JP7226914B2 - Method for manufacturing wiring material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing a wiring material.

For example, in a rear battery vehicle, a long battery cable is required to carry power from the rear to the front. Round or flat thick electric wires for automobiles are generally used as battery cables. In many of these electric wire manufacturing methods for thick electric wires, an insulating coating (polyvinyl chloride or the like) is extruded on a conductor (copper strands twisted together) as a wiring material. In the extrusion molding of the insulating coating, the insulating material is melted by heating and extruded from a die together with the linear conductor to coat the outer circumference of the conductor with the insulating material. Therefore, it is a necessary condition for the extrusion molding of the insulating coating that the conductor is twisted and flexible.

As a method for manufacturing an insulated conductor, a method for manufacturing an electric conductor made into a thin plate using an insulating pottery insert in Patent Document 1, a method for manufacturing an oxide superconducting wire in Patent Document 2, and the like are known. .

JP-A-58-142708 JP-A-2000-268649

By the way, when wiring materials such as battery cables in the vehicle interior, it is required to route them along the body panel and to reduce the thickness of the cables in accordance with the need to expand the living space in the vehicle interior. In order to route the wiring material along the body panel, it is necessary to bend the wiring material according to the shape of the body panel.
However, it is difficult to bend the thick electric wire according to the shape of the body panel. In addition, it is difficult to extrude an insulating coating on a hard conductor such as a busbar that is bent along the body panel. Therefore, there is a demand for a wiring material in which an insulating coating is formed on a thin, bent conductor that can be laid along a body panel.

The present invention has been made in view of the above situation, and its object is to provide a thinner cable than the conventional extruded coated wire, and to provide an insulating layer for the wiring material that is bent along the body panel or the like. An object of the present invention is to provide a method for manufacturing a wiring material that can be formed.

The above objects of the present invention are achieved by the following configurations.
(1) A step of extruding a long flat conductor with a die having a hole formed so that the edge portion extending in the longitudinal direction has a round shape , and extruding a plurality of the flat conductors in the plate thickness direction. When laminating, a lamination step of interposing an insulating sheet material between the adjacent flat conductors to electrically insulate them, and an insulating layer forming step of forming an insulating layer around the laminated flat conductors. and,
A method for manufacturing a wiring material, comprising:

According to the method of manufacturing the wiring member having the above configuration (1), the flat conductors are used as the wiring member, the insulating sheet material is interposed between the plurality of flat conductors, and the flat conductors are plated. By stacking in the thickness direction, it is possible to construct a wiring material for multiple circuits while suppressing the height compared to conventional thick electric wires. In this case, the plurality of flat conductors can suppress expansion of the wiring space in the width direction of the wiring material more than the conventional thick electric wire.
Also, when a plurality of flat conductors are laminated in the plate thickness direction, an insulating sheet material is interposed between the adjacent flat conductors for electrical insulation, so that the flat conductors can be easily and reliably insulated. can be done.
Furthermore, the extruded flat conductor has a round shape at the edge, and the edge is exposed from the insulating layer formed around the flat conductor, or the insulating layer is thin at the edge. never. Therefore, the wiring material is prevented from lowering in withstand voltage and insulation resistance, and can be improved in wear resistance and the like.

(2) an edge processing step of rounding at least the edges of the flat conductors extending in the longitudinal direction; A wiring material comprising: a lamination step of electrically insulating the wire by interposing an insulating sheet material; and an insulating layer forming step of forming an insulating layer around the laminated flat conductors. manufacturing method.

According to the method for manufacturing the wiring member having the configuration of (2) above, the flat conductors are used as the wiring member, and the insulating sheet material is interposed between the plurality of flat conductors, so that the flat conductors are plated. By stacking in the thickness direction, it is possible to construct a wiring material for multiple circuits while suppressing the height compared to conventional thick electric wires. In this case, the plurality of flat conductors can suppress expansion of the wiring space in the width direction of the wiring material more than the conventional thick electric wire.
Also, when a plurality of flat conductors are laminated in the plate thickness direction, an insulating sheet material is interposed between the adjacent flat conductors for electrical insulation, so that the flat conductors can be easily and reliably insulated. can be done.
Furthermore, for example, the edges extending in the longitudinal direction of a long flat conductor cut out from a plate material are rounded before forming the insulating layer. That is, the flat conductor has a rounded edge portion, and the edge is not exposed from the insulating layer formed around the flat conductor, and the insulating layer is not thinned at the edge portion. Therefore, the wiring material is prevented from lowering in withstand voltage and insulation resistance, and can be improved in wear resistance and the like.

(3) The wiring member according to (1) or (2) above, which includes a bending step of bending the plurality of laminated flat conductors into a predetermined shape before forming the insulating layer. Production method.

According to the method of manufacturing the wiring member having the configuration (3) above, the plurality of laminated flat conductors are bent in advance into a shape or the like along the body panel. In other words, a plurality of flat conductors laminated by interposing a flexible insulating sheet material can be collectively bent into a shape that conforms to a body panel or the like. Here, the flat conductor has a rounded shape at the edge portion, and the bending workability is improved. The bent flat conductors are further covered with an insulating layer. In general, the surface of a body panel such as a floor panel along which a wiring member is laid has a complex uneven surface due to cross members, reinforcing ribs, and the like. When a thick electric wire is routed along this body panel, the thick electric wire is arranged on the convex portion. Therefore, the space between the body panel and, for example, the interior material provided thereon must be at least as large as the accommodation height of the thick wires. In addition, since it is difficult to bend the thick electric wire along the convex portion, the height of the interior material cannot be lowered even in the concave portion due to the restrictions on the position of the thick electric wire. On the other hand, in the wiring member of this configuration, since a plurality of flat conductors laminated with insulating sheet materials interposed therebetween are bent, they can be easily processed into a shape that conforms to the uneven surface of a complex body panel or the like. becomes possible. As a result, in the recess, restrictions such as a thick electric wire that cannot be bent are eliminated, and the height of the interior material can be reduced. Further, an insulating layer is formed by, for example, powder coating on the surface of the wiring member, which is formed by laminating and bending the plurality of flat conductors with insulating sheet materials interposed therebetween. Powder coating can form an insulating layer with a thickness of, for example, 0.1 to 0.2 mm, whereas the insulating layer in conventional extrusion has a thickness of 1 to 2 mm. As a result, the wiring material having the above configuration can reduce the wiring space, and for example, the distance between the body panel and the interior material can be reduced.

(4) The method for manufacturing a wiring member according to any one of (1) to (3) above, characterized by including a shield layer forming step of forming a shield layer around the plurality of flat conductors. .

According to the method for manufacturing the wiring member having the configuration of (4) above, after the insulating layer is formed around the plurality of flat conductors laminated with the insulating sheet material interposed therebetween, a conductive braid is formed around the insulating layer. A shield layer is formed by covering with wire, foil, or the like. Therefore, the wiring material can suppress the emission of noise and prevent the influence of external noise. Furthermore, by providing an insulating layer on the outer side as necessary, it is possible to easily manufacture a wiring member having a shielding function using the same equipment.

According to the wiring material manufacturing method of the present invention, the insulating layer is formed on the wiring material that is thinner than the conventional extruded coated wire and is bent along the body panel or the like. becomes possible.

The present invention has been briefly described above. Furthermore, the details of the present invention will be further clarified by reading the following detailed description of the invention (hereinafter referred to as "embodiment") with reference to the accompanying drawings. .

BRIEF DESCRIPTION OF THE DRAWINGS It is a whole perspective view of the wiring material which concerns on 1st Embodiment of this invention. FIG. 2 is a cross-sectional view of the wiring material shown in FIG. 1 taken along line II-II. It is a front view of the left end part in the wiring material shown in FIG. It is a top view of the left end part in the wiring material shown in FIG. It is a cross-sectional view of the wiring material which concerns on 2nd Embodiment of this invention. It is a whole perspective view of the wiring material which concerns on 3rd Embodiment of this invention. It is a whole perspective view which shows the wiring material based on the modification of 3rd Embodiment of this invention. FIG. 10 is a perspective view showing an example of wiring in a vehicle using multiple types of wiring members; FIG. 7 is a process chart showing the procedure of the method for manufacturing the wiring member shown in FIG. 6; It is process drawing showing the procedure of the electrostatic coating method. It is a process drawing showing the procedure of the fluidized immersion method. FIG. 4 is an enlarged cross-sectional view of a main part for explaining a wiring member when the edge of a flat conductor cut out from a plate material is rounded. FIG. 5 is an enlarged cross-sectional view of a main part for explaining a wiring member according to a reference example in which edges of a flat conductor cut out from a plate material are not rounded; FIG. 11 is a perspective view showing an example of wiring in a vehicle using a thick electric wire;

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is an overall perspective view of a vehicle wiring member 100 according to a first embodiment of the present invention, and FIG. 2 is a II-II cross-sectional view of the vehicle wiring member 100 shown in FIG.
A vehicle wiring member 100 according to the first embodiment is a wiring member having a plurality of flat conductors 11A to 11D (see FIG. 2), an insulating sheet member 13, and an insulating layer 15.

A plurality of flat conductors 11A to 11D according to the first embodiment are laminated in the plate thickness direction. Various conductive materials such as copper alloys and aluminum alloys can be used for the flat conductors 11A to 11D. In this embodiment, a flat conductor made of an aluminum alloy will be described as an example.

The insulating sheet material 13 is interposed between adjacent flat conductors to electrically insulate the flat conductors. As the insulating sheet material 13, a flexible resin sheet material such as PET (polyethylene terephthalate) or PEN (polyethylene naphthalate) can be used. These insulating sheet materials 13 are provided over the entire front and back surfaces of the flat conductors 11A to 11D except for the connection portions 17 thereof. Therefore, in the case of the rectangular flat conductors 11A to 11D, the end faces on the four sides do not have to be covered with the insulating sheet material 13. FIG. The end faces on these four sides are covered with an insulating layer 15 . Therefore, only the connecting portions 17 of the laminated flat conductors 11A to 11D are exposed.

The insulating layer 15 is formed around the plurality of flat conductors 11A to 11D laminated with the insulating sheet material 13 interposed therebetween. This insulating layer 15 is formed by powder coating, which will be described later, for example.

The vehicle wiring member 100 according to the first embodiment is capable of supporting multiple circuits by stacking a plurality of flat conductors 11A to 11D with an insulating sheet member 13 interposed therebetween. In the present embodiment, the vehicle wiring member 100 made up of four layers of flat conductors 11A to 11D is illustrated, but the number of layers (sheets) is not limited to this.

The connecting portions 17 of the respective flat conductors 11A to 11D can be formed with widths obtained by dividing the total width of the vehicle wiring member 100 by the number of layers. As illustrated, the connection portion 17 is provided with a bolt fixing hole 19 .
When the vehicle wiring member 100 according to the first embodiment is used, for example, as a power cable, as shown in FIG. The wiring member 100 for a vehicle can be configured by laminating the flat conductors 11A to 11D in the order of the plus of 12V and the minus of 12V. In this case, adjacent layers are preferably of the same polarity. In the vehicle wiring member 100 of the illustrated example, "48V plus" and "12V plus" are adjacent to each other on the second and third layers. The vehicle wiring member 100 in which multiple circuits are laminated can improve the noise resistance performance by arranging the same poles adjacent to each other.

As shown in FIG. 2, the vehicle wiring member 100 uses flat conductors 11A to 11D made of an aluminum alloy having a thickness (t) of 0.8 mm and a width (W1) of 70 mm, for example. Therefore, each of the aluminum plate flat conductors 11A to 11D corresponds to an electric wire of 56 sq.
Here, the flat conductors 11A to 11D are obtained by extruding a long length from an aluminum alloy material using a die having a hole formed so that the edges extending in the longitudinal direction are rounded. That is, the flat conductors 11A to 11D extruded by a die having a flat oval hole shape have rounded edges at both ends in the width direction, as shown in FIG. round shape).

In addition, the laminated four-layered flat conductors 11A to 11D are interposed between adjacent flat conductors with an insulating sheet material 13 having a thickness (t1) of, for example, 0.2 mm, and a thickness (t2) of 0. It is surrounded by an insulating layer 15 of 0.2 mm. Therefore, the distance between laminated conductors is 0.2 mm. Therefore, the total width (W) of the vehicle wiring member 100 is 70.4 mm, and the total thickness (T) is 4.2 mm. Therefore, the thickness of the vehicle wiring member 100 can be reduced to half or less compared to the case of using a 50 sq aluminum electric wire with a standard finished outer diameter of 12.0 mm.

3 and 4 are a front view and a plan view of the left end of the wiring member 100. FIG.
As shown in FIG. 3, in the vehicle wiring member 100, the width (w) of each connection portion 17 of the flat conductors 11A to 11D is 16.0 mm. Moreover, the interval (d) between the adjacent connecting portions is set to 2.0 mm. The width (w) of the connection portion 17 is designed to prevent interference between the outer diameter of the tool used to fasten the nut to the bolt inserted through the bolt fixing hole 19 drilled in the connection portion 17 and the fastened nut. It is the minimum dimension necessary to avoid it.

Here, the plate thickness (t) of each of the flat conductors 11A to 11D in the vehicle wiring member 100 is the number of circuits (n), and the width of the connection portion 17 at both ends of each of the flat conductors 11A to 11D (w ), the interval between the adjacent connecting portions 17 is (d), and the cross-sectional area (electric wire sq) of the required wiring material is (S), the following equation (A) can be used.
t≧S/(n×w+d(n−1)) (A)
That is, according to the above formula (A), according to the electric wire sq of the conventional electric wire (corresponding to the required cross-sectional area (S) of each wiring member), the plate of each of the flat conductors 11A to 11D required The thickness (t) can be calculated, and the vehicle wiring member 100 can be easily replaced from conventional electric wires.

FIG. 5 is a cross-sectional view of a vehicle wiring member 200 according to a second embodiment of the present invention.
As shown in FIG. 5, the vehicle wiring member 200 includes a shield layer 16 around a plurality of flat conductors 11A to 11D covered with an insulating layer 15. As shown in FIG. As the shield layer 16, for example, a braided wire or a foil material can be used. The outer circumference of the shield layer 16 is further covered with an insulating layer 15 . According to the vehicle wiring member 200 provided with the shield layer 16, the emission of noise can be suppressed and the influence of external noise can be prevented.

FIG. 6 is an overall perspective view of a vehicle wiring member 300 according to a third embodiment of the present invention.
A vehicle wiring member 300 according to the third embodiment is bent into a shape that conforms to, for example, a vehicle floor panel (body panel) 21 (see FIG. 8). As will be described later, the vehicle wiring member 300 includes a plurality of flat conductors 11A to 11D laminated with a flexible insulating sheet material 13 interposed therebetween before forming the insulating layer 15 into a predetermined shape. can be bent into The vehicle wiring member 300 is configured by forming an insulating layer 15 around the plurality of bent flat conductors 11A to 11D.
Methods for bending into a predetermined shape include flatwise bending, edgewise bending, twisting, and the like. Moreover, bending into a predetermined shape includes various types of bending such as bending with a crease and bending with a bend R.

The vehicle wiring member 300 is formed with a concave bent portion 22 that straddles the tunnel portion 24 of the floor panel 21 . In this vehicle wiring member 300, four layers (four sheets) of flat conductors 11A to 11D laminated with an insulating sheet material 13 interposed are covered with an insulating layer 15 formed by powder coating. It has one connecting portion 17 .

FIG. 7 is an overall perspective view showing a vehicle wiring member 400 according to a modification of the third embodiment of the invention.
As with the vehicle wiring member 300 , the vehicle wiring member 400 includes a plurality of elongated layers laminated with flexible insulating sheet members 13 interposed before the insulating layer 15 is formed. A flat conductor is bent into a predetermined shape. The vehicle wiring member 400 is configured by forming the insulating layer 15 around the plurality of bent long flat conductors.

The vehicle wiring member 400 is formed with a plurality of bent portions 29, 31, 33, etc. along the floor panel 21, as well as a plurality of concave bent portions 35, 37 straddling the cross members of the floor panel 21. there is In this vehicle wiring member 400, four layers (four sheets) of long flat conductors laminated with insulating sheet materials 13 interposed are covered with an insulating layer 15 by powder coating. It has one connecting portion 17 .

FIG. 8 is a perspective view showing an example of wiring in a vehicle using multiple types of vehicle wiring members.
When used as a power cable, for example, the pair of vehicle wiring members 400 extend along the floor panel 21 across the front cross member 23 on the front (Fr) side and the rear cross member 25 on the rear (Rr) side of the vehicle. It is routed in the longitudinal direction of the vehicle. In addition, the vehicle wiring member 300 is routed in the lateral direction of the vehicle along the floor panel 21 across the tunnel portion 24 of the vehicle, and is electrically connected to the pair of vehicle wiring members 400 via the branch box 27. Connected. Further, the vehicle wiring member 100 is electrically connected to the vehicle wiring member 400 via the branch box 27 .

These vehicle wiring members 100, 300, and 400, which are wired along the floor panel 21 over the front (Fr) side and the rear (Rr) side of the vehicle and are interconnected, connect the vehicle battery to the vehicle. Power can be supplied to various devices.

These vehicle wiring members 100, 300, and 400 are composed of a plurality of flat conductors laminated with insulating sheet members 13 interposed therebetween, and are covered with a thin powder-coated insulating layer 15. It can be made thinner and lighter than an electric wire. By reducing the thickness of these vehicle wiring members 100, 300, and 400, the vehicle wiring space can be reduced. As a result, the vehicle wiring members 100, 300, and 400 can be routed even in a space-saving portion (for example, a gap between the floor panel 21 and the floor mat, etc.) where the wiring space is desired to be minimized due to the need to expand the living space in the vehicle interior. becomes possible.

Next, a method for manufacturing the vehicle wiring member according to each of the above embodiments will be described.
FIG. 9 is a process diagram showing the procedure of the method of manufacturing the vehicle wiring member 300 shown in FIG.
The method for manufacturing the vehicle wiring member 300 according to the present embodiment includes a step of extruding a long flat conductor 11A (11B to 11D) and stacking a plurality of flat conductors 11A to 11D in the plate thickness direction. A stacking step, an insulating step of interposing an insulating sheet material 13 between adjacent flat conductors to electrically insulate them, and an insulation of forming an insulating layer 15 around the laminated flat conductors 11A to 11D. and a layer forming step.

In the step of extruding the long flat conductor 11A (11B to 11D), a die having a hole formed so that the edge portion extending in the longitudinal direction of the flat conductor 11A (11B to 11D) has a round shape. A flat conductor 11A (11B to 11D) is extruded from an aluminum alloy material into a long length by (not shown).

In the lamination step of laminating a plurality of flat conductors 11A to 11D in the plate thickness direction, as shown in FIG. . The plurality of flat conductors 11A to 11D are electrically insulated by interposing an insulating sheet material 13 between adjacent flat conductors before bending, and the laminated flat conductor shown in FIG. 43.

Before the insulating layer 15 is formed on the outer circumference of the laminated flat conductor 43, the laminated flat conductor 43 is bent into a shape along the vehicle floor panel 21 and the like in a bending process, as shown in FIG. 9(c). In particular, in the bending of the laminated flat conductor 43, the deformation is slightly restored due to springback after processing, so this should be taken into account.

After the bending process has been completed, the laminated flat conductor 43 is powder-coated on the outer periphery, thereby forming a vehicle wiring member 300 having an insulating layer 15 formed on the surface thereof, as shown in FIG. 9(d). becomes.
At this time, the method for manufacturing the vehicle wiring member 300 according to the present embodiment can include a masking process before the painting process. In the masking process, the surfaces of the portions to be the connecting portions 17 at both ends of the laminated flat conductor 43, for example, are masked by using a masking tape 45 or the like (see FIG. 9C). At both ends of the masked laminated flat conductor 43, bolt fixing holes 19 are bored in advance by drilling. The insulating layer 15 is not formed on both ends of the masked laminated flat conductor 43 . Therefore, the exposed portions at both ends of the laminated flat conductor 43 can be used as connection terminals. The connection terminal can be directly conductively connected to a mating harness, a battery electrode, an alternator terminal, or the like by fastening bolts using the bolt fixing holes 19 described above.

An insulating layer 15 is formed on the surface of the bent laminated flat conductor 43 by powder-coating an insulating resin material. There are mainly two types of powder coating: an "electrostatic coating method (spray coating)" and a "fluidized immersion method (immersion coating)".

FIG. 10 is a process chart showing the procedure of the "electrostatic coating method".
The "electrostatic coating method" is a method in which the paint is charged with a spray gun 48 and applied to a grounded object using static electricity.
In the "electrostatic coating method" shown in FIG.

Next, in the powder coating booth 51 , the powder coating from the powder coating supply tank 53 is sprayed by compressed air from the compressor 55 . At this time, a high voltage generator 57 is connected to the spray gun 48 to charge the paint. On the other hand, by grounding the laminated flat conductor 43, the surface of the laminated flat conductor 43 is covered with a powder coating film. A recovery device 59 is connected to the powder coating booth 51 .

After the application of the powder coating, it is heated in a baking drying oven 61 to form a coating film, and after cooling, a coated laminated flat conductor 63 is obtained. The coated laminated flat conductor 63 becomes the vehicle wiring member 300 through post-processing such as removal of the masking tape 45 . Although it is difficult to control the film thickness by the "fluidization dipping method" to be described later, the "electrostatic spray method" makes it easy to control the coating film with a thin film of about 50 microns.

The thermosetting paint used in the "electrostatic spray method" undergoes a chemical change (crosslinking) by applying heat, changing its properties. Since various performances can be added by cross-linking reaction, the paint can be selected according to the application. Base resins used are generally polyester resins, acrylic resins, epoxy resins, hybrid (epoxy/polyester) resins, and the like.

FIG. 11 is a process diagram showing the procedure of the "fluidization immersion method".
In the “fluidization dipping method”, first, the laminated flat conductor 43 is washed in the pretreatment bath 47 and preheated in the preheating furnace 65 .

Next, in the fluidized bath 67, immersion is performed. For the immersion, a perforated plate is arranged at the bottom of the fluidized immersion bath 67, and compressed air 69 is sent from the perforated plate to flow the paint, and the preheated laminated flat conductor 43 is immersed in the flowing paint. do. The paint in the fluidized bath 67 is fused to the laminated flat conductor 43 by heat to form a thick coating film.

After that, it may be passed through a post-heating bath 71 for improving smoothness. Thus, a coated laminated flat conductor 63 is obtained. The coated laminated flat conductor 63 becomes the vehicle wiring member 300 through post-processing such as removal of the masking tape 45 . In the "fluidized dip coating method", a film thickness of usually 200 to 500 microns can be applied.

Resins such as vinyl chloride, polyethylene, and nylon can be mainly used for the thermoplastic powder coating used in the "fluidization dipping method". Thermoplastic paints are characterized by the fact that they soften and change shape when heat is applied, and the shape stabilizes when cooled. Thermoplastic powder coatings do not undergo chemical changes due to heat, so when heat is applied again, they repeatedly soften and change shape. Therefore, it is not a baking process like a thermosetting paint.

The method of manufacturing the vehicle wiring member according to the present embodiment includes a shield layer forming step of forming a shield layer around the powder coated laminated flat conductor 63. good too. In this shield layer forming step, the periphery of the coated laminated flat conductor 63 is covered with a braided wire or foil material as a shield layer. After that, if necessary, the outer circumference is further covered with an insulating layer 15 formed by powder coating. According to the vehicle wiring material provided with the shield layer, it is possible to suppress the emission of noise and prevent the influence of external noise.

FIG. 12 is an enlarged cross-sectional view of a main part for explaining a vehicle wiring member 500 in which the edges 12 of flat conductors 11A (11B to 11D) cut out from a plate material are rounded.
In a method for manufacturing a vehicle wiring member 500 according to another embodiment of the present invention, as shown in FIG. If it is cut out, or if the edge portion extending in the longitudinal direction of the flat conductor 11A (11B to 11D) extruded from an aluminum alloy material is not sufficiently rounded, the lamination Before the process, it includes an edge processing step of rounding at least the edges 12 extending in the longitudinal direction of the flat conductors 11A (11B to 11D).

In this edge processing step, the edges 12 extending in the longitudinal direction (perpendicular to the paper surface in FIG. 12) of the flat conductors 11A (11B to 11D) are rounded. That is, as shown in FIG. 10(b), round portions 14 are formed by cutting or grinding at the edge portions at both ends in the width direction of the flat conductors 11A (11B to 11D). Therefore, the flat conductors 11A (11B to 11D) have rounded edges (rectangular rounded shapes) at both ends in the width direction, as shown enlarged in FIG. 10(b).
Then, in the same manner as the vehicle wiring members 100, 200, 300, and 400 described above, a stacking step of stacking a plurality of flat conductors 11A to 11D in the plate thickness direction, and an insulating sheet material 13 between adjacent flat conductors. and an insulating layer forming step of forming an insulating layer 15 around the plurality of laminated flat conductors 11A to 11D. , a vehicle wiring member 500 is manufactured.

Next, the operation of the configuration described above will be described.
In the method of manufacturing the vehicle wiring members 100, 200, 300, 400, and 500 according to the above embodiments, the flat conductors 11A to 11D are used as the wiring members, and the insulating sheet material 13 is placed between these flat conductors. By laminating the flat conductors 11A to 11D in the plate thickness direction, it is possible to construct a multi-circuit vehicle wiring member while suppressing the height compared to conventional thick electric wires. In this case, the plurality of flat conductors 11A to 11D can suppress expansion of the wiring space in the width direction of the wiring material more than the conventional thick electric wire.

Moreover, according to the wiring member 200 provided with the shield layer 16, the emission of noise can be suppressed and the influence of external noise can be prevented.

In the method of manufacturing the vehicle wiring members 100, 200, 300, 400, and 500 according to the present embodiment, when laminating a plurality of flat conductors 11A to 11D in the plate thickness direction, an insulating sheet is placed between adjacent flat conductors. Since the material 13 is interposed and electrically insulated, the flat conductors can be easily and reliably insulated.

Furthermore, the extruded flat conductors 11A to 11D have rounded edges, and the edges 12 are exposed from the insulating layer 15 formed around the flat conductors 11A to 11D. Therefore, the insulating layer 15 is not thinned (see FIG. 2). Therefore, the vehicle wiring members 100, 200, 300, and 400 are prevented from lowering in withstand voltage and insulation resistance, and can improve wear resistance and the like.

FIG. 13 is an enlarged cross-sectional view of a main part for explaining a vehicle wiring member 600 according to a reference example in which the edges 12 of flat conductors 11A (11B to 11D) cut out from a plate material are not rounded. It is a diagram.
By the way, as shown in FIG. 13(a), a long flat conductor 11A (11B to 11D) cut out from an aluminum alloy plate has an edge extending in the longitudinal direction (in FIG. 13, the direction perpendicular to the paper surface). 12 are standing. Also, the edge 12 may have burrs or the like.
Then, when the insulating layer 15 is formed around the laminated flat conductors 11A to 11D having such edges 12 to manufacture the vehicle wiring member 600, the result is shown in FIG. 13(b). Thus, there is a possibility that the insulating layer 15 may become thin at the edge portion, or the edge 12 may be exposed from the insulating layer 15 . When a high voltage is applied to the vehicle wiring member 600 according to the reference example, dielectric breakdown may occur at the edge portion where the film thickness of the insulating layer 15 is thin, and leak current may flow.

On the other hand, in the method of manufacturing a vehicle wiring member 500 according to another embodiment of the present invention shown in FIG. If the flat conductor 11A (11B to 11D) has a longitudinally extending edge 12, the edge 12 is rounded before the insulating layer 15 is formed. That is, the flat conductors 11A to 11D have rounded edges, and the edges 12 are exposed from the insulating layer 15 formed around the flat conductors 11A to 11D. thin (see FIG. 12(c)). Therefore, the wiring material 500 for vehicles can prevent the fall of a withstand voltage and insulation resistance, and can aim at improvement, such as abrasion resistance.

Further, in the method of manufacturing the vehicle wiring members 300 and 400, the plurality of laminated flat conductors 11A to 11D are bent in advance into a shape along the floor panel . That is, the plurality of flat conductors 11A to 11D (that is, the laminated flat conductor 43) laminated by interposing the flexible insulating sheet material 13 are collectively bent into a shape along the floor panel 21. can be processed. Here, the flat conductors 11A to 11D have rounded edges to improve bending workability. The periphery of the bent laminated flat conductor 43 is covered with the insulating layer 15 .

In general, the surface of the floor panel 21 along which the wiring material is laid has a complicated uneven surface due to the front cross member 23, the rear cross member 25, and the like.
For example, as shown in FIG. 14, in order to connect the front alternator 41 and the like to the fuse box 39 connected to the rear battery 38, when the floor panel 21 is wired along with the thick electric wire 73, the front cross The thick electric wire 73 is arranged on the convex portions of the member 23, the rear cross member 25, and the like. Therefore, the space between the floor panel 21 and, for example, the interior material provided thereon must be at least as large as the accommodation height of the thick electric wire 73 . In addition, since it is difficult to bend the thick electric wire 73 along the convex portions of the front cross member 23 and the rear cross member 25, the position of the thick electric wire 73 is restricted even in the concave portion, and the height of the interior material is restricted. cannot be lowered.

On the other hand, in the vehicle wiring members 300 and 400 configured as described above, the plurality of flat conductors 11A to 11D (laminated flat conductors 43) laminated with the insulating sheet material 13 interposed therebetween are bent in advance. It becomes possible to easily process the shape along the uneven surface of the complicated floor panel 21 . As a result, restrictions such as the thick electric wire 73 that cannot be bent in the recess are eliminated, and the height of the interior material can be reduced (see FIG. 8). An insulating layer 15 is formed by, for example, powder coating on the surface of the wiring member obtained by laminating and bending the plurality of flat conductors A to 11D with the insulating sheet material 13 interposed therebetween. Powder coating can form the insulating layer 15 with a thickness of, for example, 0.1 to 0.2 mm, whereas the insulating layer 15 formed by conventional extrusion has a thickness of 1 to 2 mm. As a result, the vehicle wiring members 300 and 400 can reduce the vehicle wiring space, and for example, the distance between the floor panel 21 and the interior material can be reduced.

Further, in the method for manufacturing the vehicle wiring member 200, after the insulating layer 15 is formed around the plurality of flat conductors 11A to 11D laminated with the insulating sheet material 13 interposed therebetween, the insulating layer 15 is surrounded by a shield. By covering with the layer 16 and further providing the insulating layer 15 by powder coating on the outer side if necessary, the vehicle wiring material 200 having a shielding function can be easily manufactured using the same equipment (for example, powder coating equipment). can be manufactured to

Therefore, according to the method of manufacturing the vehicle wiring members 100, 200, 300, 400, and 500 according to the above-described embodiments, the thickness is thinner than that of the conventional extruded covered electric wire, and the wire is made along the floor panel 21. It becomes possible to form the insulating layer 15 on the bent wiring material.

The present invention is not limited to the above-described embodiments, and it is also possible for those skilled in the art to combine each configuration of the embodiments with each other, modify and apply based on the description of the specification and well-known technology. It is intended by the invention and falls within the scope for which protection is sought.

For example, the insulating layer formed around the flat conductor is not limited to the powder coating described above, and various forming methods such as a method of dipping in paint (dip coating) can be employed. In the above configuration example, the plurality of vehicle wiring members 100, 300, and 400 are electrically connected via the branch box 27. Needless to say, it is also possible to have a configuration in which it is routed to Furthermore, in the above-described embodiments, the method of manufacturing the vehicle wiring members 100, 200, 300, 400, and 500 used for vehicle power cables has been described as an example of the wiring member. Needless to say, the present invention is not limited to this, and can be applied to various methods of manufacturing wiring members.

Here, the features of the embodiments of the method for manufacturing the wiring member according to the present invention described above are briefly summarized in [1] to [4] below.
[1] A step of extruding a long flat conductor (11A to 11D) with a die having a hole formed so that an edge portion extending in the longitudinal direction has a round shape;
A lamination step of laminating the plurality of flat conductors (11A to 11D) in the plate thickness direction;
an insulating step of interposing an insulating sheet material (13) between the adjacent flat conductors to electrically insulate them;
an insulating layer forming step of forming an insulating layer (15) around the laminated flat conductors (11A to 11D);
A method for manufacturing a wiring member (vehicle wiring member 100, 200, 300, 400), comprising:
[2] an edge processing step of rounding at least the edges (12) extending in the longitudinal direction of the flat conductors (11A to 11D);
A stacking step of stacking a plurality of round-processed flat conductors (11A to 11D) in the plate thickness direction;
an insulating step of interposing an insulating sheet material (13) between the adjacent flat conductors to electrically insulate them;
an insulating layer forming step of forming an insulating layer (15) around the laminated flat conductors (11A to 11D);
A method for manufacturing a wiring member (vehicle wiring member 500), comprising:
[3] The above [1] or [2] characterized by including a bending step of bending the plurality of laminated flat conductors (11A to 11D) into a predetermined shape before forming the insulating layer (15). ] and a method for manufacturing the wiring member (vehicle wiring member 300, 400).
[4] Any one of [1] to [3] above, including a shield layer forming step of forming a shield layer (16) around the plurality of flat conductors (11A to 11D). A method of manufacturing the described wiring member (200).

11A to 11D... Flat conductor 13... Insulating sheet material 15... Insulating layer 16... Shield layer 100, 200, 300, 400, 500... Vehicle wiring material (wiring material)

Claims (4)

a step of extruding a long flat conductor with a die having a hole formed so that an edge portion extending in the longitudinal direction has a round shape;
A stacking step of electrically insulating by interposing an insulating sheet material between adjacent flat conductors when laminating a plurality of the flat conductors in the plate thickness direction;
an insulating layer forming step of forming an insulating layer around the plurality of stacked flat conductors;
A method for manufacturing a wiring material, comprising: an edge processing step of rounding at least the edges extending in the longitudinal direction of the flat conductor;
A stacking step of electrically insulating by interposing an insulating sheet material between adjacent flat conductors when stacking a plurality of the flat conductors that have been rounded in the plate thickness direction;
an insulating layer forming step of forming an insulating layer around the plurality of stacked flat conductors;
A method for manufacturing a wiring material, comprising: 3. The method of manufacturing a wiring member according to claim 1, further comprising a bending step of bending the plurality of laminated flat conductors into a predetermined shape before forming the insulating layer. 4. The method for manufacturing a wiring member according to claim 1, further comprising a shield layer forming step of forming a shield layer around the plurality of flat conductors.

Images