Manufacturing method of insulating cover

Abstract

The method for manufacturing an insulating cover according to the present disclosure includes the steps of creating a dip molding die by removably joining a plurality of partial dies, and manufacturing an insulating cover by dip molding using the dip molding die. Because the dip molding die is created by removably joining a plurality of partial dies, it is possible to create different insulating covers by replacing or rearranging parts of the partial dies, and since there is no need for a dedicated dip molding die for each insulating cover with a different shape, the manufacturing costs of the insulating cover can be reduced.

Description

[Technical field]

[0001] The present disclosure relates to a method of manufacturing an insulating cover. [Background technology]

[0002] In order to prevent electric shock accidents caused by an operator accidentally touching a conductor connection part to which a voltage is applied, an insulating cover is attached to the conductor connection part. One method for manufacturing such an insulating cover is to manufacture the insulating cover by dip molding using a mold created according to the inside dimensions of the insulating cover. For example, Patent Document 1 discloses an insulating cover manufactured by dip molding using an insulating resin. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 63-141272 Summary of the Invention [Problem to be solved by the invention]

[0004] The shape of the inside of the insulating cover corresponds to the shape of the conductor connection part to which the insulating cover is attached, and the shape of the inside of the insulating cover manufactured by dip molding is determined by the shape of the mold used for dip molding. Therefore, in order to manufacture insulating covers that correspond to conductor connection parts of different shapes, it is necessary to prepare molds of different shapes, which may increase manufacturing costs.

[0005] The present disclosure has been made to solve the above-mentioned problems, and provides a method for manufacturing an insulating cover that can reduce the manufacturing costs of the insulating cover. [Means for solving the problem]

[0006] A method for manufacturing an insulating cover according to the present disclosure includes: A method for manufacturing an insulating cover to be attached to a conductor connection part where a first conductor and a second conductor are connected by a fastening member, the method comprising the steps of: creating a dip-forming die by removably connecting a first partial die having the same cross-sectional shape as the first conductor, a second partial die having the same cross-sectional shape as the second conductor, and a third partial die having the same shape as the fastening member;It includes a step of manufacturing an insulating cover by dip molding using a die for dip molding.

Advantages of the Invention

[0007] The method for manufacturing an insulating cover according to the present disclosure creates a die for dip molding by removably coupling a plurality of sub-dies. Therefore, different insulating covers can be created by replacing a part of the sub-dies or changing their arrangement. Since a dedicated die for dip molding is not required for each insulating cover with a different shape, the manufacturing cost of the insulating cover can be suppressed.

Brief Description of the Drawings

[0008] [Figure 1] It is a diagram showing a configuration example of a conductor connection part according to a comparative example. [Diagram 2] It is a diagram showing a configuration example of an insulating cover according to a comparative example. [Diagram 3] It is a diagram showing a configuration example of a die for dip molding according to a comparative example. [Figure 4] It is a diagram showing a configuration example of an insulating cover according to a comparative example. [Diagram 5] It is a diagram showing a configuration example of a die for dip molding according to a comparative example. [Figure 6] It is a cross-sectional view of a die for dip molding according to a comparative example. [Figure 7] It is a diagram showing a configuration example of a sub-die according to Embodiment 1. [Figure 8] It is a diagram showing a configuration example of a die for dip molding according to Embodiment 1. [Figure 9] It is a diagram showing a configuration example of an insulating cover according to Embodiment 1. [Figure 10] It is a diagram showing a configuration example of a first sub-die, a second sub-die, and a third sub-die according to Embodiment 2. [Figure 11] It is a diagram showing a configuration example of a die for dip molding according to Embodiment 2. [Figure 12] It is a diagram showing a configuration example of an insulating cover according to Embodiment 2. [Figure 13] FIG. 11 is a diagram showing a configuration example of a dip-molding die according to embodiment 3. [Figure 14] FIG. 11 is a cross-sectional view of a dip-molding die according to a third embodiment. [Figure 15] FIG. 13 is a diagram showing an example of the configuration of a partial mold according to a fourth embodiment. [Figure 16] FIG. 13 is a diagram showing a configuration example of a dip-molding die according to embodiment 4. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, the embodiments will be described in detail with reference to the drawings. Note that the embodiments described below are merely examples. Furthermore, the embodiments can be implemented in appropriate combination.

[0010] Embodiment 1 <Explanation of Comparative Example> Before describing the method for manufacturing the insulating cover according to the first embodiment, a comparative example of the method for manufacturing the insulating cover will be described with reference to FIGS. 1 to 6. FIG.

[0011] An insulating cover 2 attached to a conductor connection part 1 will be described with reference to Fig. 1 to Fig. 3. Fig. 1 is a diagram showing a configuration example of the conductor connection part 1. The conductor connection part 1 is configured by connecting a first conductor 1a and a second conductor 1b with a fastening member 1c. Examples of the fastening member 1c include a bolt and a nut. Such a conductor connection part 1 is provided, for example, inside a switchboard.

[0012] Fig. 2 is a diagram showing a configuration example of an insulating cover 2 attached to a conductor connection part 1. In the insulating cover 2 shown in Fig. 2, unevenness and steps are formed to match the shapes of the first conductor 1a, the second conductor 1b, and the fastening member 1c of the conductor connection part 1 shown in Fig. 1. By attaching such an insulating cover 2 to the conductor connection part 1, the conductor connection part 1 is protected. To manufacture the insulating cover 2 shown in Fig. 2, a dip molding die 3 shown in Fig. 3 is used.

[0013] Next, a method for manufacturing the insulating cover 2a will be described with reference to Figs. 4 to 6. Fig. 4 shows an example of the insulating cover 2a, and Fig. 5 shows an example of the dip-molding die 3a. The insulating cover 2a shown in Fig. 4 is manufactured by dip molding using the dip-molding die 3a shown in Fig. 5. Specifically, the dip-molding die 3a shown in Fig. 5 is preheated, and then immersed in the sol-like material of the insulating cover 2a to form a coating of the material of the insulating cover 2a on the surface of the dip-molding die 3a. Here, examples of the material of the insulating cover 2a include synthetic resins. The dip-molding die 3a is pulled out from the sol-like material of the insulating cover 2a, and the coating formed on the surface of the dip-molding die 3a is heated and then cooled to solidify. The solidified coating of the insulating cover 2a is peeled off from the dip-molding die 3a to form the insulating cover 2a.

[0014] Fig. 6 is an AA cross-sectional view of the dip-molding die 3a shown in Fig. 5, showing the state before the coating of the solidified insulating cover 2a is peeled off. As shown in Fig. 6, the inside dimensions of the insulating cover 2a are determined by the dimensions of the dip-molding die 3a, and the outside dimensions of the insulating cover 2a are determined by the dimensions of the dip-molding die 3a and the thickness of the coating of the insulating cover 2a. Here, the thickness of the coating of the insulating cover 2a is determined by the preheating temperature of the dip-molding die 3a and the viscosity of the sol-like material of the insulating cover 2a.

[0015] Thus, according to the manufacturing method of the insulating cover 2a of the comparative example, the shape of the insulating cover 2a was determined based on the dimensions of the dip molding die 3a and the thickness of the coating of the insulating cover 2a, so the inner dimensions of all the insulating covers 2a manufactured from one dip molding die 3a were the same, and only the outer dimensions of the insulating cover 2a could be changed depending on the thickness of the coating of the insulating cover 2a.

[0016] Furthermore, in order to attach the insulating cover 2a to the conductor connection part 1, the inner dimensions of the insulating cover 2a need to correspond to the shape of the conductor connection part 1. As described above, since the inner dimensions of the insulating cover 2a are determined by the dimensions of the dip-forming die 3a, when manufacturing the insulating cover 2a to be attached to the conductor connection part 1, it was necessary to prepare a dedicated dip-forming die 3a that matches the shape of the conductor connection part 1.

[0017] <Description of the embodiment> Next, a method for manufacturing the insulating cover 12 according to this embodiment will be described with reference to Fig. 7 to Fig. 9. Fig. 7 shows an example of the configuration of partial molds 10a and 10b which can be removably joined according to embodiment 1, Fig. 8 shows an example of the configuration of the dip molding mold 11, and Fig. 9 shows an example of the configuration of the insulating cover 12.

[0018] 7, partial molds 10a and 10b have different shapes, with partial mold 10a being a flat mold simulating first conductor 1a or second conductor 1b of conductor connection portion 1, and partial mold 10b being a cylindrical mold simulating fastening member 1c of conductor connection portion 1. Note that partial molds 10a and 10b are not limited to these shapes, and may have any shape that allows insulating cover 12 formed by joined partial molds 10a and 10b to be attached to conductor connection portion 1.

[0019] As shown in FIG. 8, a dip-molding die 11 is prepared by removably connecting a plurality of partial dies 10a and 10b. In FIG. 8, two flat plate-shaped partial dies 10a are arranged so that they overlap with each other, and a cylindrical partial die 10b is arranged on the partial dies 10a to prepare a dip-molding die 11. However, the number, shape and arrangement of the partial dies 10a and 10b are not limited to the above, and the number, shape and arrangement of the partial dies 10a and 10b may be selected according to the dip-molding die 11 corresponding to the shape of the insulating cover 12 to be prepared. In addition, the partial dies 10a and 10b may be fixed in any manner as long as they are fixed so as not to be displaced during dip molding and are removable after dip molding. For example, the partial dies 10a and 10b may be fixed by screws, or as described in the fourth embodiment, the partial dies 10a and 10b may be fixed by magnetic force.

[0020] Next, the insulating cover 12 shown in FIG. 9 is manufactured by dip molding using the dip molding die 11 shown in FIG. 8. Specifically, the dip molding die 11 is immersed in the sol-like material of the insulating cover 12 to form a coating on the surface of the dip molding die 11, and the coating formed on the surface of the dip molding die 11 pulled out of the sol-like material of the insulating cover 12 is heated and then cooled to be solidified. The solidified coating of the insulating cover 12 is peeled off from the dip molding die 11 to form the insulating cover 12. Here, since the dip molding die 11 is made by removably joining a plurality of partial dies 10a, 10b, it is necessary to take care that the joining of the partial dies 10a, 10b does not loosen and the arrangement of the partial dies 10a, 10b does not change before the coating formed on the surface of the dip molding die 11 is solidified.

[0021] According to such a manufacturing method of the insulating cover 12, the shape of the dip-forming die 11 is determined by the number, shape, and arrangement of the partial dies 10a and 10b, and the shape of the insulating cover 12 is determined based on the shape of the dip-forming die 11 and the thickness of the insulating cover 12. Since the inner dimensions of the insulating cover 12 are determined by the dimensions of the dip-forming die 11, the inner dimensions of the insulating cover 12 can be changed by changing at least one of the number, shape, and arrangement of the partial dies 10a and 10b. Therefore, since the dip-forming die 11 corresponding to insulating covers 12 of a plurality of shapes can be created using a limited number of partial dies 10a and 10b, it is not necessary to prepare a dedicated dip-forming die 11 for each insulating cover 12 of a different shape, and the manufacturing cost of the insulating cover 12 can be suppressed.

[0022] As described above, the method for manufacturing an insulating cover according to the first embodiment includes the steps of creating a dip-forming die 11 by removably joining a plurality of partial dies 10a, 10b, and manufacturing an insulating cover 12 by dip molding using the dip-forming die 11. With this configuration, it is possible to create dip-forming dies 11 of different shapes by replacing or rearranging parts of the partial dies 10a, 10b, and to manufacture insulating covers 12 of different shapes. As a result, it is not necessary to provide a dedicated dip-forming die 11 for each insulating cover 12 of a different shape, and the manufacturing cost of the insulating cover 12 can be reduced.

[0023] Embodiment 2 A method for manufacturing an insulating cover according to the second embodiment will be described with reference to Figures 10 to 12. In the second embodiment, the configuration different from the first embodiment will be mainly described.

[0024] FIG. 10 shows a configuration example of a first split mold 20a, a second split mold 20b, and a third split mold 20c that are removably coupled according to Embodiment 2. FIG. 11 shows a configuration example of dip molding molds 21a, 21b, and 21c according to Embodiment 2. FIG. 12 shows a configuration example of insulating covers 22a, 22b, and 22c according to Embodiment 2. In Embodiment 2, the dip molding molds 21a, 21b, and 21c are composed of the first split mold 20a, the second split mold 20b, and the third split mold 20c.

[0025] The first split mold 20a has the same cross-sectional shape as the first conductor 1a of the conductor connection portion 1. The second split mold 20b has the same cross-sectional shape as the second conductor 1b of the conductor connection portion 1. The third split mold 20c has the same shape as the fastening member 1c of the conductor connection portion 1. Here, instead of attaching an insulating cover so as to cover the entire first conductor 1a and the second conductor 1b, since it is sufficient to attach the insulating cover to a part of the first conductor 1a and the second conductor 1b, the first split mold 20a has the same cross-sectional shape as the first conductor 1a, and the second split mold 20b has the same cross-sectional shape as the second conductor 1b. Also, since the entire fastening member 1c will be covered with the insulating cover, the third split mold 20c has the same shape as the fastening member 1c. Note that the "same shape" or "same cross-sectional shape" mentioned here does not have to be exactly the same. For example, it may be slightly larger to provide a margin when attaching the insulating cover. That is, the first split mold 20a, the second split mold 20b, and the third split mold 20c may have any shape as long as the insulating covers 22a, 22b, and 22c formed by the first split mold 20a, the second split mold 20b, and the third split mold 20c can be attached to the conductor connection portion.

[0026] As shown in Fig. 11, the dip-forming dies 21a, 21b, and 21c are produced by removably joining the first partial die 20a, the second partial die 20b, and the third partial die 20c. The dip-forming dies 21a, 21b, and 21c, which are composed of the first partial die 20a, the second partial die 20b, and the third partial die 20c, each have the same shape as the conductor connection part. In this way, by changing the number and arrangement of the first partial die 20a, the second partial die 20b, and the third partial die 20c, it is possible to produce the dip-forming dies 21a, 21b, and 21c having the same shapes as the conductor connection parts of a plurality of shapes.

[0027] Next, the insulating covers 22a, 22b, and 22c shown in Fig. 12 are manufactured by dip molding using the dip molding dies 21a, 21b, and 21c. Specifically, the dip molding dies 21a, 21b, and 21c are immersed in the sol-like material of the insulating covers 22a, 22b, and 22c to form a coating on the surface of the dip molding dies 21a, 21b, and 21c, and the coating formed on the surface of the dip molding dies 21a, 21b, and 21c pulled out of the sol-like material of the insulating covers 22a, 22b, and 22c is heated and then cooled to be solidified. The solidified coating of the insulating covers 22a, 22b, and 22c is peeled off from the dip molding dies 21a, 21b, and 21c to form the insulating covers 22a, 22b, and 22c. Here, the insulating cover 22a is manufactured using a dip molding die 21a, the insulating cover 22b is manufactured using a dip molding die 21b, and the insulating cover 22c is manufactured using a dip molding die 21c.

[0028] In this way, by using the first partial mold 20a having the same cross-sectional shape as the first conductor 1a of the conductor connection part 1, the second partial mold 20b having the same cross-sectional shape as the second conductor 1b of the conductor connection part 1, and the third partial mold 20c having the same shape as the fastening member 1c of the conductor connection part 1, the dip-forming molds 21a, 21b, 21c for each conductor connection part having a different shape can be made, and the insulating covers 22a, 22b, 22c for each conductor connection part having a different shape can be manufactured. Therefore, since the dip-forming molds 21a, 21b, 21c corresponding to conductor connection parts having a plurality of shapes can be made using the limited first partial mold 20a, second partial mold 20b, and third partial mold 20c, it is not necessary to prepare dedicated dip-forming molds 21a, 21b, 21c for each insulating cover 22a, 22b, 22c corresponding to conductor connection parts having different shapes, and the manufacturing cost of the insulating covers 22a, 22b, 22c can be suppressed.

[0029] As described above, the manufacturing method of the insulating cover according to embodiment 2 includes a step of creating dip molding dies 21a, 21b, 21c by removably combining a first partial die 20a having the same cross-sectional shape as the first conductor 1a of the conductor connection portion 1, a second partial die 20b having the same cross-sectional shape as the second conductor 1b of the conductor connection portion 1, and a third partial die 20c having the same shape as the fastening member 1c of the conductor connection portion 1, and a step of manufacturing the insulating covers 22a, 22b, 22c by dip molding using the dip molding dies 21a, 21b, 21c. According to this configuration, the first partial mold 20a has the same cross-sectional shape as the first conductor 1a, the second partial mold 20b has the same cross-sectional shape as the second conductor 1b, and the third partial mold 20c has the same shape as the fastening member 1c, so that by changing at least one of the number and arrangement of the first partial mold 20a, the second partial mold 20b, and the third partial mold 20c, it is possible to manufacture insulating covers 22a, 22b, and 22c corresponding to conductor connection parts of different shapes. As a result, it is not necessary to provide dedicated dip molding dies 21a, 21b, and 21c for each insulating cover 22a, 22b, and 22c of different shapes, and the manufacturing cost of the insulating covers 22a, 22b, and 22c can be reduced.

[0030] Furthermore, in the second embodiment, the dip-molding dies 21a, 21b, and 21c corresponding to each conductor connection part having a different shape are created using the first partial mold 20a having the same cross-sectional shape as the first conductor 1a, the second partial mold 20b having the same cross-sectional shape as the second conductor 1b, and the third partial mold 20c having the same shape as the fastening member 1c. With this configuration, the dip-molding dies 21a, 21b, and 21c corresponding to conductor connection parts having a plurality of shapes can be created using only the first partial mold 20a, the second partial mold 20b, and the third partial mold 20c. As a result, when manufacturing the insulating covers 22a, 22b, and 22c to be attached to the conductor connection parts having different shapes, it is not necessary to prepare partial molds with new shapes, and the manufacturing cost of the insulating covers 22a, 22b, and 22c can be further reduced.

[0031] Embodiment 3 A method for manufacturing an insulating cover according to the third embodiment will be described with reference to Figures 13 and 14. In the third embodiment, the configuration different from the first and second embodiments will be mainly described.

[0032] Fig. 13 shows a configuration example of a dip-forming die 31 to be coupled according to the third embodiment, and Fig. 14 is a BB cross-sectional view of the dip-forming die 31 shown in Fig. 13. In the third embodiment, the dip-forming die 31 is composed of a fourth partial die 30a, a fifth partial die 30b, a sixth partial die 30c, and screws 32. In this embodiment, a countersunk head screw is used as an example of the screw 32, but the screw is not limited to a countersunk head screw and other types of screws may be used as long as they can couple the fourth partial die 30a, the fifth partial die 30b, and the sixth partial die 30c.

[0033] 14, the fourth partial mold 30a, the fifth partial mold 30b, and the sixth partial mold 30c are molds in which different types of holes are formed. The fourth partial mold 30a is formed with a screw head hole, which is a conical countersink hole into which the head of the screw 32 fits, the fifth partial mold 30b is formed with a screw hole that engages with the threaded portion of the screw 32, and the sixth partial mold 30c is formed with a through hole through which the screw 32 can pass.

[0034] 13 and 14, a sixth portion mold 30c is placed between a fourth portion mold 30a and a fifth portion mold 30b, screws 32 are placed so as to pass through holes formed in the fourth portion mold 30a, the fifth portion mold 30b, and the sixth portion mold 30c, and the fourth portion mold 30a, the fifth portion mold 30b, and the sixth portion mold 30c are joined by the screws 32 to prepare a dip-forming mold 31. Depending on the shapes of the fourth portion mold 30a, the fifth portion mold 30b, the sixth portion mold 30c, the screws 32, and the dip-forming mold 31, the dip-forming mold 31 may be prepared using the fourth portion mold 30a, the fifth portion mold 30b, and the screws 32 without using the sixth portion mold 30c.

[0035] Next, the insulating cover is manufactured by dip molding using the dip molding die 31. Specifically, the dip molding die 31 is immersed in a sol-like insulating cover material to form a coating on the surface of the dip molding die 31, and the coating formed on the surface of the dip molding die 31 that is pulled out of the sol-like insulating cover material is heated and then cooled to solidify. The solidified insulating cover coating is peeled off from the dip molding die 31 to form the insulating cover.

[0036] In this way, by arranging the fourth part mold 30a, the fifth part mold 30b, the sixth part mold 30c and the screw 32 so that the head of the screw 32 fits into the screw head hole of the fourth part mold 30a, it is possible to prevent the head from protruding like a bolt from the end face of the dip molding mold 31. Therefore, the shape of the head of the screw 32 does not affect the outer shape of the dip molding mold 31, and an insulating cover without unnecessary unevenness can be manufactured, and it is possible to prevent the insulating cover from becoming difficult to attach. Here, it is considered that a cross-shaped groove or hole formed in the head of the screw 32 affects the shape of the insulating cover manufactured by the dip molding mold 31. However, the unevenness due to the groove or hole formed in the head of such a screw 32 is small, and the shape of the insulating cover is almost unchanged, so the effect on the ease of attaching the insulating cover can be ignored.

[0037] Furthermore, since the dip-molding die 31 is created by combining the fourth partial mold 30a, the fifth partial mold 30b, and the sixth partial mold 30c and connecting them with the screws 32, after the insulating cover is manufactured using the dip-molding die 31, the screws 32 can be removed to return to the state before the fourth partial mold 30a, the fifth partial mold 30b, and the sixth partial mold 30c were combined. Therefore, after the insulating cover is manufactured using the dip-molding die 31, the number and arrangement of the fourth partial mold 30a, the fifth partial mold 30b, and the sixth partial mold 30c and the length of the screws 32 can be changed to manufacture a new insulating cover of a different shape. Therefore, since the fourth partial mold 30a, the fifth partial mold 30b, and the sixth partial mold 30c can be used repeatedly, insulating covers of different shapes can be manufactured without preparing new partial molds, and the manufacturing cost of the insulating cover can be suppressed.

[0038] The above-mentioned fourth partial mold 30a and fifth partial mold 30b are joined with the screw 32 in the case of using the first partial mold 20a, the second partial mold 20b, and the third partial mold 20c described in the second embodiment. The third partial mold, which has the same shape as the fastening member 1c, is a screw. The first partial mold is formed with a screw head hole into which the head of the screw, which is the third partial mold, is accommodated, and the second partial mold is formed with a screw hole that engages with the threaded portion of the screw, which is the third partial mold. The first partial mold and the second partial mold are overlapped, and the screw is placed so that it passes through the screw head hole of the first partial mold and the screw hole of the second partial mold, and the first partial mold and the second partial mold are joined with the screw to create a dip molding mold. An insulating cover is created by dip molding using this dip molding mold.

[0039] In this way, by joining a first partial mold having the same cross-sectional shape as the first conductor 1a and a second partial mold having the same cross-sectional shape as the second conductor 1b with screws, it is possible to manufacture an insulating cover to be attached to a conductor connection part formed so that the shape of the fastening member does not protrude from the conductor. Furthermore, since the screws can be removed and the first partial mold, the second partial mold, and the screws can be used repeatedly, it is possible to manufacture insulating covers to be attached to conductor connection parts of a plurality of shapes by changing the shapes and arrangement of the first partial mold and the second partial mold and the length of the screws, and it is no longer necessary to prepare a dedicated dip molding mold for each shape of the conductor connection part, thereby reducing the manufacturing cost of the insulating cover.

[0040] As described above, the method for manufacturing an insulating cover according to the third embodiment includes the steps of: creating a dip-molding die 31 by connecting a fourth part mold 30a having a screw head hole for receiving the head of the screw 32 to a fifth part mold 30b having a screw hole for engaging with the threaded portion of the screw 32 with the screw 32; and manufacturing an insulating cover by dip molding using the dip-molding die 31. According to this configuration, a dip-molding die 31 is created in which the head of the screw 32 is received in the screw head hole of the fourth part mold 30a, and the head of the screw 32 is prevented from protruding from the end face of the dip-molding die 31. As a result, unnecessary irregularities are not formed in the shape of the insulating cover manufactured by the dip-molding die 31, and it is possible to prevent the insulating cover from being difficult to attach to the conductor connection part 1.

[0041] Further, in the third embodiment, the method includes the steps of: arranging a sixth part mold 30c having a through hole for a screw 32 between the fourth part mold 30a and the fifth part mold 30b; and connecting the fourth part mold 30a, the fifth part mold 30b, and the sixth part mold 30c with the screw 32 to create a dip-molding mold 31; and manufacturing an insulating cover by dip molding using the dip-molding mold 31. With this configuration, the shape of the dip-molding mold 31 can be changed by changing the number of the sixth part mold 30c and the length of the screw 32 according to the shape of the insulating cover to be manufactured. As a result, a dedicated dip-molding mold 31 is not required for each insulating cover having a different shape, and the manufacturing cost of the insulating cover can be reduced.

[0042] Furthermore, in the third embodiment, the dip-forming die 31 is prepared by joining the fourth portion die 30a, the fifth portion die 30b, and the sixth portion die 30c with the screws 32. With this configuration, after an insulating cover is manufactured using the dip-forming die 31, the fourth portion die 30a, the fifth portion die 30b, the sixth portion die 30c, and the screws 32 constituting the dip-forming die 31 can be disassembled. As a result, the fourth portion die 30a, the fifth portion die 30b, and the sixth portion die 30c can be used repeatedly, so that insulating covers of different shapes can be manufactured without preparing new partial dies, thereby reducing the manufacturing cost of the insulating cover.

[0043] Further, in the third embodiment, the method includes a step of creating a dip-molding mold by connecting a first partial mold having the same cross-sectional shape as the first conductor 1a and a screw head hole for receiving the head of the screw with a second partial mold having the same cross-sectional shape as the second conductor 1b and a screw hole for engaging with the threaded portion of the screw with a screw, and a step of manufacturing an insulating cover by dip molding using the dip-molding mold. With this configuration, a dip-molding mold can be created in which the head of the screw does not protrude from the surface of the first partial mold and the second partial mold having the same cross-sectional shape as the first conductor 1a. Therefore, even when manufacturing an insulating cover to be attached to a conductor connection part formed so that the shape of the fastening member does not protrude from the conductor, it is possible to manufacture insulating covers to be attached to conductor connection parts of a plurality of shapes by changing the shape and arrangement of the first partial mold and the second partial mold and the length of the screw according to the shape of the insulating cover to be manufactured. As a result, it is not necessary to prepare a dedicated dip-molding mold for each shape of the conductor connection part, and the manufacturing cost of the insulating cover can be reduced.

[0044] Embodiment 4 A method for manufacturing an insulating cover according to the fourth embodiment will be described with reference to Figures 15 and 16. In the fourth embodiment, the configuration different from the first to third embodiments will be mainly described.

[0045] Fig. 15 shows a configuration example of coupled partial molds 40a, 40b according to embodiment 4, and Fig. 16 shows a configuration example of a dip-forming mold 41 according to embodiment 4. In embodiment 3, the dip-forming mold 41 is composed of partial molds 40a, 40b.

[0046] The partial mold 40a shown in FIG. 15 is a mold made of a ferromagnetic material, and the partial mold 40b is a mold made of a magnet. By arranging the partial molds 40a and 40b as shown in FIG. 16, a dip molding mold 41 is created. Here, by arranging the partial molds 40a and 40b, the partial molds 40a and 40b are removably coupled by the magnetic force of the magnet of the partial mold 40b. Note that the materials constituting the partial molds 40a and 40b are not limited to these, and it is sufficient that at least one of the partial molds 40a and 40b has a magnet and the partial molds 40a and 40b are coupled by magnetic force. For example, the partial mold 40b is not limited to a mold made of a magnet, but may be a mold made of a ferromagnetic material with a magnet embedded therein. Also, for example, the partial mold 40a may be a mold made of a magnet, and the partial mold 40b may be a mold made of a ferromagnetic material.

[0047] Next, the insulating cover is manufactured by dip molding using a dip molding die 41. Specifically, the dip molding die 41 is immersed in a sol-like insulating cover material to form a coating on the surface of the dip molding die 41, and the coating formed on the surface of the dip molding die 41 that is pulled out of the sol-like insulating cover material is heated and then cooled to solidify. The solidified insulating cover coating is peeled off from the dip molding die 41 to form the insulating cover.

[0048] In this way, because the partial dies 40a, 40b are joined by magnetic force, a separate fastening member for joining the partial dies 40a, 40b is not required, and the outer shape of the dip-forming die 41 is not affected by the fastening member. Therefore, the outer shape of the dip-forming die 41 is determined by the partial dies 40a, 40b, and an insulating cover without unnecessary irregularities can be manufactured, preventing the insulating cover from becoming difficult to attach to the conductor connection portion 1.

[0049] Furthermore, when creating the dip molding die 41, it is only necessary to position the partial dies 40a, 40b, as the partial dies 40a, 40b are joined by magnetic force, eliminating the need to join the partial dies 40a, 40b with fastening members, and the dip molding die 41 can be easily created.

[0050] Furthermore, because the partial dies 40a, 40b are removably joined by magnetic force, after an insulating cover is manufactured using the dip-molding die 41, the partial dies 40a, 40b can be separated and returned to the state before they were combined. Therefore, after an insulating cover is manufactured using the dip-molding die 41, the number and arrangement of the partial dies 40a, 40b can be changed to manufacture a new insulating cover of a different shape. Therefore, because the partial dies 40a, 40b can be used repeatedly, insulating covers of different shapes can be manufactured without preparing a new partial die, and the manufacturing cost of the insulating cover can be reduced.

[0051] Furthermore, the above-mentioned partial molds 40a and 40b may be joined by magnetic force when the first partial mold 20a, the second partial mold 20b, and the third partial mold 20c described in the second embodiment are used. For example, if the first partial mold 20a, the second partial mold 20b, and the third partial mold 20c are made of ferromagnetic material and at least one of them is equipped with a magnet, the ferromagnetic material is magnetized in a chain manner when the magnet is brought close, so that the joined state shown in FIG. 11 can be realized. In this way, the first partial mold 20a, the second partial mold 20b, and the third partial mold 20c are detachably joined by magnetic force. Therefore, by changing at least one of the number and arrangement of the first partial mold 20a, the second partial mold 20b, and the third partial mold 20c, it is possible to manufacture insulating covers corresponding to conductor connection parts of different shapes.

[0052] As described above, the method for manufacturing an insulating cover according to the fourth embodiment includes a step of creating a dip-forming die 41 by connecting a plurality of partial dies 40a, 40b by magnetic force, and a step of manufacturing an insulating cover by dip molding using the dip-forming die 41. According to this configuration, the plurality of partial dies 40a, 40b are connected by magnetic force, so that a separate fastening member for connecting the partial dies 40a, 40b is not required. As a result, the external shape of the dip-forming die 41 is determined by the partial dies 40a, 40b, and unnecessary irregularities are not formed in the shape of the insulating cover manufactured by the dip-forming die 41, so that it is possible to prevent the insulating cover from becoming difficult to attach to the conductor connection portion 1.

[0053] Furthermore, in the fourth embodiment, the dip molding die 41 is created by combining a partial die 40a made of a ferromagnetic material with a partial die 40b equipped with a magnet. With this configuration, once the partial dies 40a, 40b are simply arranged, the partial dies 40a, 40b are joined by magnetic force, and the dip molding die 41 can be created. As a result, the task of joining the partial dies 40a, 40b with a fastening member is no longer necessary, and the dip molding die 41 can be easily created.

[0054] Furthermore, in the fourth embodiment, the dip molding die 41 is created by joining a plurality of partial dies 40a, 40b together using magnetic force. With this configuration, after an insulating cover is manufactured using the dip molding die 41, the partial dies 40a, 40b constituting the dip molding die 41 can be disassembled. As a result, the partial dies 40a, 40b can be used repeatedly, so that insulating covers of different shapes can be manufactured without preparing new partial dies, thereby reducing the manufacturing costs of the insulating covers.

[0055] Although the present disclosure describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless modifications not exemplified are assumed within the scope of the technology disclosed in this specification, including, for example, modifying, adding, or omitting at least one component, and further, extracting at least one component and combining it with a component of another embodiment. [Explanation of symbols]

[0056] 1 Conductor connection part, 1a First conductor, 1b Second conductor, 1c Fastening member, 2, 2a Insulating cover, 3, 3a Dip molding die, 10a, 10b Partial die, 11 Dip molding die, 12 Insulating cover, 20a First partial die, 20b Second partial die, 20c Third partial die, 21a, 21b, 21c Dip molding die, 22a, 22b, 22c Insulating cover, 30a Fourth partial die, 30b Fifth partial die, 30c Sixth partial die, 31 Dip molding die, 32 Screw, 40a, 40b Partial die, 41 Dip molding die

Claims

1. A method for manufacturing an insulating cover to be attached to a conductor connection part where a first conductor and a second conductor are connected by a fastening member, comprising: creating a dip molding die by removably coupling a first partial die having the same cross-sectional shape as the first conductor, a second partial die having the same cross-sectional shape as the second conductor, and a third partial die having the same shape as the fastening member; and producing an insulating cover by dip molding using the dip molding die.

2. A step of creating a dip molding die by connecting a fourth part mold having a screw head hole formed therein into which the head of the screw fits, and a fifth part mold having a screw hole formed therein which engages with the threaded portion of the screw, using the screw; and producing an insulating cover by dip molding using the dip molding die.

3. 3. The method for manufacturing an insulating cover according to claim 2, wherein the step of creating the dip molding die comprises placing a sixth part die having a through hole for the screw between the fourth part die and the fifth part die, and creating the dip molding die by connecting the fourth part die, the fifth part die, and the sixth part die with the screw.

4. The third part mold is a screw, The first partial mold has a screw head hole in which the head of the screw is inserted, The second partial mold has a screw hole that engages with the threaded portion of the screw, 2 . The method for manufacturing an insulating cover according to claim 1 , wherein the step of preparing the dip molding die comprises coupling the first and second partial dies together with the screws.

5. The method for manufacturing an insulating cover as described in claim 1, characterized in that the step of creating the dip molding mold comprises joining the first partial mold, the second partial mold, and the third partial mold by magnetic force.

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