Patent Application
20130248038
The present invention relates to a shield conductor.
A shield conductor having a shielding function is used to interconnect devices such as an inverter, a motor, and a battery in a vehicle, for example, a hybrid car and an electric car. One example of such a shield conductor is described in Patent Document 1. The shield conductor includes a metal pipe and a plurality of electric wires that are housed in the pipe. The pipe has a circular outer periphery. The pipe is bent along a wiring route.
There is a demand for arranging the shield conductor effectively using space for installation of a shield conductor in a vehicle. More specifically, when a metal pipe having a circular outer periphery is arranged under a floor of a vehicle, the space under the floor requires at least the same height as the outer diameter of the metal pipe. The space under the floor has a limitation in height and thus a significant level of layout design is required for the metal pipe. On the other hand, the space that expands lateral to the metal pipe may be larger than a size required for housing the metal pipe. Therefore, the conventional technology has a problem in arrangement of the shield conductor not effectively using the space.
This invention was accomplished in view of the foregoing circumstances. An object of this invention is to provide a shield conductor that can be arranged using a space effectively.
A shield conductor according to this invention includes a pipe made of metal and an electric wire. The electric wire is passed through the pipe. The pipe includes a round portion and a deformed portion. The round portion has a constant outer diameter in a peripheral direction of the pipe. The deformed portion is in a different position from the round portion in an extension direction in which the pipe extends. The deformed portion has a short diameter portion and a long diameter portion having different outer diameters in the peripheral direction of the pipe. The round portion curves in the extension direction.
According to the above configuration, the shield conductor is arranged such that a direction of the short diameter portion (a thickness direction) corresponds to a narrower direction of an installation space and arranged such that a direction of the long diameter portion (a thickness direction) corresponds to a wider direction of the installation space. Thus, the shield conductor can be housed in the space using a narrower space in the direction of the short diameter portion (the thickness direction) and using a wider space in the direction of the long diameter portion (the thickness direction). With this configuration, the shield conductor can be arranged using the space effectively.
In a bending process of the deformed portion, the deformed portion of the pipe can be bent relatively easier in the short diameter direction. However, the deformed portion is not easily bent in the long diameter direction. This may reduce flexibility in routing of the shield conductor. In view of the above circumstances, the pipe of this embodiment curves in the extension direction at the round portion. Thus, the pipe can be easily bent in three-dimensional directions at the round portion compared with bending at the deformed portion. Therefore, the shield conductor can enhance the routing freedom by the round portion while effectively using the space by the deformed portion.
According to the present invention, the shield conductor can be arranged using a space effectively.
10: shield conductor, 11: electric wire, 20, 50: pipe, 21: deformed portion, 22: constant portion, 22A: short diameter portion, 22B: long diameter portion, 23: transitional portion, 24: round portion, 30: forming machine, 31, 32: roller, 31A, 32A: concave surface, 33, 34: supporting member, 35: regulating mechanism, 36: fixed portion, 37: movable portion, 38: roller adjustment portion, 39: base portion, 40: heat shrinkable tube, 51: first member, 52: second member, 53: braided wire, 60: flat electric wire, W: vehicle
A first embodiment of the present invention will be described with reference to
As illustrated in
Each of the metal terminals 12 includes a terminal connecting portion and an electric wire connecting portion. The terminal connecting portion is connected to a terminal of a destination device. The terminal connecting portion includes a through hole through which a shaft of a bolt can be passed. The electric wire connecting portion continues from the terminal connecting portion so as to be integral therewith, and is connected with the electric wire 11. The electric wire connecting portion includes a wire barrel and an insulation barrel. The wire barrel is crimped onto an end of the core wire 11A of the electric wire 11 by bending. The end of the core wire 11A is exposed by stripping off the end of insulation coating 11B of the electric wire 11. The insulation barrel holds the electric wire 11 over the insulation coating 11B.
The pipe 20 is made of metal (e.g., aluminum, aluminum alloy, copper, and cooper alloy). The pipe 20 has an elongated shape. The pipe 20 includes deformed portions 21 and a round portion 24 (an area C in
The deformed portions 21 are located at a front end and a rear end of the pipe 20. The deformed portions 21 are, therefore, formed at different positions from the round portion 24 in the extension direction of the pipe 20. Each of the deformed portions 21 includes a constant portion 22 (A1 and A2 in
As illustrated in
in this embodiment, the outer diameter of the short diameter portion 22A is larger than a sum of a diameter of the electric wire 11 and thicknesses of the short diameter portion 22A (thicknesses of top and bottom parts of the short diameter portion 22A). The outer diameter of the long diameter portion 22B is slightly larger than a sum of diameters of the three electric wires 11 and thicknesses of the long diameter portion 22B (thicknesses of a right and a left parts of the long diameter portion 223). The outer diameter of the long diameter portion 22B is of a sufficient size to pass the three electric wires 11 that are laterally aligned.
As illustrated in
The round portion 24 has a round outer circumference. The round portion 24 is a non-deformed part and remains a shape of the cylindrical pipe (with a circular cross section) made of metal.
As illustrated in
The pipe 20 is connected with a braided wire such that an end of the braided wire covers the end of the pipe 20. The pipe 20 and the braided wire can be connected by welding, soldering, or swaging with a swage ring, whatever is appropriate.
The pipe 20 is formed by a cold rolling technology using a forming machine 30. As illustrated in
The rollers 31 and 32 have a cylindrical shape. Each roller 31 or 32 has a groove in the round outer periphery in the middle area thereof in the axial direction of the roller 31 or 32 for an entire circumference. The groove is formed by concaving the periphery of the roller 31 or 32 such that concave surfaces 31A and 32A are formed in the periphery. Each of the concave surfaces 31A and 32A has an appropriate curvature to form the deformed portion 21 (the transitional portion 23 and the constant portion 22). Thus, when the rollers 31 and 32 are moved closer to each other, the concave surfaces 31A and 32A can plastically deform the outer periphery of the cylindrical pipe 20, and forms the deformed portion 21.
The supporting members 33 and 34 are provided for the rollers 31 and 32, respectively. The supporting members 33 and 34 hold shafts protruding from the respective rollers 31 and 32 such that the shafts are rotatable. A lower end of the supporting member 33 is fixed to the base portion 39. The supporting member 34 (located closer to the regulating mechanism 35) is fixed to the regulating mechanism 35.
As illustrated in
The fixed portion 36 has a screw hole. The screw thread in the shaft of the roller adjustment portion 38 fits the screw hole. The movable portion 37 has a rounded through hole having no screw thread therein. The end portion of the shaft of the roller adjustment portion 38 is inserted to the through hole of the movable portion 37. The roller adjustment portion 38 is fixed to the movable portion 37 such that the shaft is rotatable but unmovable relative to the direction in which the rollers 31 and 32 are arranged. The movable portion 37 is integrated with the supporting member 34 located closer to the movable portion 37 than the supporting member 33. Accordingly, when the roller adjustment portion 38 rotates, the movable portion 37 moves and the roller 32 moves in conjunction with the movable portion 37 in the direction in which the rollers 31 and 32 are arranged.
The base portion 39 has an insertion hole 39A in which the pipe 20 is to be inserted. The insertion hole 39A is a path for the pipe 20 that is passed through between the concave surface 31A of the roller 31 and the concave surface 32A of the roller 32.
Next, a method of forming the deformed portion 21 of the pipe 20 will be described. First, a metal pipe (not illustrated) that is cylindrical with a constant outer diameter and linear for an entire length thereof is prepared. Next, the roller adjustment portion 38 of the forming machine 30 is operated to increase a distance between the rollers 31 and 32 (the distance between the concave surfaces 31A and 32A that are opposite each other). The distance between the rollers 31 and 32 is increased such that the metal pipe can pass through. Then, the metal pipe is inserted between the concave surfaces 31A and 32A until a boundary between a non-deformed part of the pipe, which is not to be deformed and to be provided as the round portion 24, and a part thereof to be provided as the transitional portion 23 reaches the concave surfaces 31A and 32A. Then, the roller adjustment portion 38 is operated to bring the concave surfaces 31A and 32A into contact with the metal pipe.
The input member of the forming machine 30 sends a signal to drive the drive member. The drive member rotates the rollers 31 and 32 in directions in which the rollers 31 and 32 wind the metal pipe. When the distance between the concave surfaces 31A and 32A is gradually decreased by the rotation of the rollers 31 and 32, the metal pipe is deformed into the transitional portion 23. When the deformation of the metal pipe proceeds to a boundary between the transitional portion 23 and a part to be provided as the constant portion 22, the rotation of the roller adjustment portion 38 is stopped. Then, the rollers 31 and 32 rotate until reaching one end of the metal pipe. As a result, the one of the constant portions 22 is formed.
The same processes are performed for the other end of the metal pipe and this forms the other one of the deformed portion 21 (the transitional portion 23 and the constant portion 22). Consequently, the non-deformed part is provided as the round portion 24. The deformed portions 21 may be plastically formed step by step together with another forming machine arranged under the forming machine 30.
Next, a bending process of the round portion 24 will be described. One arm (not illustrated) holds one end part of the one deformed portion 21 close to the round portion 24. The other arm (not illustrated) holds one end part of the other deformed portion 21 close to the round portion 24. The one arm moves until reaching at a position that corresponds to a curvature (or an inclined angle) of the round portion 24. When the round portion 24 is plastically curved, the formation of the pipe 20 is complete. The bending of the round portion 24 in the extension direction is not limited to the above process. Other known processes can be used for bending the round portion 24.
The three electric wires 11 are then inserted into the pipe 20 that is formed as described above and the shield conductor 10 is prepared. The electric wires 11 can be inserted before or after the pipe 20 is formed. The shield conductor 10 is then arranged (routed) under the floor of the vehicle W (on a bottom surface of a floor-under panel with being exposed to a lower direction (opposite a road surface)). More specifically, the shield conductor 10 is arranged such that a direction of the short diameter portion 22A (a thickness direction of the short diameter portion) corresponds to the top-bottom direction. The shield conductor 10 is further arranged such that a direction of the long diameter portion 223 (a thickness direction) and a bending direction of the round portion 24 correspond to the right-left direction (a horizontal direction). Each metal terminal 12 of the electric wire 11 is connected to a terminal of each external electric wire that is extended to an upper interior side of the vehicle W.
Next, functions and effects of the embodiment will be explained. According to the present embodiment, the shield conductor 10 includes a pipe 20 made of metal and an electric wire 11. The electric wire 11 is passed through the pipe. The pipe 20 includes a round portion 24 and a deformed portion 21. The round portion 24 has a constant outer diameter in a peripheral direction of the pipe 20. The deformed portion 21 is in a different position from the round portion 24 in an extension direction in which the pipe 20 extends. The deformed portion 21 has a short diameter portion and a long diameter portion having different outer diameters in the peripheral direction of the pipe 20. The round portion 24 curves in the extension direction. In other words, an axis that passes through the center of the round portion 24 curves.
According to the above configuration, the shield conductor 10 is arranged such that the direction of the short diameter portion 22A (the thickness direction) corresponds to the narrower direction of the installation space and arranged such that the direction of the long diameter portion 22B (the thickness direction) corresponds to the wider direction of the installation space. Thus, the shield conductor 10 can be housed in the space using the narrower space in the direction of the short diameter portion 22A (the thickness direction) and using the wider space in the direction of the long diameter portion 22B (the thickness direction). With this configuration, the shield conductor 10 can be arranged using the space effectively.
In a bending process of the deformed portion 21, the deformed portion 21 of the pipe 20 can be bent relatively easier in the short diameter direction 22A. However, the deformed portion 21 is not easily bent in the long diameter direction 22B. This may reduce flexibility in routing of the shield conductor 10. In view of the above circumstances, the pipe 20 in this embodiment curves in the extension direction at the round portion 24. Thus, the pipe 20 can be easily bent in three-dimensional directions at the round portion 24 compared with a case in which the pipe 20 is bent at the deformed portion 21. Therefore, the shield conductor 10 can enhance the routing freedom by the round portion 24 while effectively using the space by the deformed portion 21.
The deformed portion 21 has the flat shape. With this configuration, the deformed portion 21 can easily house a plurality of electric wires therein. Further, the deformed portion 21 can be arranged in a compact space compared with the other configurations.
The deformed portion 21 is formed by deforming the cylindrical pipe 20. Thus, the deformed portion 21 can be easily formed compared with a case in which the deformed portion 21 is formed using different dies for different shapes of the deformed portion 21.
A second embodiment of this invention will be described with reference to
As illustrated in
Because the heat shrinkable tube 40 adheres tightly to the outer periphery of the pipe 20, the outer periphery of the pipe 20 is protected by the heat shrinkable tube 40.
A third embodiment of this invention will be described with reference to
The pipe 20 according to the above embodiments is made of a material such as aluminum alloy. In the third embodiment, a pipe 50 is made of a cladding material including a first member 51 on an inner side and a second member 52 on an outer side that are layered as illustrated in
A braided wire 53 includes tinned copper alloy wires. The braided wire 53 covers an end part of an outer periphery of the second member 52, namely at an end part of the pipe 50. The end part of the pipe 50 and the braided wire 53 are connected to each other (at the end part of the second member 52) by a connecting means such as welding, soldering, and swaging with a swage ring.
If different kinds of metals are in contact with each other, electrical corrosion occurs in general. Because the tinned copper alloy wires are used for the braided wire 53 in this embodiment, electrical corrosion is more likely to occur if the end part of the pipe 50 made of aluminum or aluminum alloy is connected to the braided wire 53.
According to this embodiment, the braided wire 53 is connected to the second member 52 of the pipe 50. The second member 52 is made of iron or iron alloy, which is less likely to cause electrical corrosion against the tinned material compared with aluminum or aluminum alloy. Thus, electrical corrosion is less likely to occur on the braided wire 53 that is connected to the second member 52 compared with a case in which the braided wire 53 is connected to the first member 51 (aluminum or aluminum alloy).
A fourth embodiment of this invention will be described with reference to
As illustrated in
The flat electric wire 60 has a substantially rectangular cross section, that is, has less dead space. In addition, the flat electric wire 60 has a large surface area, which provides high heat release capability. Thus, the current carrying capacity of the flat electric wire 60 electric currents can be increased.
The flat electric wire 60 has short diameter sides and long diameter sides. The flat electric wire 60 is arranged inside a non-illustrated pipe such that the short diameter sides of the flat electric wire 60 correspond to the short diameter portion of the deformed portion, and the long diameter sides of the flat electric wire 60 correspond to the long diameter portion of the deformed portion. Accordingly, the pipe (not illustrated) has the long diameter portion of which diameter corresponds to the number and the shape of the flat electric wires 60 in the cross-sectional view. Consequently, the pipe is more likely to have a flat shape.
With this configuration, the shield conductor can be provided with the flat electric wire 60 having the large surface area and high heat release capability can be arranged in space that is effectively used while still can be arranged effectively using space.
This invention is not limited to the embodiments described in the above description and explained with reference to the drawings. The following embodiments may be included in the technical scope of this invention.
(1) In the above embodiments, the three electric wires 11 are inserted to the pipe 20. However, the technical scope is not limited to the three electric wires 11. The number of the electric wires 11 may be two, or equal to or more than four.
(2) The shield conductors 10 are arranged in underfloor space of the vehicle W. However, the shield conductor 10 may be arranged at different locations from the underfloor space of the vehicle W. Further, the technical scope is not limited to the vehicle W and may to anything that requires the shield conductor other than the vehicle W.
(3) According to the above embodiment, the number of the deformed portion 21 and the round portion 24, the length thereof in the extension direction, and the position thereof in the entire length of the pipes 20 and 50 are determined based on the wiring route for the electric wires 11 under the floor of the vehicle W. If the shield conductor 10 is arranged in a different location, the number of the deformed portion 21 and the round portion 24, the length thereof in the extension direction, and the position thereof in the entire length with respect to the deformed portion 21 and the round portion 24 can be determined based on the wiring route.
(4) The pipe 20 is formed by deforming the cylindrical metal pipe using the forming machine 30. However, this technical scope is not limited thereto. The pipe 20 may be formed using the following processes: preparing a board; forming a deformed portion in the board using a die; curving the board to a circular shape; and connecting edges of the board each other by welding.
(5) Each of the above embodiments includes the deformed portion 21 that has the flat shape. However, a non-flat oval shape or a shape having a recess in a part may be used for the deformed portion 21 if the shape includes at least a short diameter portion and a long diameter portion.
(6) In the above embodiments, the round portion 24 curves. However, this technical scope is not limited thereto and the axis of the round portion 24 may be sharply bent.
There is a demand for arranging the shield conductor effectively using space for installation of a shield conductor in a vehicle. More specifically, when a metal pipe having a circular outer periphery is arranged under a floor of a vehicle, the space under the floor requires at least the same height as the outer diameter of the metal pipe. The space under the floor has a limitation in height and thus a significant level of layout design is required for the metal pipe. On the other hand, the space that expands lateral to the metal pipe may be larger than a size required for housing the metal pipe. Therefore, the conventional technology has a problem in arrangement of the shield conductor not effectively using the space.
This invention was accomplished in view of the foregoing circumstances. An object of this invention is to provide a shield conductor that can be arranged using a space effectively.
The technology disclosed in this description includes a shield conductor including a pipe a pipe made of metal and an electric wire. The electric wire is passed through the pipe. The pipe includes a round portion and a deformed portion. The round portion has a constant outer diameter in a peripheral direction of the pipe. The deformed portion is in a different position from the round portion in an extension direction in which the pipe extends. The deformed portion has a short diameter portion and a long diameter portion having different outer diameters in the peripheral direction of the pipe. The round portion curves in the extension direction.
According to the above configuration, the shield conductor is arranged such that a direction of the short diameter portion (a thickness direction) corresponds to a narrower direction of an installation space and arranged such that a direction of the long diameter portion (a thickness direction) corresponds to a wider direction of the installation space. Thus, the shield conductor can be housed in the space using a narrower space in the direction of the short diameter portion (the thickness direction) and using a wider space in the direction of the long diameter portion (the thickness direction). With this configuration, the shield conductor can be arranged using the space effectively.
In a bending process of the deformed portion, the deformed portion of the pipe can be bent relatively easier in the short diameter direction. However, the deformed portion is not easily bent in the long diameter direction. This may restrict a routing freedom of the shield conductor. In view of the above circumstances, the pipe in this embodiment curves in the extension direction at the round portion. Thus, the pipe can be easily bent in three-dimensional directions at the round portion compared with a case in which the pipe is bent at the deformed portion. Therefore, the shield conductor can enhance the routing freedom by the round portion while effectively using the space by the deformed portion.
The following configurations are further preferable.
The deformed portion 21 has the flat shape. With this configuration, the deformed portion 21 can easily house the plurality of electric wires therein. Further, the deformed portion 21 can be arranged in the compact space compared with the other configurations.
The deformed portion is formed by deforming the cylindrical pipe. Thus, the deformed portion can be easily formed compared with a case in which the deformed portion is formed using different dies for different shapes of the deformed portion.
With the above configuration, the heat shrinkable tube that is coherent with the pipe can protect the outer surface of the pipe.
Each end of the pipe is connected to the shield member that continues from the pipe. The pipe is made of a cladding material including the first member on the inner side thereof and the second member on the outer side thereof that are layered with each other. The second member is made of the material that is less likely to cause electrical corrosion against the shield member compared with the material of the first member. The shield member covers the end part of the outer periphery of the second member. It is known that different metals cause electrical corrosion if the metals are connected to each other. However, the shield member according to this configuration is connected to the second member made of the material that is less likely to cause electrical corrosion against the shield member than the first member. Thus, electrical corrosion is less likely to cause compared with a case in which the shield member is connected to the first member.
The shield member is the braided member. The first member is made of aluminum or aluminum alloy. The second member is made of iron or iron alloy. The braided wire is generally made of the tinned copper alloy wire. If the end part of the pipe made of aluminum or aluminum alloy is connected to the braided wire, electrical corrosion is more likely to occur. However, the braided wire is connected to the outer surface of the pipe made of iron or iron alloy according to this configuration. Therefore, electrical corrosion is less likely to occur compared with a case in which the braided wire is connected to aluminum or aluminum alloy.
The electric wire is the flat electric wire including the flat conductor and the insulation coating. The flat conductor has the flat shape. The insulation coating coats the flat conductor. The flat electric wire is arranged such that the short diameter sides of the flat electric wire correspond to the short diameter portions of the deformed portion, and the long diameter sides of the flat electric wire correspond to the long diameter portions of the deformed portion. With this configuration, the shield conductor can be provided with the flat electric wire 60 having the large surface area and high heat release capability can be arranged in space that is effectively used while still can be arranged effectively using space.
The shield conductor is arranged under the floor of the vehicle.
According to the technology disclosed in this description, the shield conductor can be arranged using the space effectively.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-288003 | Dec 2010 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/079638 | 12/21/2011 | WO | 00 | 6/4/2013 |
