present disclosure will be described according to preferred embodiments. The present disclosure is not limited to the embodiments to be described below, and can be appropriately improved without exceeding the gist of the present disclosure. In addition, although certain configurations are not illustrated or described in the embodiments described below, it goes without saying that, within the scope of not contradicting the contents described below, known or well-known technologies can be appropriately applied to the omitted technical details.

[0017] Figure 1 is a first perspective view of a busbar wire according to an embodiment of the present disclosure, and Figure 2 is a second perspective view of a busbar wire according to an embodiment of the present disclosure. Figure 1 and Figure 2 As shown, the bus bar wire 1 according to the present embodiment is arranged in a vehicle as, for example, a wire harness, and includes a flat conductor (conductor for the bus bar wire) 10 and an insulating cover 20 .

[0018] The flat conductor 10 is composed of a conductive plate material such as aluminum and inevitable impurities, and has a cross-sectional shape of a substantially rectangular shape (including not only a complete rectangular shape but also a rectangular shape with slightly rounded corners) orthogonal to the longitudinal direction (for a cross section passing through a void 11b described later, the cross-sectional shape does not include the void 11b). In the present embodiment, the flat conductor 10 is formed of a single flat plate, but is not limited thereto, and a plurality of flat conductors 10 may be laminated in the thickness direction. In addition, as long as the layer is formed into a rectangular shape in which the width direction is longer than the thickness direction, a plurality of layers may be stacked in the width direction.

[0019] The insulating cover 20 is composed of an insulator covering the outer circumference of the flat conductor 10. The insulating cover 20 is made of, for example, polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), or the like.

[0020] In this embodiment, the flat conductor 10 has a predetermined plate thickness and a predetermined plate width, so as to ensure that the cross-sectional area is not less than a predetermined cross-sectional area (for example, the cross-sectional area is 15 mm 2 or more (such as the total cross-sectional area of ​​the flat conductor 10 composed of a plurality of flat plates, etc. rather than a single flat plate), so that the flat conductor 10 can be used as a power line.

[0021] This bus bar electric wire 1 (flat conductor 10) according to the present embodiment is constructed so as to have Figure 2 The generally linear shape shown, and when routed in a vehicle, is bent so as to include Figure 1 The bent portion 2 shown here is adapted to the shape of the vehicle. The bent portion 2a as a part of the bent portion 2 is bent in the plane direction (horizontal direction) of the flat conductor 10.

[0022] Figure 3 It shows Figure 2 A perspective view of the flat conductor 10 of the busbar wire 1 is shown, and Figure 4 yes Figure 2 A cross-sectional view of the busbar wire 1 is shown. Figure 3 The flat conductor 10 shown shows the Figure 1 The vicinity of the specific curved portion 2a1 that is curved to one side in the plane direction shown, and Figure 4 Shows a through Figure 3 Reference numeral 11b is shown as a cross section of a portion.

[0023] like Figure 3 As shown, the flat conductor 10 has a comb-tooth portion 11 at a position corresponding to a specific bent portion 2a1. The comb-tooth portion 11 is formed on one side in the plane direction of the flat conductor 10 (hereinafter, one side when the flat conductor 10 is divided into two parts in the width direction orthogonal to the longitudinal direction is referred to as one side, and the other side is referred to as the other side), and has an uneven shape. More specifically, the comb-tooth portion 11 has a plurality of flat plate portions 11a extending to one side, and a plurality of voids (openings) 11b are formed by hollowing out on both sides of the flat plate portion 11a (both sides along the longitudinal direction of the flat conductor 10). In the present embodiment, the center of gravity of the void 11b is located on one side of the flat conductor 10 in the plan view of the flat conductor 10.

[0024] In the busbar electric wire 1 according to the present embodiment, the insulating sheath 20 is provided on the flat conductor 10 by tube extrusion or the like. Figure 4 As shown, the insulating sleeve 20 does not fill the gap 11b formed in the flat conductor 10. Figure 4 In the example shown, the void 11b is not filled at all with the insulating sleeve 20. However, as long as the void 11b is at least partially unfilled and the action described later can be obtained, the void 11b may be filled with a small amount of the insulating sleeve 20. Specifically, at least 20% or more of the entire void 11b is not filled, preferably 50% or more is not filled, and further preferably 80% or more of the entire void 11b is not filled.

[0025] Although Figure 3 Only the vicinity of the specific curved portion 2a1 is shown in FIG. Figure 1 The other curved portion 2a shown is connected to the inner side of the curve Figure 3 The comb teeth 11 shown are similarly formed.

[0026] Next, the operation of the bus bar electric wire 1 according to the present embodiment will be described. Figure 5 is a top view showing the operation of the busbar wire 1 according to the embodiment. Figure 5 , the flat conductor 10 and the bending jig BJ are indicated by solid lines, and the insulating sleeve 20 is indicated by dotted lines.

[0027] when Figure 2 The linear busbar wire 1 shown is formed with Figure 1 When forming the bent portion 2a (specific bent portion 2a1) shown, the bending jig BJ is set on one side (inner side of the bend) in the plane direction. The worker bends the busbar electric wire 1 along the bending jig BJ to form the bent portions 2a each having a predetermined bend R.

[0028] Here, if Figure 5 As shown, when the busbar wire 1 is bent in the plane direction, the bent inner side of the flat conductor 10 is in a compressed state. In addition, due to the presence of the bending jig BJ, the metal constituting the flat conductor 10 cannot escape to the inner side, and the plate thickness of the flat conductor 10 tends to increase. Due to the increase in the plate thickness, cracks may be generated.

[0029] However, in the present embodiment, the comb-tooth portion 11 is formed on one side (bending inner side) in the plane direction of the flat conductor 10. In addition, the insulating sleeve 20 does not fill at least a portion of the gap 11 of the comb-tooth portion 11b. Therefore, when the flat conductor 10 is bent in the plane direction, the shape of the flat conductor 10 is changed to fill the gap 11b of the comb-tooth portion 11, thereby preventing an increase in the plate thickness.

[0030] In particular, not only is an increase in the plate thickness prevented, but also the flat plate portions 11 a are in contact with each other to fill the gaps 11 b , so that current can flow through the plurality of flat plate portions 11 a , which can serve to maintain electrical characteristics.

[0031] exist Figure 5 In the example shown, a plurality of flat plate portions 11a (see Figure 3 ) are in contact with each other, but the cross-sectional area of ​​the flat conductor 10 etc. can also be determined so as to ensure electrical characteristics under the assumption that the plurality of flat plate portions 11a are not in contact with each other.

[0032] Here, if Figure 5 As shown, the busbar electric wire 1 is bent by using a bending jig BJ so as to have a bending radius R. At this time, the distance b from the bending center CL of the busbar electric wire 1 to the center of the bending jig BJ is preferably 2.44 mm or more. As a result of intensive research conducted by the inventors of the present disclosure, measurements were performed while changing the length of the gap 11b and the like to various values, and it has been found that: when the distance b from the bending center CL to the center of the bending jig BJ is 2.44 mm or more, for example, in an object where cracks occur at R15 without the comb tooth portion 11, cracks do not occur even at R5, which means that the crack reduction effect is significantly improved. Therefore, it can be said that the distance b is preferably 2.44 mm or more.

[0033] The flat plate portion 11a is preferably a thin plate, and preferably has a thickness in the longitudinal direction of the flat conductor 10 of, for example, 7.5 mm or less. This is because the thin flat plate portion 11a is less likely to increase the thickness of the flat conductor 10 under compression when bent.

[0034] The distance between the gaps 11b (the distance between the flat plate portions 11a) is preferably long, and preferably, for example, 1.0 mm or more. This is because the long distance between the gaps 11b is less likely to increase the thickness of the flat conductor 10 under compression when bent.

[0035] Thus, according to the flat conductor 10 of the present embodiment, since the gap 11b is formed on one side in the width direction of the plate material, when the plate material is bent so that one side becomes the inner side, the gap 11b is filled by compression of the inner side, which prevents the plate thickness from increasing. Therefore, it is possible to prevent the plate thickness on the inner side of the bend from increasing when bending in the plane direction, thereby reducing the possibility of cracks.

[0036] According to the busbar wire 1 of this embodiment, since the insulating cover 20 does not fill at least a portion of the gap 11b, it is possible to prevent the insulating cover 20 from completely filling the gap 11b, thereby preventing the busbar wire 1 from being difficult to fill the gap 11b when it is bent in the planar direction.

[0037] Since the bus bar electric wire 1 is bent along a plane at a portion where the gap 11 b is formed so that one side of the bus bar electric wire 1 is located inside, it is possible to provide a bus bar electric wire 1 that can prevent the occurrence of cracks while achieving a predetermined bend R.

[0038] Although the present disclosure has been described based on the embodiments, the present disclosure is not limited to the above embodiments. The present disclosure can be appropriately modified without departing from the gist of the present disclosure, or can be appropriately combined with known or public technologies if possible.

[0039] Figures 6 to 8 2 is a diagram showing the structure of the flat conductor 10 according to Modifications 1 to 3. Figure 6 As shown, the flat conductor 10 according to Modification 1 includes a comb-tooth portion 11 protruding from one side of a main body portion 10 a extending with the same width in the longitudinal direction.

[0040] Here, in the case where the protruding comb-tooth portion 11 is not included, the bending center CL1 (see Figure 5 )yes Figure 6 That is, the bending center CL1 is the width center line of the main body 10a. On the other hand, in the portion including the protruding comb teeth 11, the bending center CL2 using the bending jig BJ is Figure 6 That is, in the portion where the protruding comb teeth 11 are formed, the bending center CL2 is shifted from the width center line of the main body 10a. Therefore, the same as the reference can be obtained. Figure 5 The same function as described in the specific bent portion 2a1 can reduce the possibility of crack occurrence.

[0041] The bent portion 2a (specific bent portion 2a1) is not limited to the case where the comb-tooth portion 11 is formed, and may be formed with Figure 7 A through hole (opening) 12 is shown that passes through the flat conductor 10 in the thickness direction. In this structure, the center of gravity of the through hole 12 is located on one side of the flat conductor 10, and when the flat conductor 10 is bent to one side in the planar direction, the shape of the flat conductor 10 is changed to fill the through hole 12, thereby reducing the possibility of cracks.

[0042] In addition, without being limited to the comb-tooth portion 11 having the gap 11b which is rectangular in plan view, the V-shaped notch 13 has Figure 8 The gap (opening) 13b shown in the plan view is triangular. In this configuration as well, the center of gravity of the gap 13b is located on one side of the flat conductor 10, and when the flat conductor 10 is bent to one side in the planar direction, the shape of the flat conductor 10 is changed to fill the gap 13b, thereby reducing the possibility of cracks. In addition, as Figure 8 Like the V-shaped notch 13 shown, when each gap 13b has a shape having a V-apex on the other side, the gap 13b can be easily filled while being bent to one side, and electrical characteristics can be easily realized after the gap 13b is filled.

[0043] Comparing the comb-tooth portion 11, the through hole 12, and the V-shaped notch portion 13, it is preferred to use the comb-tooth portion 11 and the V-shaped notch portion 13 instead of the through hole 12. Here, the comb-tooth portion 11 and the V-shaped notch portion 13 have a shape that is open to one side, while the through hole 12 is not open to one side. Therefore, when bending, the end face on one side is compressed, and the thickness of the sheet material may increase. However, in the case of a shape such as the comb-tooth portion 11 and the V-shaped notch portion 13 that is open to one side, the thickness of the sheet material is unlikely to increase. Therefore, it is preferred to use the comb-tooth portion 11 and the V-shaped notch portion 13 instead of the through hole 12.

[0044] Comparing the comb-tooth portion 11 and the V-shaped notch portion 13, the comb-tooth portion 11 is preferably used instead of the V-shaped notch portion 13. This is because the V-shaped notch portion 13 has a pointed shape on one side and may be deformed when bent using the bending jig BJ. Such deformation may invalidate the crack prevention effect initially assumed. On the other hand, in the case of the comb-tooth portion 11, since the distal end on one side is a plane, its shape cannot be easily changed by the bending jig BJ. Therefore, the comb-tooth portion 11 is preferably used instead of the V-shaped notch portion 13.

[0045] In the above description, the voids 11b, 13b and the through hole 12 are through in the thickness direction of the flat conductor 10, but are not particularly limited to through. For example, a groove having a bottom in the thickness direction instead of through can also be used. Of course, the through configuration is preferred because it is easier to obtain the effect of filling the voids 11b, 13b, etc. than the groove.

[0046] According to a first aspect of the present disclosure, a conductor (10) for a busbar wire is formed by a conductive plate having a substantially rectangular cross-sectional shape, comprising: an opening (11b, 12, 13b) formed on one side along a width direction orthogonal to a longitudinal direction of the plate, the width direction corresponding to a plane direction of the plate.

[0047] According to a second aspect of the present disclosure, a busbar wire (1) may include: the conductor (10) for the busbar wire according to the first aspect; and an insulating sleeve (20) which is an insulator covering the conductor (10) for the busbar wire. At least a portion of the opening (11b, 12, 13b) may have an unfilled portion that is not filled with the insulating sleeve (20).

[0048] According to a third aspect of the present disclosure, the busbar wire (1) may further include: a bent portion (2, 2a, 2a1) formed by bending the portion having the opening on the one side as the inner side of the bend toward the one side along the planar direction of the plate.

Claims

1. A conductor for a busbar wire, which is formed by a conductive sheet having a substantially rectangular cross-sectional shape, comprising: an opening formed on one side along a width direction orthogonal to the longitudinal direction of the plate, the width direction corresponding to a plane direction of the plate; The conductor is provided with a comb-tooth portion on the inner side of the bend of the portion to be bent in the plane direction; When the conductor is in a straight line in the plane direction, the comb-tooth portion has a plurality of flat plate portions extending toward the inner side of the bend, and the openings are formed on both sides of the flat plate portions by hollowing out both sides of the flat plate portions in the longitudinal direction; When the conductor is bent in the planar direction, the flat plate portions come into contact with each other to fill the opening.

2. A busbar wire, comprising: The conductor for busbar wire according to claim 1; as well as An insulating sleeve is an insulator covering the conductor of the busbar wire, wherein At least a portion of the opening has an unfilled portion in which the insulating sleeve is not filled.

3. The busbar wire according to claim 2, further comprising: A bent portion is formed by bending a portion having the opening on the one side as an inner side of the bend toward the one side along the planar direction of the plate material.

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