Molded electrical wire

Abstract

To provide a molded electrical wire having high adhesiveness between an insulation member and a resin molded body.SOLUTION: A molded electrical wire includes: a conductor wire; a non-crosslinked insulation member covering an outer circumference of the conductor wire; and a resin molded body directly covering the insulation member. The insulation member contains a thermoplastic polyurethane and an acrylic thermoplastic elastomer. The resin molded body contains polybutylene terephthalate. The insulation member further contains, for example, polybutylene terephthalate or a polyester-based thermoplastic elastomer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to molded electrical wires. [Background technology]

[0002] When connecting an electric wire to an equipment component such as a sensor, an electrode terminal, or other electronic circuit (hereinafter referred to as the connection object), there is known a technique for protecting the connection part between the electric wire and the connection object and its surroundings with a molded resin body (see Patent Documents 1 and 2).

[0003] High reliability is required for the connection objects when they are used in automobiles, robots, electronic devices, etc. In order to increase the reliability of the connection objects, it is desirable to have high adhesion between the insulator of the electric wire and the molded resin body. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 10-233125 [Patent Document 2] Japanese Patent Application Publication No. 10-294023 Summary of the Invention [Problem to be solved by the invention]

[0005] Conventionally, the material of the insulation of the electric wire has been thermoplastic polyurethane. It is considered to use inexpensive polybutylene terephthalate as the material of the molded resin body. When the material of the insulation is thermoplastic polyurethane and the material of the molded resin body is polybutylene terephthalate, the adhesion between the insulation and the molded resin body is insufficient.

[0006] In one aspect of the present disclosure, it is preferable to provide a molded electric wire having high adhesion between an insulating member of the electric wire and a molded resin body. [Means for solving the problem]

[0007] One aspect of the present disclosure is a molded electric wire comprising a conductor wire, a non-crosslinked insulating member covering an outer periphery of the conductor wire, and a molded resin body directly covering the insulating member, wherein the insulating member includes a thermoplastic polyurethane and an acrylic thermoplastic elastomer, and the molded resin body includes polybutylene terephthalate.

[0008] In the molded electric wire according to one aspect of the present disclosure, even if the molded resin body contains polybutylene terephthalate, the adhesion between the insulating member and the molded resin body is high. [Brief description of the drawings]

[0009] [Figure 1] Fig. 1A is a side view of a molded electric wire in a first embodiment, and Fig. 1B is a side view of the molded electric wire in a state where a molded resin body is cut in the longitudinal direction of the molded electric wire. [Diagram 2] FIG. 1B is a cross-sectional view taken along line II-II in FIG. 1A. [Diagram 3] FIG. 11 is a side view illustrating a configuration of a molded electric wire in a second embodiment. [Figure 4] FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. [Diagram 5] Fig. 5A is a side cross-sectional view showing the configuration of a sample used in the examples, and Fig. 5B is a schematic diagram showing the state in which an airtightness test is carried out. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Exemplary embodiments of the present disclosure will now be described with reference to the drawings. First Embodiment 1. Structure of molded electric wire 1 The configuration of the molded electric wire 1 will be described with reference to Fig. 1A, Fig. 1B, and Fig. 2. The molded electric wire 1 can be used in, for example, automobiles, robots, electronic devices, etc. As shown in Fig. 1A and Fig. 1B, the molded electric wire 1 includes a cable 3, an electronic circuit 5, and a molded resin body 7.

[0011] 2, the cable 3 includes insulated wires 9A and 9B and a sheath 11. The sheath 11 covers the insulated wires 9A and 9B. The insulated wire 9A includes a conductor wire 13 and an insulator 15. The conductor wire 13 is made of a conductive material such as copper.

[0012] The insulator 15 directly covers the outer periphery of the conductor wire 13. "Directly covering the outer periphery" means that the insulator 15 covers the outer periphery of the conductor wire 13 and is in direct contact with the conductor wire 13. Directly covering the outer periphery is one form of covering the outer periphery. The insulated wire 9B has a similar configuration to the insulated wire 9A.

[0013] The sheath 11 indirectly covers the outer periphery of the conductor wire 13 of the insulated wire 9A and the outer periphery of the conductor wire 13 of the insulated wire 9B. Indirectly covering the outer periphery means that the sheath 11 covers the outer periphery of the conductor wire 13, and the sheath 11 and the conductor wire 13 are not in direct contact with each other, and another member exists between them. In this embodiment, the other member is the insulator 15. Indirectly covering the outer periphery is one aspect of covering the outer periphery. The sheath 11 and the insulator 15 correspond to insulating members.

[0014] 1B, sheath 11 is removed to expose insulated wires 9A and 9B at the end of cable 3. Insulator 15 is removed at the exposed ends of insulated wires 9A and 9B to expose conductor wire 13.

[0015] 1B, the electronic circuit 5 includes electrode terminals 21A and 21B. The exposed conductor wire 13 of the insulated wire 9A is electrically connected to the electrode terminal 21A. The exposed conductor wire 13 of the insulated wire 9B is electrically connected to the electrode terminal 21B.

[0016] 1A and 1B, the molded resin body 7 covers the electronic circuit 5 to the end of the sheath 11. The molded resin body 7 covers the entire electronic circuit 5. The molded resin body 7 directly covers the insulators 15 of the insulated wires 9A and 9B in the portion where the sheath 11 has been removed. The molded resin body 7 directly covers the end of the sheath 11.

[0017] The insulated electric wires 9A, 9B in the portion where the sheath 11 has been removed correspond to a plurality of insulated electric wires. The insulated electric wires 9A, 9B in the portion where the sheath 11 has been removed are collectively covered by the molded resin body 7. Note that the number of insulated electric wires included in the cable 3 may be other than two, and may be, for example, one, or three or more.

[0018] The sheath 11 includes thermoplastic polyurethane and acrylic thermoplastic elastomer. For example, the sheath 11 further includes polybutylene terephthalate in addition to the thermoplastic polyurethane and the acrylic thermoplastic elastomer. In this case, the adhesion between the sheath 11 and the molded resin body 7 is further increased.

[0019] For example, the sheath 11 further contains a polyester-based thermoplastic elastomer in addition to the thermoplastic polyurethane and the acrylic thermoplastic elastomer. In this case, the adhesion between the sheath 11 and the molded resin body 7 is further increased.

[0020] For example, the sheath 11 further contains polybutylene terephthalate and polyester thermoplastic elastomer in addition to the thermoplastic polyurethane and acrylic thermoplastic elastomer. In this case, the adhesion between the sheath 11 and the molded resin body 7 is further increased.

[0021] When the total mass of the resins contained in sheath 11 is 100 parts by mass, the mass of the thermoplastic polyurethane contained in sheath 11 is preferably 10 parts by mass or more and 90 parts by mass or less. In this case, the adhesion between sheath 11 and molded resin body 7 is even higher.

[0022] When the total mass of the resins contained in the sheath 11 is 100 parts by mass, the mass of the acrylic thermoplastic elastomer contained in the sheath 11 is preferably 10 parts by mass or more and 90 parts by mass or less. In this case, the adhesion between the sheath 11 and the molded resin body 7 is further increased.

[0023] When the total mass of the resins contained in sheath 11 is 100 parts by mass, the mass of polybutylene terephthalate contained in sheath 11 is preferably 5 parts by mass or more and 30 parts by mass or less. In this case, the adhesion between sheath 11 and molded resin body 7 is even higher.

[0024] When the total mass of the resins contained in the sheath 11 is 100 parts by mass, the mass of the polyester-based thermoplastic elastomer contained in the sheath 11 is preferably 5 parts by mass or more and 30 parts by mass or less. In this case, the adhesion between the sheath 11 and the molded resin body 7 is further increased.

[0025] The sheath 11 may or may not contain a component other than thermoplastic polyurethane, acrylic thermoplastic elastomer, polybutylene terephthalate, or polyester thermoplastic elastomer (hereinafter referred to as the other component of the sheath). Examples of the other component of the sheath include general compounding agents such as antioxidants, plasticizers, lubricants, fillers, flame retardants, stabilizers, and colorants. The other component of the sheath may also be a resin or rubber.

[0026] It is preferable that the sheath 11 is a non-crosslinked insulating material. When the sheath 11 is not crosslinked, the adhesion between the sheath 11 and the molded resin body 7 is higher.

[0027] The molded resin body 7 contains polybutylene terephthalate. The molded resin body 7 may or may not contain a component other than polybutylene terephthalate (for example, a reinforcing material such as glass fiber). For example, the main component of the molded resin body 7 is polybutylene terephthalate. The main component is, for example, a component having the largest mass ratio in the molded resin body 7, or a component having a mass ratio of 50 mass% or more in the molded resin body 7.

[0028] 2. Benefits of Molded Wire 1 (1A) The sheath 11 contains thermoplastic polyurethane and acrylic thermoplastic elastomer. The molded resin body 7 contains polybutylene terephthalate. In the molded electric wire 1, the sheath 11 and the molded resin body 7 have high adhesion. As a result, the molded electric wire 1 can suppress the penetration of water and the like between the sheath 11 and the molded resin body 7. <Second embodiment> 1. Structure of molded electric wire 101 The configuration of the molded electric wire 101 will be described with reference to Fig. 3 and Fig. 4. The molded electric wire 101 is an automobile part that is wired inside a wheel house of an automobile. The molded electric wire 101 includes a multi-core cable 103 and a molded resin body 107.

[0029] The multi-core cable 103 includes an ABS (anti-lock braking system) sensor cable 109, two electric parking brake (EPB) cables 110, and a sheath 111. In FIG. 3, the two electric parking brake cables 110 are arranged side by side in a direction perpendicular to the paper surface.

[0030] The ABS sensor cable 109 is a cable used in an anti-lock braking system of an automobile. The ABS sensor cable 109 is a signal line that transmits signals between a wheel speed sensor that detects the number of rotations of the wheels and an electronic control unit on the vehicle body side. The tip of the ABS sensor cable 109 is provided with a connector for connecting to, for example, the wheel speed sensor.

[0031] The electric parking brake cable 110 is a cable used in an EPB system of an automobile. The electric parking brake cable 110 is a power line that electrically connects an electric motor built into a brake caliper constituting a disc brake in a wheel house to a brake control unit on the vehicle body side and supplies power for driving the brake caliper. A connector is provided at the tip of the electric parking brake cable 110 for connecting to, for example, an electric motor built into the brake caliper.

[0032] The ABS sensor cable 109 and the two electric parking brake cables 110 are collectively covered by a sheath 111. In the multi-core cable 103, the sheath 111 is removed from an end 111A of the sheath 111 shown in FIG. 3 on the tip side, so that the ABS sensor cable 109 and the two electric parking brake cables 110 are exposed.

[0033] At the portion where the sheath 111 is removed, the ABS sensor cable 109 branches off from two electric parking brake cables 110. In the embodiment shown in Fig. 3, the electric parking brake cable 110 extends along the longitudinal direction of the multi-core cable 103, and the ABS sensor cable 109 extends so as to deviate from the longitudinal direction of the multi-core cable 103. However, the extending directions of the ABS sensor cable 109 and the electric parking brake cable 110 may be directions other than those shown in Fig. 3.

[0034] 4, in the multi-core cable 103, a sheath 111 is provided around the ABS sensor cable 109 and two electric parking brake cables 110. In order to stabilize the arrangement of the ABS sensor cable 109 and the electric parking brake cable 110, an interposer 112 may be provided in the gap between the ABS sensor cable 109 and the electric parking brake cable 110. In addition, a pressure winding tape may be wound around the ABS sensor cable 109 and the electric parking brake cable 110.

[0035] The ABS sensor cable 109 includes two ABS cables 210 and a sheath 213 provided around the ABS cables 210. Each of the two ABS cables 210 includes a linear conductor wire 211 and an insulator 212. The insulator 212 directly covers the outer periphery of the conductor wire 211.

[0036] The conductor wire 211 is made of a conductive material such as copper. The insulator 212 is made of an insulating material such as cross-linked polyethylene, cross-linked ethylene vinyl acetate copolymer, etc. The material of the insulator 212 may contain a flame retardant.

[0037] Each of the two electric parking brake cables 110 includes a linear conductor wire 221 and an insulator 222. The insulator 222 directly covers the outer periphery of the conductor wire 221. The conductor wire 221 is made of a conductive material such as copper.

[0038] The sheath 111, the sheath 213, and the insulator 222 are each made of the same material as the sheath 11 in the first embodiment. The sheath 111 corresponds to an insulating member that indirectly covers the outer circumference of the conductor wire 211 and the outer circumference of the conductor wire 221. The sheath 213 corresponds to an insulating member that indirectly covers the outer circumference of the conductor wire 211. The insulator 222 corresponds to an insulating member that directly covers the outer circumference of the conductor wire 221.

[0039] The sheath 111, the sheath 213, and the insulator 222 are preferably non-crosslinked insulating members. When the sheath 111, the sheath 213, and the insulator 222 are not crosslinked, the adhesion between the sheath 111, the sheath 213, and the insulator 222 and the molded resin body 107 is higher.

[0040] 3, the molded resin body 107 directly covers the branched portion 131 of the multi-core cable 103. The branched portion 131 includes a portion where the sheath 111 is present and a portion where the sheath 111 is removed. At the branched portion 131, the ABS sensor cable 109 branches off from the two electric parking brake cables 110. The molded resin body 107 maintains the state in which the ABS sensor cable 109 branches off from the two electric parking brake cables 110.

[0041] In the portion where sheath 111 exists, molded resin body 107 directly covers sheath 111. Molded resin body 107 covers an end portion of sheath 111. In the portion where sheath 111 has been removed, molded resin body 107 directly covers sheath 213 and insulator 222.

[0042] The ABS sensor cable 109 and the two electric parking brake cables 110 correspond to a plurality of insulated electric wires. The molded resin body 107 collectively covers the plurality of insulated electric wires. The molded resin body 107 is made of the same material as the molded resin body 7 in the first embodiment.

[0043] 2. Benefits of Molded Wire 101 (2A) The sheath 111, the sheath 213, and the insulator 222 each contain a thermoplastic polyurethane and an acrylic thermoplastic elastomer. The molded resin body 107 contains polybutylene terephthalate. In the molded electric wire 101, the sheath 111, the sheath 213, and the insulator 222 are highly adhesive to the molded resin body 107. As a result, the molded electric wire 101 can suppress the penetration of water and the like between the sheath 111 and the molded resin body 107, between the sheath 213 and the molded resin body 107, and between the insulator 222 and the molded resin body 107.

[0044] (2B) The molded electric wire 101 includes an ABS sensor cable 109 and two electric parking brake cables 110. Each of these corresponds to an insulated electric wire made of a conductor wire and an insulating member. In the portion of the branch portion 131 where the sheath 111 is removed, the ABS sensor cable 109 and the two electric parking brake cables 110 are collectively covered with the molded resin body 107. Therefore, the molded electric wire 101 can improve the adhesion between the sheath 213 and the insulator 222 and the molded resin body 107.

[0045] <Example> 1. Configuration of Sample 301 Sample 301 shown in Fig. 5A was prepared for each of Examples 1 to 6 and Comparative Example 1. Sample 301 of each Example and Comparative Example 1 was identical in other respects, except for the material of insulator 311, which will be described later.

[0046] Sample 301 was composed of an insulated wire 303 and a molded resin body 307. Insulated wire 303 had a linear conductor wire 309 and an insulator 311. Insulator 311 directly covered the outer periphery of conductor wire 309. Conductor wire 309 was a twisted wire consisting of seven copper conductor wires with a diameter of 0.26 mm. Air was able to pass through conductor wire 309. Insulator 311 had a thickness of 0.36 mm. Insulator 311 had an outer diameter of 1.5 mm.

[0047] The molded resin body 307 had a cylindrical shape with a diameter of 6 mm and a length of 20 mm. The molded resin body 307 directly covered the end of the insulated electric wire 303. The molded resin body 307 directly covered the insulator 311. The central axis of the molded resin body 307 and the central axis of the insulated electric wire 303 were aligned. The length of the part of the insulated electric wire 303 covered by the molded resin body 307 was 10 mm in the longitudinal direction of the insulated electric wire 303. The composition of the materials of the insulated electric wire 303 in each of the examples and Comparative Example 1 was as shown in Table 1. The unit of the composition amount of the materials of the insulated electric wire in Table 1 is parts by mass. The insulator 311 in each of the examples and Comparative Example 1 was not crosslinked.

[0048] [Table 1]

[0049] The thermoplastic polyurethane in Table 1 was Elastollan 1180A (trade name) manufactured by BASF. The acrylic thermoplastic elastomer in Table 1 was Clarity LA2250 (trade name) manufactured by Kuraray. The polybutylene terephthalate in Table 1 was Novaduran 5026 (trade name) manufactured by Mitsubishi Chemical. The polyester thermoplastic elastomer in Table 1 was Hytrel 3046 (trade name) manufactured by Toray Celanese.

[0050] 2.Airtightness evaluation Airtightness was evaluated for each of the Examples and Comparative Example 1. The airtightness was evaluated by alternately repeating a thermal shock treatment and an airtightness test on Sample 301. That is, the following cycle was repeated: thermal shock treatment, airtightness test, thermal shock treatment, airtightness test, thermal shock treatment, airtightness test, etc.

[0051] The thermal shock treatment consisted of 100 repeated temperature cycles, each consisting of 30 minutes in air at -40°C and then 30 minutes in air at 120°C.

[0052] The airtightness test was carried out as follows. As shown in Fig. 5B, the portion of sample 301 on the side of molded resin body 307 was immersed in water 403 contained in water tank 401. The entire molded resin body 307 was immersed in water 403. A part of the portion of insulated wire 303 that was not covered by molded resin body 307 was also immersed in water 403. End 303A of insulated wire 303 opposite molded resin body 307 was not immersed in water 403. An air supplier 405 was connected to end 303A.

[0053] In this state, air was supplied from air supplier 405 to the inside of conductor wire 309. The supplied air passed through the inside of conductor wire 309 and proceeded in the direction of molded resin body 307. When air bubbles 407 leaked out from the bonding surface between molded resin body 307 and insulator 311, it was determined that the airtightness between molded resin body 307 and insulator 311 was lost. When air bubbles 407 did not leak out from the bonding surface between molded resin body 307 and insulator 311, it was determined that the airtightness between molded resin body 307 and insulator 311 was not lost. In one airtightness test, compressed air of 200 kPa was supplied from air supplier 405 for 30 seconds.

[0054] The airtightness between molded resin body 307 and insulator 311 was evaluated according to the following criteria.

[0055] ⊚: The cumulative number of temperature change cycles was 2000 or more at the time when airtightness was lost. ◯: The cumulative number of temperature change cycles was 1000 or more and 1999 or less at the time when airtightness was lost. ×: The cumulative number of temperature change cycles was less than 1000 at the time when airtightness was lost.

[0056] The evaluation results are shown in Table 1. In each example, the evaluation result of airtightness was good. In examples 3 to 6, the evaluation result of airtightness was even better. In comparative example 1, the evaluation result of airtightness was poor. Note that the better the adhesion between molded resin body 307 and insulator 311, the better the evaluation result of airtightness. <Other embodiments> Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments and can be implemented in various modified forms.

[0057] (1) In the first embodiment, for example, in addition to the sheath 11, the insulator 15 may also contain thermoplastic polyurethane and acrylic thermoplastic elastomer. In this case, the adhesion between the insulator 15 and the molded resin body 7 is also high.

[0058] In the first embodiment, the insulator 15 may contain thermoplastic polyurethane and acrylic thermoplastic elastomer instead of the sheath 11. In this case, the adhesion between the insulator 15 and the molded resin body 7 is high.

[0059] In addition to the thermoplastic polyurethane and the acrylic thermoplastic elastomer, the insulator 15 may further include either or both of polybutylene terephthalate and a polyester thermoplastic elastomer.

[0060] It is preferable that the insulator 15 is not cross-linked. When the insulator 15 is not cross-linked, the adhesion between the insulator 15 and the molded resin body 7 is higher.

[0061] (2) In the second embodiment, for example, one or two of the sheath 111, the sheath 213, and the insulator 222 may contain thermoplastic polyurethane and an acrylic thermoplastic elastomer. Examples of combinations containing thermoplastic polyurethane and an acrylic thermoplastic elastomer include a combination of the sheath 111 and the sheath 213, a combination of the sheath 213 and the insulator 222, and a combination of the sheath 111 and the insulator 222.

[0062] (3) The function of one component in each of the above embodiments may be shared by multiple components, or the functions of multiple components may be performed by one component. Also, part of the configuration of each of the above embodiments may be omitted. Also, at least part of the configuration of each of the above embodiments may be added to or substituted for the configuration of another of the above embodiments.

[0063] (4) In addition to the above-described molded electric wires 1, 101, the present disclosure can be realized in various forms, such as a system including the molded electric wires 1, 101 as a component, a manufacturing method for the molded electric wires 1, 101, and the like.

[0064] [Technical idea disclosed in this specification] [Item 1] A conductor wire; A non-bridged insulating member that covers the outer periphery of the conductor wire; a molded resin body that directly covers the insulating member; Equipped with the insulating member includes a thermoplastic polyurethane and an acrylic thermoplastic elastomer, The molded resin body contains polybutylene terephthalate. Molded wire. [Item 2] The molded electric wire according to item 1, The insulating member further includes polybutylene terephthalate. Molded wire. [Item 3] 3. The molded electric wire according to item 1 or 2, The insulating member further includes a polyester-based thermoplastic elastomer. Molded wire. [Item 4] A molded electric wire according to any one of items 1 to 3, The insulating member is an insulator that directly covers the outer periphery of the conductor wire. Molded wire. [Item 5] A molded electric wire according to any one of items 1 to 3, The insulating member is a sheath that indirectly covers the outer periphery of the conductor wire. Molded wire. [Item 6] A molded electric wire according to any one of items 1 to 5, a plurality of insulated wires each including the conductor wire and the insulating member; A plurality of the insulated electric wires are collectively covered with the molded resin body. Molded wire. [Explanation of symbols]

[0065] 1, 101...molded electric wire, 3...cable, 5...electronic circuit, 7, 107, 307...molded resin body, 9A, 9B...insulated electric wire, 11, 111, 213...sheath, 13...conductor wire, 15...insulator, 21A, 21B...electrode terminal, 103...multi-core cable, 109...ABS sensor cable, 110...electric parking brake cable, 111A...end, 112...interposition, 131...branch, 210...ABS cable, 211, 221...conductor wire, 212, 222...insulator, 303...insulated electric wire, 303A...end, 309...conductor wire, 311...insulator, 401...water tank, 403...water, 405...air supply device, 407...air bubbles

Claims

1. A conductor wire; A non-bridged insulating member that covers the outer periphery of the conductor wire; a molded resin body that directly covers the insulating member; Equipped with the insulating member includes a thermoplastic polyurethane and an acrylic thermoplastic elastomer, The molded resin body contains polybutylene terephthalate. Molded wire.

2. The molded electric wire according to claim 1, The insulating member further includes polybutylene terephthalate. Molded wire.

3. The molded electric wire according to claim 1 or 2, The insulating member further includes a polyester-based thermoplastic elastomer. Molded wire.

4. The molded electric wire according to claim 1 or 2, The insulating member is an insulator that directly covers the outer periphery of the conductor wire. Molded wire.

5. The molded electric wire according to claim 1 or 2, The insulating member is a sheath that indirectly covers the outer periphery of the conductor wire. Molded wire.

6. The molded electric wire according to claim 1 or 2, a plurality of insulated wires each including the conductor wire and the insulating member; A plurality of the insulated electric wires are collectively covered with the molded resin body. Molded wire.

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