JP6129052B2 - Method for manufacturing insulating member - Google Patents

Description

The present invention relates to a method for manufacturing an insulating member provided in a covering region of a conductor that is electrically connected to an electrical component that constitutes a circuit for controlling an electric vehicle included in the electric vehicle control device.

  The electric vehicle control device is a device that converts electric power taken from an overhead line and supplies electric power to a load such as an induction motor, an electric lamp, or an air conditioner. The electric vehicle control device is composed of various electric components such as a transformer, an inverter, and a converter. Since a high voltage is applied and a large current flows between these electrical components and between the electrical components and the load, they are connected by a conductor composed of, for example, a copper bus bar (JIS 3140) material. Some conductors have a length of 2 to 3 m depending on the size of the electric vehicle control device (see, for example, Patent Document 1 (FIG. 12)).

  In addition, in order to reduce the inductance of the conductor and reduce the noise of the current flowing through the conductor, it is desirable to reduce the distance between the conductors as much as possible and to shorten the length of the conductor (for reducing the conductor inductance). For example, see Patent Document 2 (paragraph [0010]). For this reason, some conductors are arranged so that their wide surfaces face each other and pass through the gaps in the electrical component group. As a result, edgewise bending that is bent in the width direction, two-step bending or three-step bending that is stepwise bent at relatively short intervals, and the like may be adopted, and the conductor may have a complicated three-dimensional shape.

  The outer peripheral surface of the conductor is usually provided with an insulating portion that can be insulated even when a high voltage is applied and a large current flows. For example, after winding a self-adhesive silicon rubber tape around a conductor so as to overlap about half in the width direction, a glass tape is similarly wound on the insulating portion, and further, an epoxy resin Some have been impregnated and cured.

International Publication No. 2007/138760 Japanese Patent Laid-Open No. 10-21254

  The process of winding a tape such as a silicon rubber tape or a glass tape around a conductor having a complicated three-dimensional shape often requires manual work. Moreover, a skilled technique is required to wind the tape around a conductor having a complicated three-dimensional shape so that no slack or wrinkle occurs. Therefore, it takes a lot of work to insulate the conductor, which is one of the factors that hinder the improvement of the productivity of the electric vehicle control device. This becomes a bigger problem if the conductor having a complicated three-dimensional shape is long.

The present invention is provided in the covered region of which has been made in view of the above circumstances, the electric components constituting the circuit for controlling the electric vehicle having the electric vehicle control device, conductor electrically connected It aims at facilitating the manufacturing method of an insulating member .

In order to achieve the above object, a method for manufacturing an insulating member according to the present invention provides a covered region of a conductor that is electrically connected to an electrical component that constitutes a circuit for controlling an electric vehicle included in the electric vehicle control device. A first insulating portion, which is an insulating member, is inserted in a heat-shrinkable tubular member folded in the length direction, and the tubular member is After extending along the shape of the covering region while unfolding, the diameter of the tubular member is larger than that of the tubular member and partially overlaps the outer surface of the tubular member. The conductor and the tube-shaped member are inserted into the inside, and the tube-shaped separate member is expanded and extended along the shape of the covered region, and then the tube- shaped member and the tube-shaped separate member are heated.

  According to the present invention, the conductor is inserted into the heat-shrinkable tubular member in which the first insulating portion is folded in the length direction, and the first insulating portion extends along the shape of the covered region of the conductor while the tubular member is expanded. After that, the tubular member is formed by heating. Therefore, it is possible to form the first insulating portion more easily than winding the tape as in the prior art. Therefore, the productivity of the electric vehicle control device can be improved.

It is a figure which shows the electric vehicle control apparatus which concerns on Embodiment 1 of this invention. It is a figure which shows an example of arrangement | positioning of the electrical component which a control unit has, and its electrical connection aspect. It is a figure which shows an example of the state which expand | deployed the tubular member. It is a figure which shows the state which has arrange | positioned the tubular member of the folded state which concerns on Embodiment 1 to the conductor. It is a figure which shows the state which expand | deployed the tubular member which concerns on Embodiment 1 to the middle of the covering area | region of a conductor. It is a figure which shows the state by which the whole conductor covering area | region was covered by expand | deploying the tubular member which concerns on Embodiment 1. FIG. It is a figure which shows the state which has arrange | positioned the tubular member of the state which folded the tubular member which concerns on Embodiment 1 to another conductor. It is a figure which shows the state which expand | deployed the tubular member which concerns on Embodiment 1 to the middle of the covering area | region of another conductor. It is a figure which shows the state by which the whole covering area | region of the other conductor was covered by expand | deploying the tubular member which concerns on Embodiment 1. FIG. It is a figure which shows a cross section perpendicular | vertical to the central axis of the conductor which concerns on Embodiment 2 of this invention. It is a figure which shows the electric vehicle control apparatus which concerns on Embodiment 3 of this invention. FIG. 10 is a diagram showing a cross section perpendicular to the central axis of a conductor group according to Embodiment 3. It is a figure which shows the electric vehicle control apparatus which concerns on Embodiment 4 of this invention. FIG. 9 is a diagram showing a cross section perpendicular to the central axis of a conductor according to Embodiment 4. It is a figure which shows the electric vehicle control apparatus which concerns on Embodiment 5 of this invention. It is a figure which shows the state which has arrange | positioned the tubular member of the folded state which concerns on Embodiment 5 to another conductor. It is a figure which shows the state covered to the middle of the covering area | region of the other conductor by expand | deploying all the tubular members which concern on Embodiment 5. FIG. It is a figure which shows the state which has arrange | positioned the tubular separate member of the folded state which concerns on Embodiment 5 to another conductor. It is a figure which shows the state which expand | deployed the tubular another member which concerns on Embodiment 5 to the middle of the covering area | region of another conductor. It is a figure which shows the state by which the whole covering area | region of the other conductor was covered by expand | deploying the tubular member which concerns on Embodiment 5, and a tubular separate member.

  Embodiments of the present invention will be described below with reference to the drawings. The same elements are denoted by the same reference symbols throughout the drawings. In addition, terms indicating directions such as “up”, “down”, “left”, “right”, “front”, “back” are used for explanation and are intended to limit the invention of the present application. Absent.

Embodiment 1 FIG.
Electric vehicle control apparatus 100 according to Embodiment 1 is an apparatus that controls an electric vehicle by converting electric power taken from an overhead line based on control information including a notch command, vehicle information, and the like, and outputting the converted information to a load. is there. As shown in FIG. 1, the electric vehicle control device 100 includes a plurality of control units 101a to 101c arranged in parallel in the front-rear direction, a plurality of conductors 102a to 102e connected to terminals of the control units 101b to 101c, and a conductor 102a. Are electrically insulated from each other, a plurality of wirings 104a-b connected to the terminals of the control unit 101a, and a connector 105 to which the conductors 102a-e and the wirings 104a-b are connected. With.

  The control units 101a to 101c have electric components constituting various circuits such as a main circuit and an auxiliary circuit inside, and control the electric vehicle by cooperating with each other. The electric component is, for example, a capacitor, a reactor, an inductor, a transformer, an inverter, or a switching element constituting a converter.

  Each of the conductors 102a to 102e is a member for conducting electricity. Each of the conductors 102a to 102e is configured by, for example, a copper member (copper bus bar: JISH3140) having a rectangular cross section so that a large current can be applied and a high voltage can be applied. The conductors 102a to 102e of the present embodiment are connected to the terminals of the control units 101b to 101c, and are electrically connected to the electrical components through conductors and the like disposed inside the control units 101b to 101c. ing.

  Specifically, as shown in FIG. 1, one end portions of the conductors 102a to 102c are fixed to different terminals provided on the right side surface of the control unit 101b by fastening bolts and nuts, brazing, or the like. One end portions of the conductors 102d to 102e are fixed to different terminals provided on the right side surface of the control unit 101c by fastening bolts and nuts, brazing, or the like. Each of the conductors 102a to 102e extends upward from one end portion fixed to the terminal, and is provided to extend forward through a bent portion. Each of the conductors 102a to 102e is connected to the connector 105 by extending forward from a portion extending long forward and through two edgewise bent portions.

  The edgewise bending is bending in the width direction of the conductors 102a to 102e (so that the direction of the longitudinal direction of the cross section is changed).

  As shown in the figure, the portion extending long forward of the conductors 102a to 102e includes a portion (parallel portion) where the conductors 102a to 102e are provided side by side. In the juxtaposed portion of the present embodiment, the wide surfaces of the conductors 102a to 102e arranged close to each other face each other.

  The juxtaposed portions of the conductors 102a to 102e are relatively determined by the combination of the conductors 102a to 102e. For example, for the conductor 102a and the conductor 102b, the juxtaposed portion of the conductor 102b is a portion that extends long to the front of the conductor 102b, and the side portion of the conductor 102a is the portion of the conductor 102b that extends long to the front of the conductor 102a. This is a portion provided in parallel with each other.

  For example, for the conductor 102b and the conductor 102c, the juxtaposed portion of the conductor 102c is a portion that extends long in front of the conductor 102c, and the side portion of the conductor 102b is the portion of the conductor 102c that extends long in front of the conductor 102b. This is a portion provided in parallel with each other.

  Regarding the conductor 102a, the conductor 102b, and the conductor 102c, the juxtaposed portion of the conductor 102c is a portion that extends long to the front of the conductor 102c, and the adjacent portions of the conductor 102b and the conductor 102a are to the front of the conductor 102b and the conductor 102a. Among the elongated portions, the portions are provided in parallel with the parallel portion of the conductor 102c.

  As described above, each of the conductors 102a to 102e has a complicated three-dimensional shape including a plurality of bent portions. Thereby, the juxtaposed portions where the wide surfaces of the adjacent conductors 102a to 102e face each other can be lengthened. As a result, the distance between the conductors 102a to 102e can be made as small as possible to reduce the inductance of the conductors 102a to 102e and the noise of the current flowing through the conductors.

  The first insulating portions 103a to 103e are members that cover the covering regions of the conductors 102a to 102e, respectively, and are formed using a tubular member 109 (see a development view of FIG. 3) having insulating properties and heat shrinkability. The Specifically, the first insulating portions 103a to 103e are covered with the conductors 102a to 102e inserted into the heat-shrinkable tubular member 109 folded in the length direction, while the tubular member 109 is expanded. It is formed by heating the tubular member 109 after extending along the shape of the region.

  Here, the covering region is a region appropriately determined for the conductors 102a to 102e as a region to be insulated by the first insulating portions 103a to 103e. Typically, the covering region is defined on a part or all of the outer peripheral surface excluding both end surfaces from the outer surface of each of the conductors 102a to 102e, and a tubular shape whose front and rear are open along the central axis of the conductors 102a to 102e. This is the aspect.

  Each of the covering regions of the conductors 102a to 102e is an outer peripheral surface of the conductors 102a to 102e excluding both ends, that is, a portion connected to the terminals of the control units 101a to 101c and a portion connected to the connector 105.

  The wirings 104a and 104b are linear members that conduct electricity. In the present embodiment, as shown in the figure, each end of each of the wirings 104a to 104b is connected to a terminal of the control unit 101a, and a conductor or the like disposed inside the control unit 101b to c is interposed therebetween. Are electrically connected to the electrical components. The other end of each of the wirings 104 a and 104 b is connected to the connector 105.

  As shown in the figure, the connector 105 is a member that collects the ends of the wirings 104a and 104b and the conductors 102a and 102e. From the front, a conductor, wiring, etc. (not shown) electrically connected to the load. Is connected. The load is, for example, an induction motor, an air conditioner, an electric lamp or the like. Inside the connector 105, each of the wirings 104a to 104b and the conductors 102a to 102e is electrically connected in association with each of the conductor and the conductive wire electrically connected to the load.

  From here, with reference to FIG. 2, an example of arrangement | positioning of the electrical component which control unit 101a-c has and its electrical connection aspect is demonstrated. The figure shows an example of the arrangement of the switching elements 106a-b and the capacitor 107 included in the control unit 101b and the conductors 102f-h connecting them. The conductors 102f to 102h may be connected to various electrical components other than the switching elements 106a to 106b and the capacitor 107, and the shapes of the conductors 102f to 102h can be variously changed.

  The switching elements 106a and 106b are provided side by side, and the left surface is attached to the cooling unit 108 of the control unit 101b. The cooling unit 108 releases the heat generated by the switching elements 106a and 106b to the outside air through cooling fins, for example. Each of the switching elements 106a-b has two terminals arranged vertically. Capacitor 107 is provided substantially at the center right of switching elements 106a-b and has two terminals that are lined up and down and protrude to the left.

  Like the conductors 102a to 102e, the conductors 102f to 102h are members made of, for example, copper bus bars (JISH3140) and the like so that a large current can flow and a high voltage can be applied.

  In detail, as shown in the figure, the conductor 102f and the conductor 102g have a vertically symmetrical shape, and one end of each of the conductor 102f and the conductor 102g is switched above the switching element 106a by tightening or brazing a bolt and a nut. It is fixed to the terminal below the element 106b.

  Each of the conductors 102f to 102g is bent rightward at the rear end of one end fixed to the terminal, extends downward and upward via the edgewise bent portion, and is bent backward and edgewise. Are provided to extend rightward. Furthermore, each of the conductors 102f to 102g extends upward and downward via a bent portion. The portion extending upward of the conductor 102f and the portion extending downward of the conductor 102g are respectively connected to the upper and lower terminals of the capacitor 107 as the other ends.

  The upper and lower ends of the conductor 102h are fixed below the switching element 106a and above the switching element 106b by bolts, brazing, or the like.

  As can be understood from the above description, the conductors 102f to 102g have a complicated three-dimensional shape. Accordingly, the lengths of the conductors 102f to 102g can be shortened as much as possible while passing through gaps with electrical components, conductors, and the like (not shown). In addition, the distance between the conductors 102f to 102g can be reduced by arranging the portions bent rearward of the conductors 102f to 102g to the lower end and the upper end of the other end side by side, and having the wide surfaces facing each other. Can do.

  Furthermore, regarding the conductor 102h, the length of the conductor 102h can be made the shortest by connecting the terminals linearly.

  Thus, the distance between the conductors 102f to 102g is made as small as possible, and the length of the conductors 102f to 102h is made as short as possible. Thereby, the inductance of the conductors 102f to 102h and the noise of the current flowing through the conductor can be reduced.

  Similarly to the conductors 102a to 102e, the conductors 102f to 102h are provided with first insulating portions 103f to 103f that cover the respective covered regions. The covering regions of the conductors 102f to 102h are outer peripheral surfaces of the conductors 102f to 102h excluding both ends connected to the switching elements 106a to 106b and the terminals of the capacitor 107.

  The first insulating portions 103f to 103h are formed by using a tubular member 109 having insulating properties and heat shrinkability, like the first insulating portions 103a to 103e. Specifically, the first insulating portions 103f to 103h insert the conductors 102f to 102h inside the heat-shrinkable tubular member 109 folded in the length direction, respectively, similarly to the first insulating portions 103a to 103e. The tube-shaped member 109 is stretched along the shape of the covering region while being expanded, and then the tube-shaped member 109 is heated.

  So far, the configuration of the electric vehicle control device 100 according to the present embodiment has been described. From here, an example of the manufacturing method of the electric vehicle control apparatus 100 is demonstrated.

  A conductor 102f and a tubular member 109 folded in the length direction are prepared.

  Here, a development view of the tubular member 109 is shown in FIG. The tube-shaped member 109 is a tube-shaped member having a predetermined length (for example, 1 to 3 m) in the length direction, and is formed by joining the left and right ends of the sheet-shaped material shown in FIG. As described above, this material has insulating properties and heat shrinkability.

  The tubular member 109 is folded in the length direction by folding the alternate long and short dash line shown in the figure as a valley fold (fold toward the back of the figure) and the dotted line as a mountain fold (fold toward the front of the figure). . The folds shown in the figure are called Miura folds, Yoshimura patterns, diamond patterns, and the like, and the tubular member has a PCCP shell (Pseudo-Cylindrical Converged Polyshell) structure.

  The conductor 102f is inserted into the folded tubular member 109 from the other end. The rear end of the tubular member 109 in the insertion direction is positioned at one end of the covering region (see FIG. 9) and fixed. For this fixing, for example, an instrument (not shown) that holds the vicinity of one end of the covering region of the conductor 102f together with the tubular member 109 may be used.

  The tubular member 109 is extended along the shape of the covering region of the conductor 102f by moving forward from the rear while the rear end is fixed (see FIG. 5). Thereby, the tubular member 109 covers the whole covering region (see FIG. 6). At this time, if the tubular member 109 has an excess portion, the portion may be cut off.

  Thereafter, the tubular member 109 is heated together with the conductor 102f by, for example, a dedicated heating and drying furnace. With this heat, the tubular member 109 contracts and comes into close contact with the covered region of the conductor 102f (see the conductor 102f shown in FIG. 2). As a result, the first insulating portion 103f is formed in the covering region of the conductor 102f.

  By the same procedure, the first insulating portions 103g to 103h are formed on the conductors 102g to 102h. Subsequently, the electrical components such as the switching elements 106a to 106b and the capacitor 107 are electrically connected by the conductors 102f to 102h formed with the first insulating portions 103f to 103h, the wirings, etc., and the control units 101a to 101c. Arranged inside. Thereby, each of the control units 101a to 101c is completed.

  Next, the conductor 102a and the tubular member 109 folded in the length direction are prepared. The conductor 102a is inserted from one end thereof into the folded tubular member 109. The rear end of the tubular member 109 in the insertion direction is positioned at one end of the covering region (see FIG. 7), and is fixed using a tool (not shown).

  The tube-shaped member 109 is extended along the shape of the covering region of the conductor 102a by moving forward from the rear while the rear end is fixed (see FIG. 8). Since the tubular member 109 is unfolded from the folded state, the tubular member 109 can pass through the bent portion of the conductor 102a with the minimum radius, and can extend along any shape of the bent portion. Extending in this way, the tubular member 109 covers the entire covered region (see FIG. 9). At this time, if the tubular member 109 has an excess portion, the portion may be cut off.

  Thereafter, the tubular member 109 is heated together with the conductor 102a by, for example, a dedicated heating and drying furnace. With this heat, the tubular member 109 contracts and comes into close contact with the covered region of the conductor 102a (see the conductor 102a shown in FIG. 1). Thereby, the first insulating portion 103a is formed in the covering region of the conductor 102a.

  By the same procedure, the first insulating portions 103b to 103b are formed on the conductors 102b to 102e. The terminals of the control units 101a to 101c and the connector 105 are connected by the conductors 102a to 102e formed with the first insulating portions 103a to 103e and the wirings 104a to 104b. Thereby, the electric vehicle control apparatus 100 is completed.

  According to the present embodiment, the first insulating portions 103a to 103h are inserted into the heat-shrinkable tubular member folded in the length direction through the conductors 102a to 102h, and the tubular member 109 is expanded. It is formed by heating the tubular member 109 after extending along the shape of the covered region of the conductors 102a to 102h. Therefore, the first insulating portions 103a to 103h having a uniform thickness and high adhesion can be formed faster and more easily than when the tape is wound as in the prior art. Accordingly, the productivity of the electric vehicle control device 100 can be improved. As a result, the price of the electric vehicle control device 100 can be reduced.

  As described above, each of the conductors 102a to 102g according to the present embodiment has a complicated three-dimensional shape, that is, a shape including a plurality of bent portions. When the tube-shaped member 109 is not folded, for example, a member corresponding to the first insulating portions 103a to 103g using the heat-shrinkable tube-shaped member 109 whose inner diameter is the smallest circle among the circles including the image projected on the plane. It is conceivable to provide a method. However, in this case, the tubular member 109 may be too large than each of the conductors 102a to 102g, and may not be sufficiently adhered to each of the conductors 102a to 102g even when thermally contracted. As a result, a desired insulating effect may not be obtained.

  According to the present embodiment, the tubular member 109 having an inner diameter sufficient to accommodate the cross sections of the conductors 102a to 102g may be used. For example, when the basic cross section has a rectangular shape with a size of 60 mm × 30 mm, the tubular member 109 may have an inner diameter (diameter) of about 60 several mm, which is slightly larger than the width dimension 60 mm. Therefore, the first insulating portions 103a to 103g that are in close contact with the conductors 102a to 102g having a complicated three-dimensional shape can be provided by thermally shrinking the tubular member 109. Therefore, even when the conductors 102a to 102g have a complicated three-dimensional shape, the conductors 102a to 102g through which a high voltage is applied and a large current flows are easily insulated using the heat-shrinkable tubular member 109. Is possible.

  According to the present embodiment, the length of the tubular member 109 is long enough to seamlessly cover the covered regions of the conductors 102a to 102c having a long central axis. According to this, the tube-shaped member 109 can be used for a length necessary for covering each of the covered regions of the conductors 102a to 102c. Therefore, waste of the tubular member 109 can be suppressed.

  Although the first embodiment of the present invention has been described above, the first embodiment is not limited to this.

  For example, the number, shape, arrangement, and the like of the control units 101a to 101c, the conductors 102a to 102h, and the wirings 104a to 104b are not limited to those shown in FIG.

  For example, the method of folding the tube-shaped member 109 is not limited to the above-described Miura folding, and any method can be used as long as the tube-shaped member 109 can be contracted in the length direction, and an internal space for inserting the conductors 102a to 102h can be used. What can be widely used is desirable.

  For example, in order to heat the conductors 102a to 102h whose covering regions are covered with the tubular member 109, a dedicated heating and drying furnace is not necessarily used. When the conductors 102a to 102h are relatively small, or when the number of the conductors 102a to 102h is small, a simple heating device, a dryer, or the like may be used. Thereby, it becomes possible to perform the operation | work for providing 1st insulation part 103a-h in the covering area | region of conductor 102a-h in various places.

Embodiment 2. FIG.
In the first embodiment, the example in which the conductors 102a to 102h are insulated by only one layer of the insulating portion (the first insulating portions 103a to 103h) has been described. However, when a high voltage is applied to the conductors 102a to 102h, high-performance insulation is required, and it may not be possible to sufficiently insulate with only one layer of the insulating portion made of the tubular member 109. In such a case, a plurality of layers of insulating portions are preferably provided. In this embodiment, an example in which a conductor is insulated by a two-layer insulating portion will be described as an example.

  In the present embodiment, as shown in FIG. 10, which is a cross-sectional view perpendicular to the central axis of the conductor 102a, the second insulating portion 210a that is in direct contact with the covering region of the conductor 102a, and the second insulating portion 210a A first insulating portion 203a that covers the covering region of the conductor 102a from above is provided.

  This figure shows a cross section perpendicular to the central axis in a portion extending long forward of the conductor 102a. The configurations of the conductor 102a, the second insulating portion 210a, and the first insulating portion 203a shown in the figure are substantially the same at any position as long as the cross section is perpendicular to the central axis of the covering region of the conductor 102a. Similarly, members corresponding to the second insulating portion 210a and the first insulating portion 203a may be provided for the other conductors 102b to 102h.

  The second insulating portion 210a is an insulating member provided between the first insulating portion 203a and the conductor 102a, and covers, for example, a covered region of the conductor 102a. The second insulating portion 210a may be formed by, for example, winding a self-bonding silicon rubber tape around a conductor so as to overlap approximately half in the width direction. Further, for example, the second insulating portion 210a may be formed using the tubular member 109, similarly to the first insulating portion 103a according to the first embodiment.

  The first insulating portion 203a is formed using a tubular member 109 having insulating properties and heat-shrinkable properties, like the first insulating portion 103a according to the first embodiment. Specifically, the first insulating portion 203a is inserted into the heat-shrinkable tubular member 109 folded in the length direction through the conductor 102a provided with the second insulating portion 210a. It is formed by heating the tubular member 109 after extending along the shape of the covering region while expanding.

  According to the present embodiment, the same effects as those of the first embodiment are obtained.

  Furthermore, according to the present embodiment, since the second insulating portion 210a is provided in addition to the first insulating portion 203a, the insulation of the conductor 102a can be improved. Thereby, even when a high voltage is applied to the conductor 102a, the conductor 102a can be sufficiently insulated.

  In general, the silicon rubber tape has a relatively low mechanical strength. Therefore, when the second insulating portion 210a is formed of a self-bonding silicon rubber tape, the second insulating portion 210a may be damaged due to collision with other members, and the insulating property of the damaged portion may be deteriorated. is there. According to the present embodiment, since the second insulating portion 210a is covered with the first insulating portion 203a, the second insulating portion 210a can be prevented from being damaged. Therefore, it is possible to sufficiently insulate the conductor 102a by preventing a decrease in insulation due to the damage of the second insulating portion 210a.

  When the second insulating portion 210a is formed by the tubular member 109, the second insulating portion 210a having a uniform thickness and high adhesion can be formed faster and more easily than using a self-bonding silicon rubber tape. it can. Therefore, it is possible to provide a two-layer insulating portion quickly and easily. Therefore, it is possible to improve the productivity of the electric vehicle control device that covers and insulates the covering region of the conductor 102a, thereby reducing the cost.

Embodiment 3 FIG.
In the first and second embodiments, the example in which the covering region of one conductor 102a is covered by the first insulating portions 103a and 203a has been described. In the present embodiment, an example will be described in which the first insulating portion 303 covers the covering region of the juxtaposed portions of the plurality of conductors 102a to 102c.

  As shown in FIG. 11, electric vehicle control apparatus 300 according to the present embodiment has substantially the same configuration as electric vehicle control apparatus 100 according to the first embodiment, and the first insulation according to the first embodiment. Instead of the portions 103a to 103c, the second insulating portions 310a to 310c that are in direct contact with the respective covered regions of the conductors 102a to 102c, and the parallel portions of the conductors 102a to 102c from above the second insulating portions 310a to 310c A first insulating portion 303 is provided to cover the covering region. FIG. 12 shows a cross section perpendicular to the central axis of the conductors 102a to 102c in the covered region of the juxtaposed portions of the conductors 102a to 102c.

  Each of the second insulating portions 310a to 310c is a member similar to the second insulating portion 210a according to the second embodiment. That is, the second insulating portions 310a to 310c are insulating members provided between the first insulating portion 303 and the conductors 102a to 102c, respectively, and cover, for example, the covered regions of the conductors 102a to 102c. The second insulating portions 310 a to 310 c may be formed of a self-bonding silicon rubber tape, or may be formed using the tubular member 109.

  The first insulating portion 303 is formed by using the tubular member 109 having insulating properties and heat shrinkability, like the first insulating portion 103a according to the first embodiment. Specifically, the first insulating portion 303 includes three conductors 102a to 102c provided with second insulating portions 310a to 310c inside a heat-shrinkable tubular member 109 folded in the length direction. The tube-shaped member 109 is expanded and stretched along the shape of the covering region of the parallel portions of the conductors 102a to 102c, and then the tube-shaped member 109 is heated.

  In addition, the 1st insulating part 303 may be provided so that not only the covering area | region of the parallel arrangement part of the conductors 102a-c but the parallel arrangement part of arbitrary adjacent conductors 102a-h may be covered.

  According to the present embodiment, the covering region of the parallel portions of the conductors 102 a to 102 c is covered with the first insulating portion 303. Thereby, the plurality of conductors 102a to 102c can be integrated. As a result, the conductors 102a to 102c can be easily positioned and attached to the control unit 101b. In addition, when the conductors 102a to 102c are attached to the control unit 101b, they may be appropriately fixed to the control unit 101c or the like. 300 assembly operations can be reduced.

Embodiment 4 FIG.
In the third embodiment, the example in which the first insulating portion 303 covers the covering region of the juxtaposed portions of the plurality of conductors 102a to 102c has been described. In this embodiment, an example will be described in which the first insulating portion 403 covers a portion parallel to the wirings 104a and 104b in the covered region of the conductor 102a together with the wirings 104a and 104b.

  As shown in FIG. 13, electric vehicle control device 400 according to the present embodiment has substantially the same configuration as electric vehicle control device 100 according to the first embodiment, and the first insulation according to the first embodiment. In place of the parts 103a to 103c, the second insulating part 210a according to the second embodiment and the first covering the part of the covering region of the conductor 102a parallel to the wirings 104a to 104b from above the second insulating part 210a. An insulating unit 403 is provided. FIG. 14 shows a cross section perpendicular to the central axis of the conductor 102a in a portion parallel to the wiring 104a-b in the covered region of the conductor 102a.

  The first insulating portion 403 is formed by using the tubular member 109 having insulating properties and heat shrinkability, like the first insulating portion 103a according to the first embodiment. Specifically, the first insulating portion 403 is inserted through the wires 104a and 104b together with the conductor 102a provided with the second insulating portion 210a into the heat-shrinkable tubular member 109 folded in the length direction. The tube-shaped member 109 is expanded along the shape of the covering region of the conductor 102a parallel to the wirings 104a and 104b while being expanded, and then the tube-shaped member 109 is heated.

  According to the present embodiment, a portion of the covering region of the conductor 102a that is parallel to the wirings 104a and 104b is covered with the first insulating portion 403. Thereby, the conductor 102a and wiring 104a-b can be integrated. As a result, the conductor 102a and the wirings 104a and 104b can be easily positioned and attached to the control units 101a and 101b.

Embodiment 5. FIG.
In the first embodiment, an example has been described in which the length of the tubular member 109 is long enough to seamlessly cover the covered regions of the conductors 102a to 102c having a long central axis. However, when the length of the tubular member 109 is increased, workability may be reduced. In the present embodiment, an example in which the length of each tubular member 109 is shorter than the central axis of the covered region of the conductors 102a to 102c will be described.

  As shown in FIG. 15, electric vehicle control device 500 according to the present embodiment has substantially the same configuration as electric vehicle control device 100 according to the first embodiment, and the first insulation according to the first embodiment. Instead of the parts 103a to 103c, first insulating parts 503a to 503c are provided.

  The first insulating portions 503a to 503c are members that cover the covered regions of the conductors 102a to 102e, respectively, similarly to the first insulating portions 103a to 103c according to the first embodiment. Unlike the first insulating portions 103a to 103c according to the first embodiment, the first insulating portions 503a to 503c are formed using a tubular member 509a and a separate tubular member 509b having insulating properties and heat shrinkability, respectively. Is done.

  Specifically, each of the first insulating portions 503a to 503c includes a tubular member 509a and a separate tubular member 509b having a diameter larger than that of the tubular member 509a and partially overlapping the outer surface of the tubular member 509a. .

  The first insulating portions 503a to 503c are respectively inserted into the heat-shrinkable tubular members 509a folded in the length direction through the conductors 102a to 102c, and the tubular members 509a are expanded while the conductors 102a to 503c are expanded. After extending along the shape of the covering region, the conductors 102a to 102c and the tubular member 509a are inserted into the heat-shrinkable tubular separate member 509b folded in the length direction, and the tubular separate member 509b is inserted. It is formed by heating the tube-shaped member 509a and the tube-shaped separate member 509b after extending along the shape of the covered region of the conductors 102a to 102c while expanding.

  So far, the configuration of electric vehicle control apparatus 500 according to the present embodiment has been described. From here, an example of the manufacturing method of the electric vehicle control apparatus 500 is demonstrated.

  The manufacturing method of the electric vehicle control device 500 according to the present embodiment is the same as that of the electric vehicle control device 100 according to the first embodiment except for the step of forming the first insulating portions 503a to 503c in the conductors 102a to 102c. It is almost the same as the manufacturing method.

  Therefore, in this embodiment, a process of forming the first insulating portion 503a in the conductor 102a will be described with reference to the drawings.

  A conductor 102a and a tubular member 509a folded in the length direction are prepared. The conductor 102a is inserted from one end thereof into the folded tubular member 509a. The rear end of the tubular member 509a in the insertion direction is positioned at one end of the covering region (see FIG. 16), and is fixed using a tool (not shown).

  The tube-shaped member 509a is extended along the shape of the covering region of the conductor 102a by moving forward from the rear while the rear end is fixed (see FIG. 17). Since the conductor 102a is long in the front-rear direction, even if all of the tubular member 509a is developed, it does not reach the entire covered region.

  A tubular separate member 509b is further prepared. The tube-shaped separate member 509b has an inner diameter larger than the outer diameter of the tube-shaped member 509a already developed on the conductor 102a, and the material, the folding method, and the like may be the same as the tube-shaped member 509a.

  The conductor 102a is inserted from one end thereof into the tubular separate member 509b together with the expanded tubular member 509a. The rear end of the tubular member 509b in the insertion direction is positioned in the middle of the expanded tubular member 509a (near the front end) (see FIG. 18), and is fixed using a tool (not shown).

  The tube-shaped separate member 509b is extended along the shape of the covered region of the conductor 102a by moving forward from the rear while the rear end is fixed (see FIG. 19). Thereby, the tube-shaped member 509a and the tube-shaped separate member 509b cover the whole covering region in a state where the front portion and the rear portion overlap each other by a predetermined length (see FIG. 20). At this time, if there is a surplus portion in the tubular member 509b, the portion may be cut off.

  Thereafter, the tube-shaped member 509a and the tube-shaped separate member 509b are heated together with the conductor 102a by, for example, a dedicated heating and drying furnace. Due to this heat, the tubular member 509a and the separate tubular member 509b contract and come into close contact with the covering region of the conductor 102a (see the conductor 102a shown in FIG. 15). As a result, the first insulating portion 503a is formed in the covered region of the conductor 102a. By the same procedure, the first insulating portions 503b to 503c are also formed on the conductors 102b to 102c.

  According to the present embodiment, the first insulating portions 503a to 503c are connected to the conductor 102a by arranging the tube-shaped member 509a and the tube-shaped separate member 509b having different diameters so as to overlap each other. To c. Thereby, the length per one of the tubular member 509a and the tubular member 509b is set to an appropriate length that can ensure workability, and the covering region of the conductors 102a to 102c having a long central axis is covered. It becomes possible to provide 1 insulation part 103a-c.

  As mentioned above, although embodiment of this invention was described, this invention is not limited to each embodiment, The form which combined each embodiment and the modification suitably, and the form which added the various change to it including.

  100, 300, 400, 500 Electric vehicle control device, 101a-c control unit, 102a-h conductor, 103a-h, 203a, 303, 403, 503a-c first insulating part, 104a-b wiring, 109, 509a tube -Shaped member, 210a, 310a-c 2nd insulation part, 509b Tube-shaped another member.

Claims (7)

A method for manufacturing an insulating member provided in a covering region of a conductor that is electrically connected to an electric component that constitutes a circuit for controlling an electric vehicle included in the electric vehicle control device,
The first insulating portion, which is the insulating member, is inserted into the heat-shrinkable tube-shaped member folded in the length direction, along the shape of the covering region while the tube-shaped member is expanded. The conductor and the tube inside the heat-shrinkable tube-shaped separate member folded in the length direction, having a diameter larger than that of the tube-shaped member and partially overlapping the outer surface of the tube-shaped member Forming the tubular member and extending the tubular separate member along the shape of the covering region, and then heating the tubular member and the tubular separate member .
Manufacturing method of insulating member. The tubular member has a PCCP shell (Pseudo-Cylindrical Concave Polyhederal Shell) structure.
The manufacturing method of the insulating member of Claim 1. Covering the covered region of the conductor with an insulating second insulating portion;
The first insulating portion is inserted into the heat-shrinkable tubular member folded in the length direction through the conductor covered with the second insulating portion, and the covering is expanded while the tubular member is expanded. After extending along the shape of the region, the diameter is larger than that of the tubular member, and partly overlaps the outer surface of the tubular member. Formed by inserting the conductor and the tube-shaped member, extending the tube-shaped separate member while extending the shape along the shape of the covering region, and then heating the tube-shaped member and the tube-shaped separate member To
The manufacturing method of the insulating member of Claim 1 or 2. After extending the second insulating portion along the shape of the covered region while inserting the conductor into the heat-shrinkable tubular member folded in the length direction and expanding the tubular member, The conductor and the tube-shaped member are inserted into a heat-shrinkable tube-shaped separate member folded in the length direction, which has a diameter larger than that of the tube-shaped member and partially overlaps the outer surface of the tube-shaped member. And after extending along the shape of the covering region while developing the tubular separate member, the tubular member and the tubular separate member are formed by heating.
The manufacturing method of the insulating member of Claim 3. The second insulating portion is in close contact with the covering region of the conductor, and the first insulating portion is in close contact with the second insulating portion;
The manufacturing method of the insulating member of Claim 3 or 4. The heat-shrinkable, folded in the length direction, the first insulating portion provided in the covering region of the side-by-side portion where each of the conductors is provided side by side, which is included in at least a part of the plurality of conductors The plurality of conductors are inserted into the inside of the tube-shaped member, and the tube-shaped member is expanded along the shape of the covering region while being expanded, and then the outer diameter of the tube-shaped member is larger than the tube-shaped member The conductor and the tubular member are inserted into a heat-shrinkable tubular member folded in the length direction, and the shape of the covering region is expanded while expanding the tubular member. after stretched along the form by heating and said tubular another member and the tubular member,
The manufacturing method of the insulating member of any one of Claim 1 to 5. The first insulating portion is inserted into the heat-shrinkable tubular member folded in the length direction with a wiring provided in parallel to the conductor covering region together with the conductor, and the tubular member is expanded. However, after extending along the shape of the covering region parallel to the wiring, the diameter is larger than the tube-shaped member, and the heat-shrinkability folded in the length direction partially overlaps the outer surface of the tube-shaped member inside inserted through said tubular member and the conductor of the tubular another member, after stretched along the shape of the coverage area while developing the tubular another member, the tubular member and the tubular by Formed by heating the member ,
The manufacturing method of the insulating member of any one of Claim 1 to 6.

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