[0001] The present invention relates to a coil type high-voltage or high-tension resistive
cable for preventing noise which is used, for example, as an ignition cable in an
internal combustion engine and is particularly designed to obtain a satisfactory dielectric
strength without reducing a noise preventing effect with a thin resistive cable having
an outer diameter of 7 mm or smaller.
[0002] Generally, a high-voltage resistive or resistant or resistance cable is structured
as shown in Fig. 2. Specifically, a rubber layer 2 is formed around the outer circumferential
surface of a core 1 made of a bundle of high-strength fibers such as aramid fibers,
and a resistance wire 3 is wound around the outer circumferential surface of the rubber
layer 2 in a direction normal to the longitudinal axis of the core 1, thereby forming
a conductor 4. An insulator layer 5, a net 6 made of glass fibers and a sheath 7 are
formed around the outer circumferential surface of the conductor 4, i.e., over the
resistance wire one after another in this order.
[0003] A variety of modifications have been made in above high-voltage resistive cables
in order to improve the noise preventing performance, to increase the inductance per
unit length, to stabilize the resistance value and to make the cable thinner.
[0004] For example, a magnetic material such as ferrite powder has been mixed in the rubber
layer 2 in order to improve the noise preventing performance and the resistance wire
is wound densely at a small pitch in order to make the inductance per unit length
larger. Further, in order to prevent the variation of the pitch of the wound resistance
wire, the resistance wire is wound around the rubber layer in an unvulcanized state
so that it cuts in the rubber layer, and the rubber layer is then vulcanized (Japanese
Unexamined Patent Publication No. 63-168915) or the resistance wire is wound such
that it cuts in the already vulcanized rubber layer (Japanese Unexamined Patent Publication
No. 3-184213).
[0005] There has been also proposed a high-voltage resistive cable designed to eliminate
a resistance value variation, which cable is provided with an inner conductor layer
over the resistance wire 3. For example, as shown in Fig. 3, a bundling layer 8 made
of resin is formed around the outer circumferential surface of the core 1 and the
resistance wire 3 is wound around the outer circumferential surface of the bundling
layer 8. Thereafter, a partially conductive silicone rubber layer 9 which acts as
an inner conductor layer is formed over the resistance wire 3 by means of extrusion,
and the insulator layer 5, the net 6 and the sheath 7 are formed around the outer
circumferential surface of the silicone rubber layer 9 one over another in this order
(Japanese Unexamined Patent Publication No. 60-3809).
[0006] Further, there has been proposed a high-voltage resistive cable designed to have
a small diameter. A core is immersed in liquid resin so that fibers making up the
core are combined and a liquid rubber coating material including silicone rubber and
ethylene propylene rubber is applied to the surface of the core. A resistance wire
is wound around the outer circumferential surface of this coat, and an insulator layer,
a net and a sheath are formed over the resistance wire one over another in this order
(Japanese Unexamined Patent Publication No. 63-69107).
[0007] For use as an ignition cable, the high-voltage resistive cables of the above types
are required to have an outer diameter of 5 mm or smaller so that they can be bent
freely in a densely stuffed engine compartment and are also required to have a distributed
capacitance of 80 pF/m or smaller in order to prevent a voltage reduction.
[0008] Further, there is a demand for a higher voltage in an ignition system in order to
improve the mileage of an internal combustion engine. The high-voltage resistive cables
are required to have a specified dielectric strength against this high voltage.
[0009] However, when the outer diameter is set at 5 mm or smaller and the capacitance is
set at 80 pF/m or smaller under the condition of a required high voltage, the conventional
high-voltage resistive cables cannot have a specified dielectric strength without
reducing the noise preventing effect.
[0010] More specifically, the rubber layer containing a magnetic material such as ferrite
powder displays a noise preventing effect. However, being formed by means of extrusion,
this rubber layer has a large thickness and the inner conductor layer cannot be provided
between the resistance wire and the insulator layer in order for the high-voltage
resistive cable to have an outer diameter of 5 mm or smaller. Since the resistance
wire is directly coated with the insulator layer and no inner conductor layer is provided
therebetween, the dielectric strength cannot be increased.
[0011] On the other hand, since the high-voltage resistive cable provided with the inner
conductor layer to increase the dielectric strength is not provided with the rubber
layer containing ferrite powder, the noise preventing effect is reduced.
[0012] The high-voltage resistive cable obtained by applying the liquid rubber coating material
to the surface of the core and winding the resistance wire around the rubber coat
is allowed to have a small outer diameter. However, with this resistive cable, the
noise preventing effect is reduced since the liquid rubber does not contain ferrite
powder and the dielectric strength cannot be increased since no inner conductor layer
is provided.
[0013] In view of the problems residing in the prior art, it is an object of the invention
to provide a coil type high-voltage resistive cable which has an outer diameter of
5 mm or smaller, a capacitance of 80 pF/m, an improved dielectric strength against
high voltage, and an enhanced noise preventing performance.
[0014] In order to realize the object, in one embodiment, the invention is directed to a
coil type high-voltage resistive cable for preventing noise, wherein a coating material
obtained by mixing fluororubber and ferrite powder is applied to the outer circumferential
surface of a core made of reinforced fibers to form a rubber layer, that a resistance
wire is wound around the outer circumferential surface of the rubber layer in a direction
normal to the axis of the core, thereby obtaining a conductor having an outer diameter
of 0.6 mm or smaller, and that an inner conductor layer formed of partially conductive
material, a resin layer, a net and a sheath are formed around the outer circumferential
surface of the conductor one over another in this order such that the obtained coil
type high-voltage resistive cable has an outer diameter of 5 mm or smaller.
[0015] The rubber layer is preferably formed of the coating material obtained by mixing
300 to 500 parts by weight of ferrite powder with 100 parts by weight of fluororubber.
The inner conductor layer is preferably formed by extruding partially conductive polyolefin
resin.
[0016] Further, the inner conductor layer may be formed by means of extrusion after applying
a release agent to the outer circumferential surface of the conductor.
[0017] The rubber layer of the conductor is formed by applying the fluororubber coating
material containing a high concentration of ferrite powder to the outer circumferential
surface of the core. Accordingly, the rubber layer is allowed to have a small thickness
while the noise preventing performance is not reduced. This enables the partially
conductive inner conductor layer for improving the dielectric strength to be formed
between the conductor and the insulator layer by means of extrusion.
[0018] These and other objects, features and advantages of the present invention will become
more apparent upon a reading of the following detailed description and accompanying
drawings in which:
Fig. 1 is a perspective view showing a high-voltage resistive cable for preventing
a noise according to the invention;
Fig. 2 is a front view showing a conventional high-voltage resistive cable; and
Fig. 3 is a front view showing another conventional high-voltage resistive cable.
[0019] Fig. 1 shows an embodiment of a coil type high-voltage resistive cable 1 according
to the invention. The outer circumferential surface of a core 11 is coated with a
rubber layer 12, a resistance wire 13, a release agent 14, an inner conductor layer
15, an insulator layer 16, a net 17 and a sheath 18 one over another in this order.
[0020] The core 11 is obtained by twisting reinforced fibers such as aramid fibers and glass
fibers. In this embodiment, three reinforced fibers having 400 denier are twisted
to make up the core 11 having an outer diameter of 0.4 mm to 0.45 mm.
[0021] The rubber layer 12 is formed by immersing the core 11 in a liquid fluororubber based
coating material obtained by mixing ferrite powder with fluororubber and dissolving
this mixture in an organic solvent. A mixing weight ratio of fluororubber to ferrite
powder in the coating material is set at 100 : 400 in this embodiment. The rubber
layer 12 contains a high concentration of ferrite powder having a noise preventing
performance.
[0022] By applying the above ferrite rubber, the rubber layer 12 is allowed to have an outer
diameter of as small as 0.56 mm and a capacitance of 80 pF/m or smaller. In extruding
the ferrite rubber in a conventional manner, the rubber needs to be made softer so
that it can be smoothly extruded. However, in this embodiment, the ferrite rubber
is applied as a coating material. Since the rubber is dissolved in the solvent in
this embodiment, hard rubber can be used. Although the rubber layer 12 contains a
high concentration of ferrite powder, a coating strength thereof is not reduced because
of the use of hard rubber.
[0023] The resistance wire 13: a nichrome (Ni-Cr) wire having a diameter of 40 µm, is wound
around the outer circumferential surface of the rubber layer 12 densely at a small
pitch (10000 winds/m) in a direction normal to the longitudinal axis of the core 11
by a winding machine. The resistance wire 13 is wound before the applied ferrite rubber
is completely vulcanized, so that it is secured to the rubber layer 12 and the pitch
thereof does not vary.
[0024] A conductor 20 made of the core 11, rubber layer 12 and resistance wire 13 has an
outer diameter of 0.6 mm.
[0025] Since the outer diameter of the conductor 20 can be as small as 0.6 mm, the resistive
cable 10 is allowed to have an outer diameter of 5 mm or smaller even if the inner
conductor layer 15 is formed around the outer circumferential surface of the conductor
20. After applying the release agent 14 over the resistance wire 13, the inner conductor
layer 15 having an outer diameter of 0.8 mm is formed by extruding partially conductive
polyethylene (PE) obtained by mixing carbon with polyethylene. The presence of the
inner conductor layer 15 brings about an improved dielectric strength.
[0026] In forming the inner conductor layer 15 by means of extrusion, the rubber layer 12
comes off due to the pressure and heat generated during this operation unless the
rubber layer 12 has a sufficient strength. This leads to an inability to form the
inner conductor layer 15 by means of extrusion. However, since fluororubber is used
to form the rubber layer 12, the rubber layer 12 is allowed to have a coating strength
required during the extrusion of the inner conductor layer 15 even if it contains
as high a concentration as 300 to 500 parts by weight of ferrite powder which assures
a satisfactory noise preventing performance.
[0027] After the high-voltage resistive cable is fabricated, a terminal fitting (not shown)
is cramped to the conductor 20. The release agent 14 is applied so that the inner
conductor layer 15, resin layer 16, net 17 and sheath 18 can be easily peeled during
this cramping operation.
[0028] The insulator layer 16 having an outer diameter of 3.8 mm or smaller is formed around
the outer circumferential surface of the inner conductor layer by extruding ethylene
propylene copolymer which is nonflammable and has a small dielectric constant.
[0029] The net 17 made of glass fibers is wound around the outer circumferential surface
of the insulator layer 16 so as to increase a cramping force when the terminal (not
shown) is cramped to the resistive cable 10 and to enhance a breaking strength.
[0030] The sheath 18 which is an outermost layer of the resistive cable 10 is formed around
the outer circumferential surface of the net 17 by extruding ethylene propylene copolymer
or silicone rubber. The sheath 18 is formed such that the obtained resistive cable
10 has an outer diameter of 5 mm or smaller.
[0031] In the thus structured coil type high-voltage resistive cable 10, since the rubber
layer 12 is formed by applying the ferrite rubber coating material to the core 11,
the conductor 20 made of the core 11, rubber layer 12 and resistance wire 13 is allowed
to have a small outer diameter. Thus, the partially conductive inner conductor layer
15 can be formed by means of extrusion between the conductor 20 and an outer layer
21 including the insulator layer 16, net 17 and sheath 18. This inner conductor layer
15 functions to enhance a dielectric strength against a high voltage.
[0032] The rubber layer 12 of the conductor 20 contains a high concentration of ferrite
powder because it is formed of the mixture obtained by mixing 300 to 500 parts by
weight of ferrite powder with 100 parts by weight of fluororubber. Thus, the noise
preventing performance can be improved despite the thin rubber layer 12.
[0033] If the content of ferrite powder is smaller than 300 parts by weight, the noise preventing
performance is unsatisfactory because the magnetic permeability µ is low. If the content
of ferrite powder is larger than 500 parts by weight, the properties of the rubber
layer 12 such as strength and heat resistance are reduced, thereby making it impossible
to form the inner conductor layer 15 by means of extrusion.
[0034] As is clear from the above description, in the coil type high-voltage resistive cable
according to the invention, a rubber layer of a conductor is formed by applying a
fluororubber based coating material containing ferrite powder to a core. A resistance
wire is wound around the outer circumferential surface of the rubber layer in a direction
normal to the axis of the core and the rubber layer contains ferrite powder three
to five times as much as fluororubber in part by weight; accordingly the noise preventing
performance can be enhanced.
[0035] Since the ferrite rubber containing a high concentration of ferrite powder is applied
as a coating material to form the rubber layer, the thickness of the rubber layer
can be made smaller. This enables the conductor to have an outer diameter of 0.6 mm
or smaller.
[0036] As a consequence, the resistive cable is allowed to have an outer diameter of 5 mm
or smaller even if a partially conductive inner conductor layer for improving the
dielectric strength can be formed by means of extrusion between the conductor and
an outer layer including an insulator layer, a net and a sheath.
[0037] While this inventive resistive cable has an outer diameter of 5 mm or smaller and
a capacitance of 80 pF/m or smaller, the resistance value thereof does not vary upon
being subjected to high voltage, thereby improving the dielectric strength characteristic,
and the noise preventing performance thereof can be enhanced. Thus, this resistive
cable can be suitably used as an ignition cable for an automotive vehicle which requires
higher voltage.
Lists of Reference Numerals
[0038]
- 10
- High-voltage Resistive Cable
- 11
- Core
- 12
- Rubber Layer
- 13
- Resistance Wire
- 14
- Release Agent
- 15
- Inner Conductor Layer
- 16
- Insulator layer
- 17
- Net
- 18
- Sheath
- 20
- Conductor
1. A coil type high-voltage resistive cable (10) for preventing noise, comprising:
a rubber layer (12) which is applied to the outer circumferential surface of a
core (11) made of reinforced fibers as a coating,
a resistance wire (13) which is wound around the outer circumferential surface
of the rubber layer (12) in a direction normal to the longitudinal axis of the core
(11), thereby obtaining a conductor (20), and
an intermediate layer means (15,16), a net (17) and a sheath (18) which are formed
around the outer circumferential surface of the conductor (20) one over another in
this order such that the obtained coil type high-voltage resistive cable (10) has
an outer diameter of 5 mm or smaller.
2. A cable (10) according to claim 1, wherein the rubber layer (12) is made by applying
a coating material obtained by mixing fluororubber and ferrite powder to the outer
circumferential surface of the core (11) and wherein the conductor (20) has an outer
diameter of 0.6 mm or smaller.
3. A cable (10) according to claim 1 or 2, wherein a release agent (14) is provided between
the conductor (20) and the intermediate layer means (15, 16).
4. A cable (10) according to claim 1 or 2, wherein the intermediate layer means comprises
an inner conductor layer (15) and a resin layer (16).
5. A cable (10) according to one or more of claims 1 to 4, wherein the core (11) is made
to have an outer diameter of 0.4 to 0.45 mm by twisting three reinforced aramid or
glass fibers of about 400 denier each.
6. A cable (10) according to one or more of claims 1 to 5, wherein the rubber layer (12)
is formed of a coating material mixture of 300 to 500 parts by weight of ferrite powder
and 100 parts by weight of fluororubber.
7. A cable (10) according to claim 6, wherein the rubber layer (12) is formed of a coating
material mixture of 300-400 parts by weight of ferrite powder and 100 parts by weight
of fluororubber.
8. A cable (10) according to claim 6, wherein the rubber layer (12) is formed of a coating
material mixture of 400-500 parts by weight of ferrite powder and 100 parts by weight
of fluororubber.
9. A cable (10) according to claim 6, wherein the rubber layer (12) is formed of a coating
material mixture of 400 parts by weight of ferrite powder and 100 parts by weight
of fluororubber.
10. A cable (10) according to one or more of claims 1 to 6, wherein the inner conductor
layer (15) is formed by extruding partially conductive polyolefin resin.
11. A method for making a coil type high-voltage resistive cable (10) for preventing noise,
said method comprising the steps of:
providing an elongate core (11) made of reinforced fibers;
applying a rubber layer (12) as a coating on the core (11);
winding a resistance wire (13) around the rubber layer (12) in a direction normal
to the longitudinal axis of the core (11) to define a conductor (20);
applying an inner conductor layer (15) to the conductor (20);
applying a resin layer (16) to the inner conductor layer (15);
applying a net (17) around the resin layer; and
applying a sheath (18) around the net (17) to define the high-voltage resistive
cable.
12. The method of claim 16, wherein the step of coating the rubber layer (12) on the core
(11) comprises coating the core (11) with a rubber layer (12) defining a mixture of
300 to 500 parts by weight of ferrite powder and 100 parts by weight of fluororubber.
13. The method of claim 17, wherein the step of winding the resistance wire (13) comprises
winding the resistance wire (13) at a pitch of approximately 10,000 lines per meter.
14. The method of claim 17, further comprises the step of vulcanizing the rubber layer
(12) after coating the rubber layer (12) onto the core (11) and wherein the step of
winding the resistance wire (13) is carried out prior to completing the vulcanizing
step.