Electric wire and method for producing electric wire

Abstract

To provide an electric wire and a method for producing an electric wire, by which proper performance can be secured.SOLUTION: An electric wire 1 includes a conductor part 10 that has conductivity, an insulation coating part 20 that has insulation and covers the conductor part 10, a portion 20A forming a deformation allowing part 30, where the insulation coating part 20 covering the conductor part 10 is one layer, and a portion 20B forming a deformation restricting part 40, where the insulation coating part 20 covering the conductor part 10 is multiple layers.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an electric wire and a method for manufacturing the electric wire. [Background technology]

[0002] For example, Patent Document 1 discloses an electric wire having a deformation-restricting portion consisting of a portion of the insulating coating that insulates a plurality of wires, which is partially heated and compressed, and a deformation-permitting portion consisting of a portion of the insulating coating that is not heated and compressed and maintains its original tubular shape. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-91895 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the electric wire described in Patent Document 1 has a conductor portion made up of a plurality of wires and an insulating coating portion that insulates the conductor portion, and is manufactured by extrusion molding, and then the insulating coating portion is partially reheated, which may reduce the durability of the insulating coating portion due to heat. As a result, there is a risk of the performance of the electric wire being reduced, and in this respect, there is room for further improvement.

[0005] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide an electric wire that can ensure appropriate performance, and a method for manufacturing the electric wire. [Means for solving the problem]

[0006] In order to achieve the above object, the electric wire of the present invention is characterized by comprising a conductor portion having electrical conductivity, an insulating coating portion having electrical insulation and coating the conductor portion, a portion forming a deformation-allowing portion, in which the insulating coating portion is one layer, and a portion forming a deformation-regulating portion, in which the insulating coating portion is multiple layers.

[0007] In order to achieve the above object, the electric wire manufacturing method of the present invention is characterized by comprising a first extrusion process in which an insulating coating portion that has insulating properties and coats a conductor portion is extruded onto the outer peripheral surface of a conductive conductor portion to form a first layer of the insulating coating portion, and a second extrusion process in which a new insulating coating portion is extruded onto the outer peripheral surface of the first layer of the insulating coating portion to partially form a second layer of the insulating coating portion, thereby forming a portion that forms a deformation-permitting portion and has one layer of the insulating coating portion, and a portion that forms a deformation-regulating portion and has multiple layers of the insulating coating portion. [Effects of the Invention]

[0008] The electric wire and the method for manufacturing the electric wire according to the present invention have the effect of ensuring appropriate performance. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram showing a schematic configuration of the electric wire according to the present embodiment. [Figure 2] FIG. 2 is a cross-sectional view taken along the line AA shown in FIG. [Figure 3] FIG. 3 is a cross-sectional view taken along the line BB shown in FIG. [Figure 4] FIG. 4 is a flowchart showing the wire manufacturing method according to this embodiment. [Figure 5] FIG. 5 is a flowchart showing a modified example of the electric wire manufacturing method according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the present invention is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially the same.

[0011] [Embodiment] An electric wire 1 shown in FIG. 1 is wired, for example, in a vehicle, and electrically connects various devices.

[0012] The electric wire 1 of this embodiment has a configuration that can ensure appropriate performance by changing flexibility using a deformation-permitting portion 30 in which the insulating coating portion 20 that covers the conductor portion 10 is composed of a single layer, and a deformation-restricting portion 40 in which the insulating coating portion 20 is composed of multiple layers. Hereinafter, the configuration of the electric wire 1 will be described in detail with reference to Figs. 1 to 3.

[0013] In the following description, of the first, second, and third directions that intersect with one another, the first direction will be referred to as the "length direction X," the second direction will be referred to as the "width direction Y," and the third direction will be referred to as the "height direction Z." Here, the length direction X, width direction Y, and height direction Z are perpendicular to one another. Furthermore, the length direction X shown in FIGS. 1 to 3 typically corresponds to the extending direction (axial direction) of the electric wire 1. Unless otherwise specified, the directions used in the following description will be described as directions in a state in which the parts of the electric wire 1 are assembled.

[0014] As shown in Figs. 1 to 3, the electric wire 1 includes a linear conductor portion 10 having electrical conductivity, an insulating covering portion 20 having insulation properties and covering the outside of the conductor portion 10, a deformation-permitting portion 30 in which the insulating covering portion 20 is configured as a single layer, and a deformation-regulating portion 40 in which the insulating covering portion 20 is configured as a plurality of layers. The electric wire 1 of this embodiment is an insulated electric wire in which the conductor portion 10 is covered with the insulating covering portion 20. Furthermore, as shown in Fig. 1, the electric wire 1 is provided with connectors C at both ends, and is used to electrically connect various devices via the connectors C.

[0015] The conductor portion 10 is a core wire formed by bundling a plurality of wires 10a (see FIGS. 2 and 3) made of a conductive metal such as copper, a copper alloy, aluminum, or an aluminum alloy.

[0016] The insulating coating 20 is a wire coating that coats the outer periphery of the conductor 10. The insulating coating 20 is formed, for example, by extrusion molding an insulating resin material (such as PP, PVC, or cross-linked PE, which is appropriately selected taking into consideration abrasion resistance, chemical resistance, heat resistance, etc.). The insulating coating 20 of this embodiment includes a first insulating coating 21 (see FIGS. 2 and 3) as the first layer of insulating coating 20 that coats the conductor 10, and a second insulating coating 22 (see FIG. 3) as the second layer of insulating coating 20 that coats the first insulating coating 21.

[0017] The deformable portion 30 is a softer portion than the deformation restricting portion 40. In this embodiment, the deformable portion 30 is a portion 20A where the insulating coating portion 20 is a single layer, and is composed of a single layer of the first insulating coating portion 21 (see FIG. 2). Therefore, the deformable portion 30 is composed of a portion where the insulating coating portion 20 is relatively thin. Furthermore, the deformable portion 30 has lower rigidity than the deformation restricting portion 40, and is configured so that the amount of deformation in response to an external force such as bending or twisting is larger than that of the deformation restricting portion 40.

[0018] The deformation restricting portion 40 is a harder portion than the deformation-permitting portion 30. In this embodiment, the deformation restricting portion 40 is the portion 20B of the insulating coating portion 20 that is made up of multiple layers, and is composed of two layers: a first insulating coating portion 21 and a second insulating coating portion 22 (see FIG. 3). The deformation restricting portion 40 is formed by extrusion-molding the second insulating coating portion 22 on the outer peripheral surface 21m side of the first insulating coating portion 21, that is, by extrusion-molding the second insulating coating portion 20 on the outer peripheral surface 20m side of the first insulating coating portion 20. As shown in FIG. 1, three deformation restricting portions 40 are provided. Therefore, two deformation-permitting portions 30 described above are provided by being formed between the deformation restricting portions 40. In this embodiment, the deformation restricting portions 30 and the deformation restricting portions 40 are formed alternately. The deformation restricting portions 40 are formed by portions of the insulating coating portion 20 that are relatively thick. Furthermore, the deformation restricting portion 40 has higher rigidity than the deformation allowing portion 30, and is configured so that the amount of deformation caused by external forces such as bending and twisting is smaller than that of the deformation restricting portion 40.

[0019] The first insulating coating portion 21 and the second insulating coating portion 22 described above are formed from the same resin material. As a result, the deformation restricting portion 40 formed by laminating the second insulating coating portion 22 on the first insulating coating portion 21 can prevent the first insulating coating portion 21 and the second insulating coating portion 22 from cracking due to differences in thermal expansion coefficients. The first insulating coating portion 21 and the second insulating coating portion 22 may be formed from different resin materials. The thicknesses of the first insulating coating portion 21 and the second insulating coating portion 22 are not particularly limited.

[0020] Furthermore, as shown in Figures 2 and 3, the cross-sectional shape of the conductor portion 10 of the electric wire 1 configured as described above (cross-sectional shape in a direction intersecting the extension direction) is approximately circular, and the cross-sectional shape of the insulating coating portion 20 is approximately annular, resulting in an overall cross-sectional shape that is approximately circular.

[0021] The electric wire 1 has the insulating sheath 20 stripped off at least one end thereof, and the conductor 10 is exposed from the insulating sheath 20. The electric wire 1 is also provided with a connector C at the end of the conductor 10 exposed from the insulating sheath 20.

[0022] Furthermore, the wire 1 can be routed in an appropriate state by providing the deformation-allowing portion 30 in a portion where it is desired to deform as needed in a predetermined routing path, and by providing the deformation-restricting portion 40 in a portion where it is desired not to deform (i.e., a portion where it is desired to restrict the path). Furthermore, by varying the number of layers of the insulating coating portion 20, the deformation-allowing portion 30 and the deformation-restricting portion 40 are realized, and the flexibility of the wire 1 can be changed with a simple structure.

[0023] <Wire manufacturing method> Next, a method for manufacturing the electric wire 1 will be described with reference to FIG.

[0024] As shown in Fig. 4, the manufacturing method of the electric wire 1 includes a first extrusion step (step S1), a first cooling step (step S2), a winding step (step S3), a second extrusion step (step S4), and a second cooling step (step S5). The first extrusion step (step S1) here is a step of forming a first layer of insulating coating 20 by extruding the insulating coating 20 toward the outer peripheral surface 10m of the conductor portion 10. The first cooling step (step S2) is a step of solidifying the insulating coating 20 by cooling the electric wire with one layer of insulating coating 20 extruded toward the outer peripheral surface 10m of the conductor portion 10. The winding step (step S3) is a step of winding the electric wire with one layer of insulating coating 20 extruded toward the outer peripheral surface 10m of the conductor portion 10, around a reel. The second extrusion step (step S4) is a step of extruding a new insulating sheath portion 20 toward the outer peripheral surface 20m of the first-layer insulating sheath portion 20 to form the second-layer insulating sheath portion 20, thereby forming a portion 20A where the deformation-permitting portion 30 is formed and where the insulating sheath portion 20 is a single layer, and a portion 20B where the deformation-restricting portion 40 is formed and where the insulating sheath portion 20 is a multi-layer insulating sheath portion 20. The second cooling step (step S5) is a step of solidifying the second-layer insulating sheath portion 20 by cooling the electric wire where two layers of insulating sheath portion 20 have been extruded toward the outer peripheral surface 10m of the conductor portion 10. This electric wire manufacturing method will be described as being performed using an extruder. The outer peripheral surface 10m of the conductor portion 10 will be described as an imaginary circle formed when multiple strands 10a are bundled together (see FIGS. 2 and 3).

[0025] Specifically, first, in preparation for the first extrusion step (step S1), the worker prepares a linear conductor portion 10. Next, in the first extrusion step (step S1), the worker extrudes the first insulating coating portion 21 onto the outside of the conductor portion 10. At this time, the worker puts the conductor portion 10 into an extruder and extrudes the first insulating coating portion 21 into a substantially annular shape using an extrusion head provided in the extruder, thereby coating the conductor portion 10 with the first insulating coating portion 21.

[0026] Next, after the above-described first extrusion step (step S1), the worker performs a first cooling step (step S2) to cool the electric wire with the first insulating coating portion 21 extruded outside the conductor portion 10. At this time, the worker cools the electric wire extruded from the extruder to solidify the first insulating coating portion 21.

[0027] Next, after the first cooling step (step S2) described above, the worker performs a winding step (step S3) in which the worker winds up the electric wire, with the first insulating coating portion 21 extruded onto the outside of the conductor portion 10, onto a reel. At this time, the worker stores the electric wire by winding up the electric wire, which has been extruded from the extruder and then cooled, onto a reel.

[0028] Next, after the winding step (step S3) described above, the worker extrudes the second insulating coating portion 22 toward the outer peripheral surface 21m of the first insulating coating portion 21 as a second extrusion step (step S4). At this time, the worker puts the conductor portion 10 into the extruder again and extrudes the second insulating coating portion 22 into a substantially annular shape using an extrusion head provided in the extruder, thereby coating the first insulating coating portion 21 with the second insulating coating portion 22. The worker also extrudes the second insulating coating portion 22 partially in the extension direction of the electric wire from which the first insulating coating portion 21 has been extruded outside the conductor portion 10, thereby coating any part of the electric wire with the second insulating coating portion 22.

[0029] Next, after the second extrusion step (step S4), the worker cools the electric wire in which the second insulating sheath portion 22 is extruded outside the first insulating sheath portion 21 in a second cooling step (step S5). At this time, the worker cools the electric wire extruded from the extruder to solidify the second insulating sheath portion 22. Therefore, in the electric wire manufacturing method described above, the first extrusion step (step S1) and the second extrusion step (step S4) are performed twice using the extruder, thereby forming a portion 20A, which is a portion that forms the deformation-permitting portion 30 and where the insulating sheath portion 20 is one layer of the first insulating sheath portion 21, and a portion 20B, which is a portion that forms the deformation-restricting portion 40 and where the insulating sheath portion 20 is two layers, the first insulating sheath portion 21 and the second insulating sheath portion 22. Furthermore, the flexibility of the electric wire 1 manufactured by the electric wire manufacturing method described above (steps S1 to S5) can be changed by forming the deformation-permitting portion 30 and the deformation-restricting portion 40 according to the specifications of the electric wire 1. Furthermore, for example, when transporting the electric wire 1, the electric wire 1 can be folded into a small size by bending the deformable portion 30, which is a relatively soft portion. Therefore, the electric wire 1 can be improved in storability. Furthermore, for example, when wiring the electric wire 1 in a vehicle, the electric wire 1 can be wired in an appropriate state along a predetermined wiring path by bending the deformable portion 30, which is a relatively soft portion, while fixing the deformation restricting portion 40, which is a relatively hard portion, to a vehicle body panel with a fixing member such as a clamp. Therefore, the electric wire 1 can be improved in workability during assembly. Furthermore, the electric wire 1 forms the deformation restricting portion 40, which is a relatively hard portion, without performing a process of reheating and solidifying the insulating coating portion 20, thereby preventing a decrease in durability of the insulating coating portion 20 due to heat during reheating. Therefore, the electric wire 1 can prevent a decrease in performance (e.g., the electrical conductivity of the electric wire 1) from decreasing.

[0030] The electric wire 1 described above comprises a conductive conductor portion 10, an insulating coating portion 20 that is insulating and coats the conductor portion 10, a portion 20A that forms the deformation-permitting portion 30 and in which the insulating coating portion 20 is a single layer, and a portion 20B that forms the deformation-regulating portion 40 and in which the insulating coating portion 20 is a multiple-layer. Furthermore, the wire manufacturing method for manufacturing the electric wire 1 described above includes a first extrusion process (step S1) in which an insulating coating portion 20 that has insulating properties and coats the conductor portion 10 is extruded onto the outer peripheral surface 10m side of the conductive conductor portion 10 to form a first layer of insulating coating portion 20, and a second extrusion process (step S4) in which a new insulating coating portion 20 is extruded onto the outer peripheral surface 20m side of the first layer of insulating coating portion 20 to partially form a second layer of insulating coating portion 20, thereby forming a portion 20A where the insulating coating portion 20 is one layer and forms the deformation-permitting portion 30, and a portion 20B where the insulating coating portion 20 is multiple layers and forms the deformation-regulating portion 40.

[0031] According to this configuration, the wire 1 can have the deformation-permitting portion 30 and the deformation-restricting portion 40 by varying the number of layers of the insulating coating portion 20. The wire 1 can be routed in an appropriate state by providing the deformation-permitting portion 30 in a portion where deformation is desired as needed along a predetermined routing path and the deformation-restricting portion 40 in a portion where deformation is not desired (i.e., a portion where the routing is desired to be restricted). The wire 1 can change its flexibility with a simple structure by realizing the deformation-permitting portion 30 and the deformation-restricting portion 40 by varying only the number of layers of the insulating coating portion 20. The wire 1 can form the deformation-restricting portion 40 without performing a process of reheating and solidifying the insulating coating portion 20, thereby preventing a decrease in durability of the insulating coating portion 20 due to heat during reheating. Therefore, the wire 1 can prevent a decrease in performance (e.g., the electrical conductivity of the wire 1) from decreasing.

[0032] [Variations] Next, a modified example of the method for manufacturing the electric wire 1 will be described with reference to Fig. 5. The method for manufacturing the electric wire 1 has been described as including a first extruding step (step S1), a first cooling step (step S2), a winding step (step S3), a second extruding step (step S4), and a second cooling step (step S5), but the steps are not limited to these.

[0033] Specifically, the manufacturing method of the electric wire 1 described above (steps S1 to S5) forms the deformation-permitting portion 30 and the deformation-regulating portion 40 in the electric wire 1 by using an extruder with one extrusion head twice, while the modified manufacturing method of the electric wire 1 described below (steps S11 to S13) differs in that the deformation-permitting portion 30 and the deformation-regulating portion 40 are formed in the electric wire 1 by using an extruder with two extrusion heads only once.

[0034] 5, the modified manufacturing method of the electric wire 1 includes a first extrusion step (step S11), a second extrusion step (step S12), and a first cooling step (step S13). The first extrusion step (step S11) here is a step of forming a first layer of insulating coating portion 20 by extruding the insulating coating portion 20 toward the outer peripheral surface 10m of the conductor portion 10. The second extrusion step (step S12) is a step of forming a second layer of insulating coating portion 20 by extruding a new insulating coating portion 20 toward the outer peripheral surface 20m of the first layer of insulating coating portion 20, thereby forming a portion 20A of the insulating coating portion 20 where the deformation-permitting portion 30 is formed and where the insulating coating portion 20 is a single layer, and a portion 20B of the insulating coating portion 20 where the deformation-regulating portion 40 is formed and where the insulating coating portion 20 is a multi-layer portion. In addition, the first cooling process (step S13) is a process of solidifying the first layer of insulating coating 20 and the second layer of insulating coating 20 by cooling the electric wire in which two layers of insulating coating 20 have been extruded onto the outer surface 10m side of the conductor portion 10.

[0035] Specifically, first, in preparation for the first extrusion step (step S11), the worker prepares a linear conductor portion 10. Next, in the first extrusion step (step S11), the worker extrudes the first insulating coating portion 21 onto the outside of the conductor portion 10. At this time, the worker puts the conductor portion 10 into an extruder and extrudes the first insulating coating portion 21 into a substantially annular shape using the first extrusion head (the front side in the extrusion direction) provided in the extruder, thereby coating the conductor portion 10 with the first insulating coating portion 21.

[0036] Next, after the above-described first extrusion step (step S11), the worker continues to perform a second extrusion step (step S12) in which the second insulating coating portion 22 is partially extruded toward the outer peripheral surface 21m of the first insulating coating portion 21. At this time, while the electric wire with the first insulating coating portion 21 extruded outside the conductor portion 10 is set in the extruder, the worker extrudes the second insulating coating portion 22 into a substantially annular shape using a second extrusion head (the rear side in the extrusion direction) provided on the extruder, thereby coating the first insulating coating portion 21 with the second insulating coating portion 22. Furthermore, the worker partially extrudes the second insulating coating portion 22 in the extension direction of the electric wire with the first insulating coating portion 21 extruded outside the conductor portion 10, thereby coating any part of the electric wire with the second insulating coating portion 22.

[0037] Next, after the second extrusion step (step S12) described above, the worker cools the electric wire in which the second insulating coating portion 22 is extruded outside the first insulating coating portion 21 in a first cooling step (step S13). At this time, the worker cools the electric wire extruded from the extruder to solidify the first insulating coating portion 21 and the second insulating coating portion 22. Therefore, in a modified example of the electric wire manufacturing method described above, by using the extruder once to successively perform the first extrusion step (step S11) and the second extrusion step (step S12), it is possible to form the portion 20A where the deformation-permitting portion 30 is formed and where the insulating coating portion 20 is one layer, and the portion 20B where the deformation-regulating portion 40 is formed and where the insulating coating portion 20 is multiple layers. Furthermore, the electric wire 1 manufactured by the above-described modified example of the electric wire manufacturing method (steps S11 to S13) can change its flexibility by forming the deformation-permitting portion 30 and the deformation-regulating portion 40 according to the specifications of the electric wire 1, similarly to the electric wire 1 manufactured by the electric wire manufacturing method (steps S1 to S5). Furthermore, the electric wire 1 can be improved in storability by folding the deformation-permitting portion 30 to make it compact. Furthermore, the electric wire 1 can be routed along a predetermined routing path by folding the deformation-permitting portion 30 while fixing the deformation-regulating portion 40 to a vehicle body panel with a fixing member such as a clamp, thereby improving workability during assembly. Furthermore, the electric wire 1 can be formed with the deformation-regulating portion 40 without performing a step of reheating and solidifying the insulating coating portion 20, thereby preventing a decrease in durability of the insulating coating portion 20 due to heat during reheating. Therefore, the electric wire 1 can be prevented from a decrease in performance (for example, the electrical conductivity of the electric wire 1).

[0038] The electric wire 1 according to the embodiment of the present invention and the electric wire manufacturing method (steps S1 to S5, steps S11 to S13) are not limited to the above-described embodiment, and various modifications are possible within the scope of the claims.

[0039] For example, the conductor portion 10 may be a stranded core wire formed by twisting together a plurality of wires 10a.

[0040] Furthermore, although the deformation restricting portion 40 has been described as being made up of two layers, the first insulating covering portion 21 and the second insulating covering portion 22, the number of layers is not particularly limited as long as there is a plurality of layers.

[0041] Furthermore, the positions and numbers of the deformation permitting portions 30 and the deformation restricting portions 40 are not limited to the form shown in FIG.

[0042] Moreover, the electric wire 1 according to this embodiment and the electric wire manufacturing method (steps S1 to S5, steps S11 to S13) may be configured by appropriately combining the components of the embodiments described above. [Explanation of symbols]

[0043] 1 electric wire 10 Conductor 10m Outer surface of conductor 20 Insulation coating 20m Outer surface of insulating coating 30 Deformation allowance section 40 Deformation control section S1, S11 First extrusion process S4, S12 2nd extrusion process X length direction Y width direction Z height direction

Claims

1. a conductive conductor portion; an insulating coating portion having insulating properties and coating the conductor portion; a portion that forms a deformable portion, and the insulating coating portion is a single layer; a part that forms a deformation restricting part, and the insulating coating part has a plurality of layers, Electric wire.

2. a first extrusion step of extruding an insulating coating portion having insulating properties onto an outer peripheral surface side of a conductive conductor portion to cover the conductor portion, thereby forming the insulating coating portion as a first layer; a second extrusion process for extruding a new insulating coating portion onto the outer peripheral surface side of the insulating coating portion that will be the first layer, thereby partially forming the insulating coating portion that will be the second layer, thereby forming a portion that will form a deformation-allowing portion and has one layer of the insulating coating portion, and a portion that will form a deformation-restricting portion and has multiple layers of the insulating coating portion. Electric wire manufacturing method.

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