POWER CORD

Abstract

The present invention has an object of providing a power cord which prevents breakage of a plug or cord/conductors certainly even when treated roughly and thus has a longer life. The power cord comprises a plurality of cores 5, of a synthetic resin, each for covering a connection section of a single blade 3 among a plurality of blades 3; and an outer skin 6, of a synthetic resin, for covering the plurality of cores 5 together such that the blades 3 are held at a specified interval spacing, so as to form a plug 4. The synthetic resin forming the outer skin 6 is softer than the synthetic resin forming the cores 5. The outer skin 6 includes a thicker part 6b for covering a border part Y of each cord 2 (internal covering member 2b) between a part covered with the core 5 and a part exposed therefrom.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a power cord according to an embodiment of the present invention.

FIG. 2 is a perspective view of an important part of the power cord.

FIG. 3 is a cross-sectional view of the power cord taken along one direction;

FIG. 4 is cross-sectional view of the power cord taken along another direction generally perpendicular to the direction in FIG. 3; and

FIG. 5 is a cross-sectional view of the power cord taken along line A-A in FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, an embodiment of the present invention will be described in detail with reference to the figures.

As shown in FIG. 1 and FIG. 2, a power cord 1 includes a plug 4, and blades 3 connected to a leading end of a cord 2. A leading end (outlet insertion part) of each blade 3 is projected from the plug 4. The plug 4 is formed by two molding steps, i.e., a molding step for forming cores 5 and a molding step for forming an outer skin 6 (both shown in FIG. 2). In this embodiment, the power cord 1 is described as including two blades 3, but the present invention is also applicable to, for example, a power cord of a type usable for a three-phase alternating current power source.

As shown in FIG. 3 through FIG. 5, the cord 2 includes conductors 2a, internal covering members 2b each for covering an outer surface of a bundle of the conductors 2a, and an external covering member 2c for covering the internal covering members 2b together. The internal covering members 2b and the external covering member 2c are formed of, for example, a rubber material such as chloroprene rubber, EP rubber, chlorosulphonated polyethylene rubber or the like, or an appropriate vinyl material. One internal covering members 2b covers the conductors 2a connected to one blade 3, and the other internal covering members 2b covers the conductors 2a connected to the other blade 3. The external covering member 5c covers outer circumferential surfaces of both the internal covering members 2b.

A leading end part of the cord 2 has a structure as shown in FIG. 3 and FIG. 4. The internal covering members 2b are extended out of the external covering member 2c, so as to be separated from each other by a greater distance as approaching leading ends thereof. At the leading end of each internal covering member 2b, the conductors 2a are exposed. The conductors 2a are pressure-contacted by crimping to, and thus connected to, a base 3a of each blade 3 at a trailing end thereof.

The blades 3 each have a wider part 3b, which is wider than the outlet insertion part, adjacent to the base 3a toward a leading end thereof. The width of the blade 3 becomes smaller at a position between the wider part 3b and the outlet insertion part.

The conductors 2a are spot-welded to the wider part 3b. The conductors 2a are connected to the blade 3 via a nugget 7 formed by the spot welding, in addition to being connected by the crimping. As described above, the blade 3 and the conductors 2a (cord 2) are connected to each other via the base 3a and the nugget 7 in a trailing end part of the blade 3.

The trailing end part of one blade 3 and the leading end of the internal covering member 2b (cord 2) connected thereto, and the trailing end part of the other blade 3 and the leading end of the internal covering member 2b (cord 2) connected thereto, are insert-molded in the cores 5 in the state of being positioned at a specified interval spacing. A plurality of cores 5 are provided such that one core 5 is usable for one blade 3. The plurality of cores 5 are independent from one another. After the insert molding, the cores 5 respectively integrated with blades 3 are insert-molded in the outer skin 6 represented by the one-dot chain line so as to realize the state shown in FIG. 3. Thus, the plug 4 is formed.

The cores 5 each having the trailing end part of the blade 3 and the leading end of the internal covering member 2b inserted therein are specifically formed as follows. In the state where leading ends of the conductors 2a are connected to the bases 3a of the blades 3, the leading ends of the internal covering members 2b are held at an angle relative to each other and thus directed so as to be separated as described above, whereas the blades 3 are held parallel to each other. The blades 3/the internal covering members 2b are positioned at such a specified interval spacing in a molding die. Then, injection molding is performed using a synthetic resin. Thus, the cores 5 are formed. The resultant cores 5 hold the internal covering members 2b as directed so as to be separated from each other and hold the blades 3 parallel to each other. As the synthetic resin for forming the cores 5, 66 nylon, which is a hard thermoplastic resin, is used.

The cores 5 each include an inclining part 5a at a trailing end part thereof. The inclining parts 5a extend at an angle relative to each other and thus directed so as to be separated from each other. Each core 5 includes a middle part 5b having a gradually increasing thickness from the base 3a of the blade 3. Each core 5 also includes a parallel part 5c which extends parallel to the other parallel part 5c from the nugget 7 where the blade 3 are connected to the conductors 2a. The parallel part 5c is thickest of the core 5. In this manner, the cores 5 extend in compliance with the internal covering members 2b and the blades 3 which extend in sequentially changing directions secured by the insert molding.

The cores 5 formed of a hard resin may be, for example, parallelepiped in order to be increased in thickness. However, the cores 5 having a shape matching the shape of the internal covering members 2b and the blades 3 as in this embodiment allow the blades 3 and the cord 2 to be protected by a minimum necessary thickness while guaranteeing a necessary thickness of the outer skin 6 formed of a soft material. Therefore, the outer skin 6 can be protected from being broken against a strong tensile force or bending stress.

Trailing end surfaces 5d of the cores 5 extend in a direction perpendicular to a longitudinal direction of the power cord 1, and are aligned to the same plane X represented by the dashed line in FIG. 3 and FIG. 4.

Each core 5 further includes a projecting part Se at a leading end thereof projecting from the center of the parallel part 5c toward the leading end of the blade 3. The outlet insertion part is exposed from the projecting part 5e.

The outer skin 6 is formed as follows. The cores 5, each integrated with the corresponding set of the internal covering member 2b and the blade 3 as a result of the insert molding, are put into a molding die having a specified shape. Then, injection molding is performed using a synthetic resin. Thus, the outer skin 6 is formed. As a result, the plug 4 including the plurality of cores 5 and the outer skin 6 for covering the plurality of cores 5 together is completed. As a synthetic resin for forming the outer skin 6, polyvinyl chloride, which is a thermoplastic resin softer than the synthetic resin used for the cores 5, is used.

As described above, the internal covering members 2b are held as directed to be separated from each other and the blades 3 are held parallel to each other by the cores 5. Therefore, the blades 3 are prevented from being directed outward owing to the rigidity of the internal covering members 2b, and do not need to be forcibly directed parallel to each other when forming the outer skin 6. In this way, the cores 5 can improve the molding operability of the outer skin 6, and generation of defective products including the blades 3 extending in a wrong direction can be prevented.

Unlike the power cord disclosed in Japanese Laid-Open Patent Publication No. 2003-178835 having covering and fixing sections connected to each other via a bridge, the power cord 1 in this embodiment includes the cores 5 such that one core 5 is provided for one blade 3. This is facilitates the fine adjustment of the distance between the blades 3 when forming the outer skin 6.

The outer skin 6 formed by the above-described injection molding includes a constricted part Ga. The outer skin 6 gradually becomes thinner from a leading end thereof toward the constricted part Ga. The outer skin 6 also includes a thicker part 6b adjacent to the constricted part 6a toward a trailing end thereof. The thicker part 6b is largely projected outward, has a greater thickness than the remaining part, and is continuous from the constricted part 6a. The outer skin 6 further includes a tapering part 6c adjacent to the thicker part 6b toward the trailing end thereof. The tapering part 6c is continued from the thicker part 6b while gradually becoming thinner toward the trailing end thereof. The tapering part 6c extends up to a position far from a leading end of the external covering member 2c in the longitudinal direction of the power cord 1.

The constricted part 6a covers the outer circumferential surfaces of the cores 5. The thicker part 6b covers the border parts Y of the internal covering members 2b between the parts covered with the cores 5 and the parts exposed therefrom.

A part of the outer skin 6 between the constricted part 6a and the thicker part 6b is formed to be recessed in a curve in the shape of a portion of a circle or an ellipse as shown in FIG. 3 and FIG. 4. With such a shape, the user can easily position his/her fingers on the plug 4 when pulling the plug 4 from the outlet (not shown).

When the user carries an electric appliance including the power cord 1, for example, with the cord 2 being hung on his/her shoulder while the plug 4 being held in his/her hand, or treats the power cord 1 excessively roughly in any other way, a strong tensile force, or bending stress or the like is applied to the plug 4. In the case of a plug as disclosed in Japanese Laid-Open Patent Publication No. 2003-178835 including a core having a bridge, the tensile force or bending stress may exceed the bending limit of the bridge, resulting in breakage of the bridge.

In this embodiment, the same number of cores 5 are provided as that of the blades 3. Therefore, the cores 5 are not restricted by each other, and the blades 3 can be individually displaced with a high degree of freedom in the outer skin 6. Therefore, even when a strong tensile force, bending stress or the like is applied by the rough treatment as described above, the connection parts of the conductors 2a and the blades 3 are prevented from being broken owing to the cores 5 and the outer skin 6, and the cores 5 are prevented from being broken owing to the outer skin 6.

The outer skin 6 includes the thicker part 6b. Owing to this, the outer skin 6 can be recovered to the original shape with certainty when the plug 4 is released from the strong tensile force, bending stress or the like after being subjected thereto. The thicker part 6b is formed to cover the border parts Y, which prevents the plug 4 from being bent at the border parts Y when the plug 4 is subjected to the strong tensile force, bending stress or the like. In other words, a part of the plug 4 which has a large hardness difference due to the cores 5 and the internal covering members 2b can be protected with certainty, and thus the conductors 2a and the internal covering members 2b (cord 2) are prevented from being broken at the border parts Y with certainty.

As described above, the provision of the plurality of cores 5 and the thicker part 6b of the outer skin 6 guarantees protection of the internal components of the plug 4 against a strong tensile force, bending stress or the like even when the power cord 1 is treated excessively roughly. As a result, the life of the power cord 1 can be extended.

The outer skin 6 includes the constricted part 6a for covering the cores 5. Owing to this, the position at which the power cord 1 is bent can be displaced to the part where the blades 3 and the internal covering members 2b are covered with the cores 5. This prevents the internal covering members 2b from being broken with a higher degree of certainty.

The outer skin 6 includes the tapering part 6c in a trailing end part thereof, which extends to a position sufficiently far from the connection part of the conductors 2a and the blades 3. Owing to this, the position at which the power cord 1 is bent can be displaced toward the trailing end as represented by the two-dot chain line in FIG. 3 and FIG. 4. Therefore, the influence of the bending stress or the like on the parts Y can be alleviated.

The trailing end surfaces 5d of the cores 5 are aligned to the same plane X. This allows the position of the thicker part 6b and the position of the trailing end surfaces 5d to be precisely matched to each other in the longitudinal direction of the power cord 1. Thus, the border parts Y can be protected with certainty. For example, in the case where the trailing end surfaces 5d are formed to be angled with respect to each other as represented by the two-dot chain line (trailing end surfaces 5d′) in FIG. 2 and FIG. 3, the internal covering members 2b are exposed from the trailing end surfaces 5d═ of the cores 5 at different positions on the inner side and the outer side of the core 5. In this case, the thicker part 6b needs to have a complicated shape.

In this embodiment, 66 nylon is used as the synthetic resin for forming the cores 5, and polyvinyl chloride is used as the synthetic resin for forming the outer skin 6. The synthetic resins are not limited to these materials. Any combination of synthetic resins such that the outer skin 6 and the cores 5 have a hardness difference and the outer skin 6 is softer than the cores 5 is usable.

The blades 3 are reinforced in the trailing end parts thereof against a strong tensile force or bending stress by providing the wider parts 3b. In addition, both of side edges of each blade 3 are stepped because of the wider part 3b. Owing to this, the wider part 3b is usable as a locking part for preventing the blade 3 from being pulled off from the core 5. Conventionally, a hole 3c represented by the two-dot chain line in FIG. 4 is formed at a generally central position of the trailing end part of the blade 3, and a locking part is formed while the core 5 is molded. In this case, there is a problem that the strength of the trailing end part of the blade 3 is lowered due to the hole 3c.

By contrast, this embodiment realizes the locking function by the wider part 3b. There is no need to form the hole 3c, and the blade 3 can have a continuous flat surface. This maintains the strength of the connection part of the blade 3 and the internal covering member 2b. The wider part 3b also provides a sufficient space for spot welding.

If the conductors 2a are pressure-contacted by crimping to the base 3a too strongly, the durability of the conductors 2a may be lowered against the tensile force, bending stress or the like in a part exposed from the trailing end of the base 3a. In this embodiment, the conductors 2a are connected to the blade 3 via the nugget 7 as well as being connected to the base 3a by crimping. Therefore, the crimping force for pressure-contacting the conductors 2a to the base 3a can be set to be relatively weak. Thus, the conductors 2a can be prevented from being broken due to the crimping.

Since the nugget 7 electrically connects the conductors 2a and the blade 3 with certainty, the electric characteristics of the power cord 1 can be stabilized.

The outer circumferential surface of the connection part of the blade 3 and the conductors 2a is covered with the middle part 5b and the parallel part 5c of the core 5, and thus is certainty protected against the tensile force, bending stress or the like.

As shown in FIG. 5, the cord 2 has a multi-layer structure including a buffering member 2d formed of a fiber material or the like sandwiched between the internal covering members 2b respectively provided for the blades 3 and the common external covering member 2c. Owing to such a structure, even when a tensile force is generated in a twisting direction as represented by the arrows in FIG. 5, each bundle of conductors 2a covered with the corresponding internal covering member 2b can be displaced with a certain degree of freedom without being restricted by the other bundle of conductors 2a. Therefore, the conductors 2a are protected against an excessive tensile force.

The elements of the present invention and the elements in the above-described embodiment correspond to each other as follows.

The crimping section of the present invention corresponds to the base 3a in the embodiment;

the joint section corresponds to the nugget 7;

the thicker part of the core corresponds to the parallel part 5c; and

the common covering member corresponds to the outer covering member 2c.

However, the present invention is not limited to the above-described embodiment and can be provided in various other embodiments.

Claims

1. A power cord, comprising: a plurality of blades each including an outlet insertion part at a leading end thereof and a connection section at a trailing end thereof, the connection section being connected to a plurality of conductors exposed from a leading end of a corresponding cord among a plurality of cords;a plurality of cores each for covering the connection section of a single corresponding blade of the plurality of blades, the cores being formed of a synthetic resin; andan outer skin for covering the plurality of cores together such that the plurality of blades are held at a specified interval spacing, so as to form a plug, the outer skin being formed of a synthetic resin;wherein:the synthetic resin forming the outer skin is softer than the synthetic resin forming the cores; andthe outer skin includes a thicker part for covering a border part of each cord between a part covered with the core and a part exposed from the core.

2. A power cord of claim 1, wherein the cores hold leading ends of the cords as directed to be separated from each other, and hold the blades so as to be parallel to each other.

3. A power cord of claim 2, wherein the cores each include a trailing end part and a leading end part, and the trailing end parts of the cores are angled relative to each other as directed to be separated from each other whereas the leading end parts of the cores are parallel to each other.

4. A power cord of claim 1, wherein: trailing end surfaces of the cores are aligned to the same plane as each other; andthe thicker part of the outer skin is aligned to the same plane as the trailing end surfaces of the cores.

5. A power cord of claim 1, wherein the outer skin includes a constricted part at a position closer to a leading end of the outer skin than the thicker part, the constricted part being thinner than the thicker part and covering an outer circumferential surface of the cores.

6. A power cord of claim 5, wherein the constricted part is formed to be recessed from the thicker part in a curve in the shape of a portion of a circle or an ellipse.

7. A power cord of claim 1, wherein the outer skin includes a tapering part at a position closer to a trailing end of the outer skin than the thicker part, the tapering part continuously extending from the thicker part and becoming gradually thinner.

8. A power cord of claim 1, wherein the blades each have a wider part in a trailing end part thereof which is wider than a leading end part thereof.

9. A power cord of claim 8, wherein the wider part has a continuous flat surface.

10. A power cord of claim 8, wherein: the connection section includes a crimping section and a joint section;the crimping section pressure-contacts the conductors to the trailing end of the blade; andthe joint section joints the conductors to the wider part by welding.

11. A power cord of claim 10, wherein the cores each have a thicker part, which is thicker than the remaining part thereof, for covering the wider part of the blade.

12. A power cord of claim 1 wherein; a single cord among the plurality of cords is provided for each blade; andthe plurality of cords are covered together with a common external covering member in the state where a buffering member is interposed between plurality of cords and the common external covering member.

13. A power cord of claim 1, wherein the synthetic resin forming the cores is 66 nylon, and the synthetic resin forming the outer skin is polyvinyl chloride.