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The stranded wire design with alternating thick and thin wires and intermediate materials addresses the issue of outer layer smoothness, achieving a nearly circular cross-section and improved functionality for automotive and medical applications.
Patent Information
- Application Number
- JP2025112716
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2025-07-03
- Publication Date
- 2025-11-17
- Estimated Expiration
- 2045-07-03
AI Technical Summary
Existing stranded conductors have issues with impaired smoothness of the outer layer surface due to small-diameter and medium-diameter outer layer wires falling into the outer valley portions formed by adjacent inner layer wires, which affects the overall circularity and functionality of the wire.
The stranded wire is structured with alternating thin and thick inner and outer layer wires, with large-diameter wires positioned to abut along the axial direction and intermediate materials placed in gaps between adjacent wires to prevent movement and maintain circularity, ensuring all wires are in contact and the outer layer surface remains smooth.
The improved structure enhances the smoothness of the outer layer surface, allowing for a nearly perfect circular cross-section without compression, reducing insulating material usage, and maintaining physical properties like elongation and flexibility, suitable for automotive and medical wires.
Smart Images
Figure 0007770734000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to a stranded wire. [Background technology]
[0002] In recent years, in the electric wire market, from the viewpoint of making electric wires and cables thinner, lighter, and more functional, there has been a demand for stranded wires having a cross section that is nearly circular and having an excellent smoothness of the outer layer surface.
[0003] As shown in FIG. 4 , such a stranded conductor 115 has one center wire 101, and a first layer 103 made up of six first inner layer wires 102 is disposed outside the center wire 101, a second inner layer 106 made up of six small-diameter second inner layer wires 104 and six large-diameter second inner layer wires 105 is disposed outside the first layer 103, a third inner layer 109 made up of six small-diameter third inner layer wires 107 and twelve large-diameter third inner layer wires 108 is disposed outside the second inner layer 106, and an outer layer 113 made up of six small-diameter outer layer wires 110, twelve medium-diameter outer layer wires 111, and six large-diameter outer layer wires 112 is disposed outside the third inner layer 109, The second inner layer 106 is formed by disposing the thin-diameter second inner layer wire 104 and the thick-diameter second inner layer wire 105 in the circumferential direction. The thin-diameter third inner layer wires 107 are arranged at intervals in the circumferential direction, and two thick-diameter third inner layer wires 108, 108 are arranged in the circumferential direction between adjacent thin-diameter third inner layer wires 107, 107 to form a third inner layer 109; A known outer layer 113 is constructed by arranging thick outer layer wires 112 at intervals in the circumferential direction, arranging one thin outer layer wire 110 between adjacent thick outer layer wires 112, 112, and arranging one medium diameter outer layer wire 111 between adjacent thick outer layer wires 112 and thin outer layer wires 110 (see Patent Document 1). [Prior art documents] [Patent documents]
[0004] [Patent Document 1] Patent No. 6001130 Summary of the Invention [Problem to be solved by the invention]
[0005] However, in the stranded conductor 115 described in Patent Document 1, the small-diameter outer layer wire 110 and the medium-diameter outer layer wire 111 that constitute the outer layer 113 are not located within the outer valley portion 120 that is formed by the adjacent small-diameter third inner layer wire 107 and the large-diameter third inner layer wire 108 that constitute the third inner layer 109. Therefore, if the small-diameter outer layer wire 110 or the medium-diameter outer layer wire 111 falls into this outer valley portion 120, the smoothness of the outer surface of the outer layer 113 will be impaired.
[0006] SUMMARY OF THE INVENTION An object of the present invention is to provide a stranded wire that can improve the smoothness of the outer layer surface of the stranded wire. [Means for solving the problem]
[0007] In order to solve the above-mentioned problems, the present invention provides a first inner layer comprising a plurality of first inner layer wires arranged in a circumferential direction, a second inner layer is formed on the outside of the first inner layer by thin second inner layer wires, the number of which is the same as that of the first inner layer wires, and thick second inner layer wires, the number of which is the same as that of the first inner layer wires, and the thin second inner layer wires and the thick second inner layer wires are thicker than the thin second inner layer wires and are arranged alternately in the circumferential direction; a third inner layer is formed on the outside of the second inner layer by thin third inner layer wires in the same number as the first inner layer wires, and thick third inner layer wires that are thicker than the thin third inner layer wires and twice the number of the first inner layer wires, the thin third inner layer wires being arranged spaced apart in the circumferential direction, and two thick third inner layer wires being arranged in the circumferential direction between two thin third inner layer wires adjacent in the circumferential direction; an outer layer is formed on the outside of the third inner layer by thin outer layer wires, the number of which is twice the number of the first inner layer wires, and thick outer layer wires, which are thicker than the thin outer layer wires and the number of which is twice the number of the first inner layer wires, and two thin outer layer wires are arranged in a circumferential direction as a set, with these sets of thin outer layer wires being spaced apart from each other in the circumferential direction, and two thick outer layer wires are arranged in the circumferential direction between each adjacent set of thin outer layer wires; the large-diameter third inner layer wire is disposed inside the small-diameter outer layer wire so as to abut on the entire axial direction or a part of the axial direction of the large-diameter third inner layer wire; This stranded wire is characterized by having one intermediate material disposed in a gap formed by two circumferentially adjacent small-diameter outer layer wires and two circumferentially adjacent large-diameter third inner layer wires located inside them.
[0008] In addition, one large-diameter second inner layer wire is disposed in an outer valley portion formed by the outer surfaces of two first inner layer wires adjacent in the circumferential direction, a thick-diameter third inner layer wire is disposed in an outer valley portion formed by the outer surfaces of the thin-diameter second inner layer wire and the thick-diameter second inner layer wire that are adjacent in the circumferential direction; One large-diameter outer layer wire may be disposed in an outer valley portion defined by the outer surfaces of a small-diameter third inner layer wire and a large-diameter third inner layer wire that are adjacent in the circumferential direction.
[0009] Furthermore, the strands constituting the stranded wire may be arranged so as to abut on all adjacent strands over the entire axial direction or over part of the axial direction.
[0010] The distance from the center of the stranded wire to the outermost edge of the thick outer layer wire may be the same as the distance from the center of the stranded wire to the outermost edge of the thin outer layer wire.
[0011] Furthermore, the thick outer layer wire and the thin outer layer wire constituting the outer layer do not need to be compressed and deformed from the outside. [Effects of the Invention]
[0012] According to the present invention, a first inner layer is formed by arranging a plurality of first inner layer wires in the circumferential direction, a second inner layer is formed by arranging small-diameter second inner layer wires and the large-diameter second inner layer wires alternately in the circumferential direction, the small-diameter third inner layer wires are arranged spaced apart in the circumferential direction, two large-diameter third inner layer wires are arranged in the circumferential direction between adjacent small-diameter third inner layer wires to form the third inner layer, two small-diameter outer layer wires are arranged in a set in the circumferential direction, and the set of small-diameter outer layer wires is arranged spaced apart in the circumferential direction, and two large-diameter outer layer wires are arranged in the circumferential direction between adjacent sets of small-diameter outer layer wires to form the outer layer, By disposing one intermediate material in a gap formed by two circumferentially adjacent small-diameter outer layer wires and two circumferentially adjacent large-diameter third inner layer wires located inside them, the intermediate material prevents the small-diameter outer layer wires and large-diameter outer layer wires that make up the outer layer from moving in the circumferential direction, making it possible to improve the smoothness of the outer layer surface compared to the twisted wires of the prior art described above. [Brief explanation of the drawings]
[0013] [Figure 1] 1 is a cross-sectional view of a stranded wire according to a first embodiment of the present invention. [Figure 2] FIG. 10 is a cross-sectional view of an example of a stranded wire according to a third embodiment of the present invention. [Figure 3] FIG. 10 is a cross-sectional view of another example of the stranded wire according to the third embodiment of the present invention. [Figure 4] FIG. 1 is a cross-sectional view of a prior art stranded wire. DETAILED DESCRIPTION OF THE INVENTION
[0014] DETAILED DESCRIPTION OF THE INVENTION The present invention will be described with reference to the accompanying drawings, in which: FIG. 1 is a cross-sectional view of a stranded wire according to an embodiment of the present invention;
[0015] [Example 1] FIG. 1 is a cross-sectional view of a stranded wire 1 according to Example 1 of the present invention, cut in a direction perpendicular to the axial direction, and the diagonal lines indicating the cross sections of each strand have been omitted to avoid cluttering the drawing.
[0016] As shown in Fig. 1, the stranded wire 1 is composed of a center wire 2, a first inner layer 3 provided on the outside of the center wire 2, a second inner layer 4 provided on the outside of the first inner layer 3, a third inner layer 5 provided on the outside of the second inner layer 4, and an outer layer 6 provided on the outside of the third inner layer 5. The first inner layer 3, the second inner layer 4, and the third inner layer 5 form an inner layer 7.
[0017] The first inner layer 3 is composed of six first inner layer wires 11, the second inner layer 4 is composed of six thin-diameter second inner layer wires 12 and six thick-diameter second inner layer wires 13 of the first inner layer wires 11, the third inner layer 5 is composed of six thin-diameter third inner layer wires 14 and twelve thick-diameter third inner layer wires 15, and the outer layer 6 is composed of twelve thin-diameter outer layer wires 16 and twelve thick-diameter outer layer wires 17.
[0018] The stranded wire 1 is made up of eight types of wires 2, 11, 12, 13, 14, 15, 16, and 17, and all of the wires 2, 11, 12, 13, 14, 15, 16, and 17 are twisted in the same direction.
[0019] When the stranded wire 1 is used as a stranded wire conductor, the wire material that forms the base of each of the wires 2, 11, 12, 13, 14, 15, 16, and 17 can be, for example, copper wire such as bare copper wire, oxygen-free copper wire, linear crystal oxygen-free copper wire, single crystal high-purity oxygen-free copper wire, copper wire plated with tin, nickel, silver, etc., aluminum wire, various alloy wires, and wires with an insulating coating such as enameled wire, Litz wire, and formalin wire.
[0020] When the stranded wire 1 is used as a medical wire, the wire material that forms the base of each of the strands 2, 11, 12, 13, 14, 15, 16, and 17 may be, for example, a hard copper wire, an alloy wire, a nickel wire, a stainless steel wire, or a titanium wire.
[0021] The wires 2, 11, 12, 13, 14, 15, 16, and 17 may be made of the same material or different materials.
[0022] The diameter d2 of the first inner layer wire 11 is set to be the same as the diameter d1 of the center wire 2. Six first inner layer wires 11 are arranged in the circumferential direction outside the center wire 2 to form the circumferential first inner layer 3.
[0023] The first inner layer wires 11, 11 adjacent to each other in the circumferential direction are arranged to abut over the entire axial direction or a portion of the axial direction. The first inner layer wire 11 and the center line 2 are arranged to abut over the entire axial direction or a portion of the axial direction.
[0024] The diameter d4 of the large-diameter second inner layer wire 13 is larger than the diameter d3 of the small-diameter second inner layer wire 12. The large-diameter second inner layer wire 13 and the small-diameter second inner layer wire 12 are alternately arranged in the circumferential direction to form the circumferential second inner layer 4. The number of small-diameter second inner layer wires 12 and the number of large-diameter second inner layer wires 13 are the same as the number of first inner layer wires 11, i.e., six.
[0025] One large-diameter second inner layer wire 13 is disposed in an outer valley portion 21 formed by the outer peripheral surfaces of circumferentially adjacent first inner layer wires 11, 11. The adjacent first inner layer wire 11 and large-diameter second inner layer wire 13 are disposed so as to abut over the entire axial direction or over a portion of the axial direction. Also, the large-diameter second inner layer wire 13 and small-diameter second inner layer wire 12 adjacent to each other in the axial direction are disposed so as to abut over the entire axial direction or over a portion of the axial direction.
[0026] The diameter d6 of the large-diameter third inner layer wire 15 is larger than the diameter d5 of the small-diameter third inner layer wire 14. The small-diameter third inner layer wires 14 are spaced apart in the circumferential direction, and two large-diameter third inner layer wires 15 are circumferentially arranged between two small-diameter third inner layer wires 14 adjacent to each other in the circumferential direction, thereby forming a circumferential third inner layer 5. The number of small-diameter third inner layer wires 14 is six, the same as the number of first inner layer wires 11, and the number of large-diameter third inner layer wires 15 is 12, which is twice the number of first inner layer wires 11.
[0027] One large-diameter third inner layer wire 15 is disposed in an outer valley portion 22 defined by the outer peripheral surfaces of circumferentially adjacent small-diameter second inner layer wires 12 and large-diameter second inner layer wires 13. The adjacent small-diameter second inner layer wires 12, large-diameter second inner layer wires 13, and large-diameter third inner layer wires 15 are disposed so as to abut over the entire axial direction or a portion of the axial direction. Also, the small-diameter third inner layer wires 14 and large-diameter third inner layer wires 15 adjacent to each other in the circumferential direction, and the large-diameter third inner layer wires 15 and large-diameter third inner layer wires 15 adjacent to each other in the circumferential direction, are disposed so as to abut over the entire axial direction or a portion of the axial direction.
[0028] The diameter d8 of the thick outer layer wire 17 is greater than the diameter d7 of the thin outer layer wire 16. Two thin outer layer wires 16, 16 form one set, and these sets of thin outer layer wires 16, 16 are spaced apart in the circumferential direction, with two thick outer layer wires 17, 17 disposed circumferentially between adjacent sets of thin outer layer wires 16, 16 to form the circumferential outer layer 6. The number of thin outer layer wires 16 is 12, which is twice the number of first inner layer wires 11, and the number of thick outer layer wires 17 is 12, which is twice the number of first inner layer wires 11.
[0029] One large-diameter outer layer wire 17 is disposed within an outer valley portion 23 defined by the outer peripheral surfaces of circumferentially adjacent small-diameter third inner layer wires 14 and large-diameter third inner layer wires 15. The adjacent small-diameter third inner layer wires 14, large-diameter third inner layer wires 15, and large-diameter outer layer wires 17 are disposed so as to abut over the entire axial direction or over a portion of the axial direction. Also, the small-diameter outer layer wires 16 and large-diameter outer layer wires 17 adjacent to each other in the circumferential direction, the two small-diameter outer layer wires 16, 16 adjacent to each other in the circumferential direction, and the two large-diameter outer layer wires 17, 17 adjacent to each other in the circumferential direction are disposed so as to abut over the entire axial direction or over a portion of the axial direction.
[0030] One intermediate material 26 is disposed in a gap 25 surrounded by the outer surfaces of two circumferentially adjacent small-diameter outer layer wires 16, 16 and the outer surfaces of two circumferentially adjacent large-diameter third inner layer wires 15, 15 located inside thereof. The number of intermediate materials 26 is configured to be the same as the number of first inner layer wires 11. The wire material that forms the base of the intermediate material 26 may be made of any material such as a resin material or an insulating material in addition to the wire material that makes up the element wires 2, 11, 12, 13, 14, 15, 16, 17.
[0031] In this Example 1, when the diameter of the intermediate material 26 is d9, the wires 2, 11, 12, 13, 14, 15, 16, 17 and the intermediate material 26 are used such that the relationships d1 = d2, d3 = 0.76 × d2, d4 = 1.15 × d2, d5 = 0.75 × d2, d6 = 1.04 × d2, d7 = 0.85 × d2, d8 = 0.98 × d2, and d9 = 0.39 × d2 hold.
[0032] The cross-sectional shape of the stranded wire 1 is formed to be a nearly perfect circle, that is, the distance L1 from the center A of the stranded wire 1 to the outermost edge B of each thin-diameter outer layer wire 16 constituting the outer layer 6 is nearly the same as the distance L2 to the outermost edge C of each thick-diameter outer layer wire 17.
[0033] The stranded wire 1 of the present invention has the above-described structure and therefore provides the following functions and effects.
[0034] The outer shape of the stranded wire 1 can be made substantially circular without being compressed, and the wires 2, 11, 12, 13, 14, 15, 16, and 17 can be in contact with all of the adjacent wires 2, 11, 12, 13, 14, 15, 16, and 17. In addition, the outer shape of the stranded wire 1 can be made substantially circular without being compressed.
[0035] The intermediate material 26 suppresses the circumferential movement of the thin outer layer wire 16 and the thick outer layer wire 17 that make up the outer layer, preventing the thin outer layer wire 16 and the thick outer layer wire 17 from falling into the gap 25 surrounded by the outer surfaces of the two circumferentially adjacent thick third inner layer wires 15, 15. This improves the smoothness of the outer layer surface of the stranded wire compared to the stranded wire conductor 115 of the prior art described above.
[0036] By making the outer shape of the twisted wire 1 almost perfectly circular without compressing it, the outer layer surface can be made smooth, and the thickness of the insulating coating applied to the outer periphery of the twisted wire 1 can be made thin and uniform, thereby reducing the amount of insulating material used and reducing costs.
[0037] By forming the outer shape of the stranded wire 1 into a substantially perfect circle without compressing it, the physical properties of the strands 2, 11, 12, 13, 14, 15, 16, and 17 can be maintained without impairing their elongation, flexibility, pliability, etc. Therefore, the stranded wire 1 can have highly reliable quality and can be effectively used in fields such as automotive electric wires, acoustic electric wires, and medical wires.
[0038] [Example 2] As long as an arrangement similar to that of the stranded wire 1 of Example 1 can be formed, stranded wire 1 can be formed using strands of any diameter other than the strands having the diameters described in Example 1, as long as the diameter d4 of the thick-diameter second inner layer wire 13 is thicker than the diameter d3 of the thin-diameter second inner layer wire 12, the diameter d6 of the thick-diameter third inner layer wire 15 is thicker than the diameter d5 of the thin-diameter third inner layer wire 14, and the diameter d8 of the thick-diameter outer layer wire 17 is thicker than the diameter d7 of the thin-diameter outer layer wire 16. Furthermore, the stranded wire 1 may be compressed from the outside of the outer layer 6, which is the outermost layer, using a compression die or the like. This allows for a stable formation of the stranded wire 1 at a compression rate lower than that of the prior art.
[0039] This compression compresses and deforms the outer peripheries of the small-diameter outer layer wires 16 and the large-diameter outer layer wires 17 that make up the outer layer 6, making the outer shape of the stranded wire 1 closer to a perfect circle. Compression using a compression die or the like may be performed during or after the stranded wire 1 is manufactured. The compression rate can be set arbitrarily, but even if a compression rate lower than that of the prior art is used, the stranded wire 1 can be formed with a stable shape.
[0040] The other structures are the same as those in the first embodiment, and therefore the explanation will be omitted.
[0041] In the second embodiment, the same effects as those in the first embodiment can be achieved.
[0042] [Example 3] In the above-mentioned first and second embodiments, the stranded wire 1 is composed of six first inner layer wires 11, six thin second inner layer wires 12, six thick second inner layer wires 13, six thin third inner layer wires 14, and six intermediate members 26, and twelve thick third inner layer wires 15, twelve thin outer layer wires 16, and twelve thick outer layer wires 17. However, if the number of thin second inner layer wires 12, twelve thick second inner layer wires 13, twelve thin third inner layer wires 14, and twelve intermediate members 26 is the same as the number of first inner layer wires 11, and the number of thick third inner layer wires 15, thin outer layer wires 16, and thick outer layer wires 17 is twice the number of first inner layer wires 11, the number of each of the stranded wires 2, 11, 12, 13, 14, 15, 16, and 17 can be set to any number as long as it is three or more.
[0043] The wires 2, 11, 12, 13, 14, 15, 16, and 17 and the intermediate material 26 are arranged in the same regularity as in the first and second embodiments.
[0044] For example, as shown in Fig. 2, even in the case of a stranded wire 31 that is composed of five first inner layer wires 11, five thin-diameter second inner layer wires 12, five thick-diameter second inner layer wires 13, five thin-diameter third inner layer wires 14, and five intermediate wires 26, and ten thick-diameter third inner layer wires 15, five thin-diameter outer layer wires 16, and ten thick outer layer wires 17, which is twice the number of first inner layer wires 11, the cross section of the stranded wire 31 can be made substantially circular without compression or with a low compression ratio, as shown in Fig. 2. The center wire 2 does not need to be provided.
[0045] For example, as shown in Fig. 3, even in the case of a stranded wire 41 that is composed of seven first inner layer wires 11, seven thin-diameter second inner layer wires 12, seven thick-diameter second inner layer wires 13, seven thin-diameter third inner layer wires 14, and seven intermediate wires 26, and fourteen thick-diameter third inner layer wires 15, thin-diameter outer layer wires 16, and fourteen thick outer layer wires 17, which is twice the number of first inner layer wires 11, the cross section of the stranded wire 32 can be made substantially circular without compression or with a low compression ratio, as shown in Fig. 3. The center wire 2 does not have to be provided.
[0046] The other structures are the same as those in the first and second embodiments, and therefore the explanation will be omitted.
[0047] In this third embodiment, the same effects as those in the first and second embodiments can be achieved. [Explanation of symbols]
[0048] 1,31,41 stranded wire 3 First inner layer 4 Second inner layer 5 Third Inner Layer 6 outer layer 11 First Inner Line 12 Thin-diameter second inner layer wire 13 Large diameter second inner layer wire 14 Thin-diameter third inner layer wire 15 Large diameter third inner layer wire 16 Small diameter outer layer wire 17 Thick diameter outer layer wire 26 Intermediate materials
Claims
1. A first inner layer is formed by disposing a plurality of first inner layer wires in a circumferential direction; a second inner layer is formed on the outside of the first inner layer by thin second inner layer wires, the number of which is the same as that of the first inner layer wires, and thick second inner layer wires, the number of which is the same as that of the first inner layer wires, and the thin second inner layer wires and the thick second inner layer wires are thicker than the thin second inner layer wires and are arranged alternately in the circumferential direction; a third inner layer is formed on the outside of the second inner layer by thin third inner layer wires in the same number as the first inner layer wires, and thick third inner layer wires that are thicker than the thin third inner layer wires and twice the number of the first inner layer wires, the thin third inner layer wires being arranged spaced apart in the circumferential direction, and two thick third inner layer wires being arranged in the circumferential direction between two thin third inner layer wires adjacent in the circumferential direction; an outer layer is formed on the outside of the third inner layer by thin outer layer wires, the number of which is twice the number of the first inner layer wires, and thick outer layer wires, thicker than the thin outer layer wires and twice the number of the first inner layer wires, the thin outer layer wires being arranged in a set of two thin outer layer wires in the circumferential direction, the sets of thin outer layer wires being spaced apart in the circumferential direction, and two thick outer layer wires being arranged in the circumferential direction between each adjacent set of thin outer layer wires; the large-diameter third inner layer wire is disposed inside the small-diameter outer layer wire so as to abut on the entire axial direction or a part of the axial direction of the large-diameter third inner layer wire; A stranded wire characterized in that one intermediate material is disposed in a gap formed by two circumferentially adjacent small-diameter outer layer wires and two circumferentially adjacent large-diameter third inner layer wires located inside the outer layer wires.
2. one large-diameter second inner layer wire is disposed in an outer valley portion defined by outer surfaces of two circumferentially adjacent first inner layer wires; a third thick-diameter inner layer wire is disposed in an outer valley portion defined by outer surfaces of the second thin-diameter inner layer wire and the second thick-diameter inner layer wire adjacent to each other in the circumferential direction; 2. The stranded wire according to claim 1, wherein one large-diameter outer layer wire is disposed in an outer valley portion defined by the outer surfaces of the small-diameter third inner layer wire and the large-diameter third inner layer wire that are adjacent in the circumferential direction.
3. 3. The stranded wire according to claim 1, wherein the wires constituting the stranded wire are arranged so as to abut on all adjacent wires over the entire axial direction or over part of the axial direction.
4. 3. The stranded wire according to claim 1, wherein the distance from the center of the stranded wire to the outermost edge of the large-diameter outer layer wire is the same as the distance from the center of the stranded wire to the outermost edge of the small-diameter outer layer wire.
5. 3. The stranded wire according to claim 1, wherein the thick outer layer wire and the thin outer layer wire constituting the outer layer are not compressed and deformed from the outside.
Citation Information
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