EP0938099A1 - Flachkabel und sein herstellungsverfahren - Google Patents

Flachkabel und sein herstellungsverfahren Download PDF

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Publication number
EP0938099A1
EP0938099A1 EP98919609A EP98919609A EP0938099A1 EP 0938099 A1 EP0938099 A1 EP 0938099A1 EP 98919609 A EP98919609 A EP 98919609A EP 98919609 A EP98919609 A EP 98919609A EP 0938099 A1 EP0938099 A1 EP 0938099A1
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EP
European Patent Office
Prior art keywords
flat cable
resin
extrusion coating
rectangular conductors
coating layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP98919609A
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English (en)
French (fr)
Inventor
Hajime-The Furukawa Electic Co. Ltd. WATANABE
Hiroshi-The Furukawa Electric Co. Ltd. HIRUKAWA
Mizuki-The Furukawa Electric Co. Ltd. OHIKE
Takuya-The Furukawa Electric Co. Ltd. NISHIMOTO
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Furukawa Electric Co Ltd
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Furukawa Electric Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Furukawa Electric Co Ltd filed Critical Furukawa Electric Co Ltd
Publication of EP0938099A1 publication Critical patent/EP0938099A1/de
Withdrawn legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/08—Flat or ribbon cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/143—Insulating conductors or cables by extrusion with a special opening of the extrusion head
    • H01B13/144—Heads for simultaneous extrusion on two or more conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/08—Flat or ribbon cables
    • H01B7/0823—Parallel wires, incorporated in a flat insulating profile

Definitions

  • the present invention relates to a flat cable and a manufacturing method therefor and, especially, to a flexible flat cable which has a superior lifetime when subjected to a repetition of flection and stretch and is functional as, for example, a cable for a rotary connector on an automotive steering wheel (steering roll connector) or for a harness, and a method of manufacturing the flat cable with high productivity.
  • a printing section of a printer is connected to a section for transmitting operation signals with a flat cable so that a preset printing operation is performed on receipt of the operation signal from the transmitting section.
  • the printing operation sets the flat cable in a jerky swing from flection to stretch or the reversal. Therefore, the flat cable to be used in such a field is rehired to remain unbroken or unaffected even when being subjected to repeated flection and stretch for a long period of time.
  • a repetition of flection and stretch implies incessant shifts and turns of bending radii or variant points of bending on a flat cable.
  • This flat cable A is made up of outer layers 3, 3, resin films such as electrical-insulating polyethylene terephthalate films, inner layers 2, 2, each having an adhesive resin composition such as a saturated polyester copolymer interposed between the resin films 3, 3, and a plurality (four in the FIG. 1) of rectangular conductors 1 arranged in parallel at predetermined intervals, which are embedded in the inner layers 2, 2.
  • the foregoing inner layers 2 and outer layers 3 combine to form the insulating layer of the topical flat cable.
  • This flat cable A is manufactured in a production line as shown in FIG. 2.
  • a plurality of rectangular conductors 1 are reeled out from a bobbin 4 in a state of being arranged in parallel at predetermined intervals.
  • resin films 3a and 3b which are formed with a layer 2 of adhesive resin composition are reeled out from a pair of spools 5a and 5b onto the surfaces of the rectangular conductors 1, and led to rolling surfaces of a pair of heating rolls 6a and 6b in contact with the upper and lower faces of the rectangular conductors 1.
  • all the components are heat-pressed into a flat cable A shown in FIG. 1, and is wound around a spool 7. If a thermal crosslinking type of adhesive resin composition is applied then, crosslinking takes place as concurrent with the heated bonding press in a process of passing bonding press through the heated rolls 6a and 6b.
  • a pair of heating rolls 6c and 6d are further disposed on the downstream side of the heating rolls 6a and 6b in the production line shown in FIG. 2 to give a second heat bonding press to the flat cable through the heating rolls 6a and 6b.
  • the whole line speed can be more increased than in the production line shown in FIG. 2.
  • any of Unexamined Japanese Patent Publication No. 49-57381, Unexamined Japanese Patent Publication No. 62-206710, and Unexamined Japanese Patent Publication No. 1-276514 has disclosed a method of manufacturing the flat cable by using the extrusion coating process.
  • Unexamined Japanese Patent Publication No. 49-57381 has proposed a method in which a hollow tube made of a resin is extruded to cover the periphery of a plurality of insulated conductors; then, the whole is led to a pair of rolls having an annular groove to thermally form the hollow tube into a flat cable.
  • this prior art requires the insulated conductors (to be prepared in advance), and the rolls having an annular groove, resulting in an increase in manufacturing cost. Further, since the whole insulating layer has a two-fold construction, consisting of the insulating layer for the insulated conductors and the layer of a formed hollow tube, not only the material cost increases, but also it is difficult to form a thin insulating layer. Therefore, this method is unsuitable as a manufacturing method for a flat cable which uses rectangular conductors as conductors and is equipped with an excellent flexing property.
  • Unexamined Japanese Patent Publication No. 62-206710 has proposed a method of manufacturing a flat cable, in which an ordinary round conductors are extrusion coated with a resin, and when the resin is in a semi-molten state, the structure is led to a die (forming block) having a desired cross-section to cool and set the resin.
  • Unexamined Japanese Patent Publication No. 1-276514 has proposed a method of manufacturing a flat cable, in which when a plurality of rectangular conductors are extrusion coated with a soft insulator, gaps between the rectangular conductors are adjusted considering the degree of heat shrinkage of soft insulator in extrusion coating.
  • An object of the present invention is to provide a flat cable of outstanding flexibility (bending characteristics) as contrasted with a conventional flat cable and a manufacturing method for the flat cable in which an extrusion coating process is applied to realize high manufacturing rates.
  • the present invention provides a flat cable comprising a plurality of rectangular conductors arranged in parallel which are embedded in an insulating resin layer, the insulating resin layer in contact with at least the rectangular conductors being an extrusion coating layer formed of a thermoplastic resin with a flexural modulus of 800 to 2400 MPa. Also, the present invention provides a manufacturing method for a flat cable comprising the steps of feeding a plurality of rectangular conductors arranged in parallel to a cross-head of an extruder, supplying a thermoplastic resin with a flexural modulus of 800 to 2400 MPa, and extrusion coating the rectangular conductors.
  • FIG. 4 shows a cross-sectional structure of a first example of a flat cable in accordance with the present invention.
  • the extrusion coating layer has a unitary structure, not a bonded structure of two films, unlike a conventional flat cable shown in FIG. 1. Therefore, there is no possibility that an upper portion 8a and a lower portion 8b of the extrusion coating layer 8, which is an insulating resin layer, are separated from each other. Specifically, even if the whole structure is flexed and stretched repeatedly, because a pressure applied locally to the rectangular conductor 1 is diffused moderately, there is no possibility that the extrusion coating layer 8 is made separate by a stress generated at the time of flection.
  • the rectangular conductor 1 and the extrusion coating layer 8 be bonded to each other, they do not necessarily need to be bonded.
  • the extrusion coating layer 8, described onward is formed, the thermoplastic resin with which the rectangular conductor 1 is extrusion coated shrinks. Therefore, even if the rectangular conductor 1 and the extrusion coating layer 8 are not bonded to each other, they are in tight contact with each other, so that the flexibility is not degraded.
  • the flat cable can be manufactured inexpensively at a high speed. Also, the flat cable can be downsized because the mutual intervals between the rectangular conductors 1 arranged in parallel can be made shorter than in the conventional laminate system.
  • Preferred material examples of the rectangular conductor 1 are oxygen free copper, phosphor bronze, tough pitch copper, tin-plated copper, nickel-plated copper, if a few named off.
  • a strip of copper foil, a rolled or flattened wire, or the like can be used as discretionary. Further, the rectangular conductors 1 may be varied in thickness or width according to the application of a flat cable to be manufactured.
  • thermoplastic resin to form the aforementioned insulating resin layer 8 is required to have a flexural modulus of 800 to 2400 Mpa, preparatory to the later-described extrusion coating.
  • the flexural modulus of the thermoplastic resin should be 1000 to 2000 MPa.
  • the extrusion coating layer 8 is formed by using a thermoplastic resin whose flexural modulus before extrusion coating is lower than 800 MPa, the extrusion coating layer 8 cannot sufficiently diffuse the stress applied to the flat cable during flection, so that the rectangular conductors 1 of the obtained flat cable are broken at an early stage. If the extrusion coating layer 8 is formed by using a thermoplastic resin whose flexural modulus before extrusion coating is higher than 2400 MPa, cracks and the like occur in the extrusion coating layer 8 before the life of the rectangular conductors 1 is exhausted by flection, so that the function as the flat cable cannot be maintained.
  • the flexural modulus referred to in the present invention is defined as a value obtained by the measuring method specified in ASTM D790 (value at a temperature of 23°C).
  • thermoplastic resin count as preferred examples of such a thermoplastic resin.
  • the polyamide resin having high self-lubricity and wear resistance, is suitable as a material for enhancing the life of a flat cable subjected to repetitive Election and stretch-
  • the polyamide resin has a low natural frequency and a large logarithmic decrement, and therefore can absorb vibration, where the flat cable in motion is restrained from generating noise, so that it can preferably be used for manufacturing, for example, an automotive flat cable.
  • it can preferably be used for a flat cable for an automotive rotary connector on a steering wheel.
  • the extrusion coating of the rectangular conductors 1 can preferably be performed smoothly even if the line speed of the later-described production line is increased, so that a flat cable in which the aforementioned characteristics are high can preferably be manufactured with high productivity.
  • Such polyamide resin includes, for example, a ring-opening polymer obtained by various types of ring-opening polymerization of ⁇ -caprolactam, ⁇ -laurocaprolactam, and like; a condensation polymer made of diamine such as hexamethylenediamine, methaxylylenediamine and 2,4,4- or 2,2,4-trimethylhexamethylenediamine, and a dibasic acid such as adipic acid, sebacic acid, dodecanedione acid and terephthalic acid; a condensation polymer made of amino calboxylic acid such as ⁇ -amino undecanoic acid and 12-amino dodecanoic acid, and the like.
  • These substances are generally known as nylon; namely, nylon 6, nylon 66, nylon 610, nylon 12, nylon 11, nylon 46, nylon MXD ⁇ 6, nylon 6/66,
  • nylon 12 is preferable because it has particularly higher flexibility than the aforementioned polyamide resins, also has a high adhesive property with metal, and the flexibility can be secured and the flexing property is not degraded even at low temperatures, in addition to the aforementioned properties.
  • nylon 12 is preferably used for manufacturing automotive flat cables.
  • a second thermoplastic resin desirable for the extrusion coating layer 8 is a polyolefin resin.
  • This polyolefin resin is preferable because it generally does not adhere to the rectangular conductor 1, so that the flat cable manufactured of this resin can be terminated easily.
  • polystyrene resin for example, polypropylene, polyethylene, ionomer can count.
  • polypropylene is preferable because it has particularly high extrusion workability and a small difference in shrinkage between the longitudinal and transverse directions in an extrusion coating, in addition to the aforementioned properties, so that flat cables with intended design dimensions can be manufactured with a high yield and therefore at a low cost.
  • a polymer alloy with a sea-island structure is also a desirable thermoplastic resin. If a polymer alloy is used, extrusion coating can be performed smoothly even if the line speed of production line is increased, and also the stresses during flection are diffused and attenuated because an island component is distributed in a sea component, so that very high repeated flection life characteristics can be obtained.
  • a polymer alloy for example, (1) a polymer alloy in which polyamide resin is the sea component and polypropylene modified with epoxy etc. is the island component, (2) a polymer alloy in which polypropylene is the sea component and polyamide resin is compatibilized by polypropylene modified with acid etc.
  • a polymer alloy in which ethylene-propylene copolymer is the sea component and polypropylene is the island component (3) a polymer alloy in which ethylene-propylene copolymer is the sea component and polypropylene is the island component, (4) an ethylene-propylene block copolymer, (5) a polymer alloy in which polyamide resin is graft polymerized to modified polyphenylene ether, and (6) a polymer alloy in which modified polyphenylene ether and polybutylene terephthalate are blended with each other can count.
  • the polymer alloy which contains polyamide resin and epoxy-modified polypropylene as main ingredients is preferable because of being capable of enhancing the life of a flat cable subjected to repetitive reflection and stretch. This polymer alloy will be explained below.
  • This polymer alloy contains polyamide resin as the sea component and epoxy-modified polypropylene, described later, as the island component.
  • polyamide resin the polyamide resins already exemplified as preferred examples of thermoplastic resin used in the present invention can be used.
  • the epoxy-modified polypropylene is synthesized by polymerizing polypropylene polymer, epoxy group-containing vinyl monomer, and aromatic vinyl monomer in the presence of a free-radical initiator.
  • polypropylene polymer used for synthesizing the epoxy-modified polypropylene a homopolymer of propylene, or a copolymer of propylene, the main ingredient, and olefin monomer or ethylene vinyl monomer, which contains polypropylene of 75 wt% or higher is used.
  • isotactic polypropylene, propylene-ethylene copolymer, propylene-butene copolymer, or the like can count. These materials may be used singly or by mixing two or more kinds. Further, they may be used by mixing with other polymers unless the property is reduced.
  • epoxy group-containing vinyl monomer for example, glycidylmethacrylate, glycidylacrylate, allylglycidylether, and methacrylglycidylether can count. These materials may be used singly or with a mixture of two or more kinds. The glycidylmethacrylate is particularly preferable.
  • the usage of the epoxy group-containing vinyl monomer should preferably be 10 parts by weight or less with respect to 100 parts by weight of the polypropylene polymer. If the usage is more than 10 parts by weight, not only the obtained epoxy-modified polypropylene becomes lower in molecular weight but also the hygroscopicity (water absorbency) is enhanced, so that the mechanical strength is lowered.
  • the preferred usage ranges from 0.1 to 5 parts by weight with respect to 100 parts by weight of the polypropylene polymer.
  • the aromatic vinyl monomer is & component for increasing the graft polymerization efficiency of epoxy group-containing vinyl monomer to propylene polymer, and for increasing the compatibility between epoxy-modified polypropylene, (island component) in an intended polymer alloy, and polyamide resin, (the sea component) therein.
  • styrene, methylstyrene, vinyltoluene, vinylxylene, ethyl vinylbenzene, isopropylstyrene, chlorostyrene, dichlorostyrene, and bromostyrene can count. These materials may be used singly or with mixture of two or more kinds.
  • the usage of the aromatic vinyl monomer should preferably be 50 parts by weight or less with respect to 100 parts by weight of the propylene polymer.
  • the usage of the aromatic vinyl monomer should preferably be equal to or more than the usage of the epoxy group-containing vinyl monomer.
  • the usage of the aromatic vinyl monomer should preferably be one to five times that of the epoxy group-containing vinyl monomer.
  • the synthesis using the aforementioned components is carried out through the use of a closed vessel such as a Banbury mixer or a kneader such as an extruder in the presence of a free-radical initiator.
  • a closed vessel such as a Banbury mixer or a kneader such as an extruder in the presence of a free-radical initiator.
  • powder- or pellet-form propylene polymer is supplied to the extruder to be heated to a temperature of 130 to 250°C and melted under pressure. Then, predetermined quantities of free-radical initiator, epoxy group-containing vinyl monomer, and aromatic vinyl monomer are added to the melted propylene polymer and kneaded to carry out polymerization reaction. Thereafter, a strand led from a die is cooled and pelletized by a pelletizer.
  • t-butyl peroctate bis(t-butyl peroxy)trimethyl cyclohexane, cyclohexanoneperoxide, benzoylperoxide, dicumylperoxide, t-butylperbenzoate, dimethyl-di(t-butyl peroxy)hexane, and dimethyl-di(t-butyl peroxy)hexyne can count.
  • the usage of the free-radical initiator should usually be 0.1 t 10 parts by weight, preferably be 1 to 5 parts by weight, with respect to 100 parts by weight of the total quantity of the epoxy group-containing vinyl monomer and the aromatic vinyl monomer.
  • the propylene polymer is, unlike ethylene polymer, a radical degradative polymer, of which main chains are delinked, simply when heated and melted; of which molecular weight becomes low. Therefore, at the time of the aforementioned molten polymerization reaction, it is preferable that a stabilizer incapable of retarding the aforesaid function of the epoxy group- containing vinyl monomer and aromatic vinyl monomer be further added to the reaction system.
  • a stabilizer for example, a hindered phenol stabilizer, a phosphoric stabilizer, metallic soap, and an antiacid adsorbent, such as hydrotalcite can count. These materials may be added singly or with a mixture of two or more kinds. The quantity of addition is usually 0.01 to 1 part by weight, preferably 0.05 to 0.5 part by weight with respect to 100 parts by weight of polypropylene polymer.
  • the polymer alloy used for the formation of extrusion coating layer is prepared.
  • nylon 6 is used as the polyamide resin, the flexibility of a flat cable is enhanced, and the extrusion coating of rectangular conductors can preferably performed smoothly even if the line speed of the production line is increased.
  • the mixing ratio of these materials can be set at 5 to 50 wt% of an epoxy-modified polypropylene, and reciprocally 95 to 50 wt% of polyamide resin.
  • the mixing ratio of an epoxy-modified polypropylene is lower than 5 wt%, the effect that the stresses exerted on the flat cable during flection and stretch are diffused sufficiently is not exhibited; consequently, the life under repetitive flection and stretch becomes insufficient. If the mixing ratio of the epoxy-modified polypropylene is higher than 50 wt%, the elongation and strength of the resultant polymer alloy at high temperatures are decreased, so that it becomes difficult to perform extrusion coating, resulting in difficulty in obtaining a flat cable with high dimensional accuracy.
  • This flat cable B1 can be manufactured in a production line shown in FIG. 5.
  • a plurality of rectangular conductors 1 are pulled off a bobbin 4 as arranged in parallel at predetermined intervals, and passes through a cross-head 10 mounted on an extruder 9, where extrusion coating of the rectangular conductors 1 is performed.
  • the obtained flat cable B1 is reeled around a spool 7.
  • an extruding nipple 11 and an extruding die 12 are arranged as shown in FIGS. 6 and 7.
  • the extruding nipple 11 is formed with a plurality of (four in FIG. 6) nipple holes for arranging the fed rectangular conductors 1 paralleling at predetermined intervals.
  • the extruding die 12 is formed with a die hole 12a for regulating the external form of an extrusion coating layer to be formed.
  • the rectangular conductors 1 fed to the extrusion nipple 11 are arranged in parallel by the nipple holes 11a, coated with a thermoplastic molten resin supplied to a surrounding space 12b (inners of cross-head) in a process of passing through a space between the extruding nipple 11 and the die 12, and passes through the die hole 12a, by which the extrusion coating layer is formed on the rectangular conductors 1.
  • thermoplastic resin used at this time is as described above.
  • the molecular weight of this thermoplastic resin is generally unspecific, but the thermoplastic resin having a relative viscosity ( ⁇ rel) not lower than 0.5, preferably not lower than 2.0, is desirable because it allows smooth formation of the extrusion coating layer, and enhances the mechanical strength properties, such as toughness and elongation of the formed extrusion coating layer, so that the flexibility of the obtained flat cable is enhanced, and further the dimensional accuracy can be increased.
  • a distance between the nipple holes 11a of the extruding nipple 11 and the die opening (bearing) 12a of the die 12 is set at a value (space) to allow the rectangular conductors 1, a slight widthwise move so that they can be brought into the final layout before the rectangular conductors coming out of the nipple holes 11a as arranged in parallel enter the die hole 12a.
  • the shape and pressure inside the die 12 be adjusted so that the pressures of molten resin exerted on the upper and lower faces of the rectangular conductors 1 fed from the nipple holes 11a are equal. This is because the obtained flat cable is prevented from being uneven in thickness; that is, the thicknesses of the extrusion coating layers overlying and underlying the rectangular conductors 1 are made more uniform.
  • the total thickness of the obtained flat cable is determined by the shapes and sizes of the extruding nipple 11 and the extruding die 12. However, since the molten resin somewhat shrinks after extrusion coating, it is preferable to design the shapes and sizes of the extruding nipple and extruding die, considering the amount of shrinkage.
  • the flat cable B1 coming out of the cross-head 10 is cooled down with disallowing the whole to curve after being cooled.
  • the flat cable may be allowed to cool in the air because the whole molten resin will uniformly set by nature in the cooling process.
  • water cooling should be avoided because water cooling causes a difference in shrinkage between the outside and inside of the molten resin, by which the flat cable is curved as a whole, so that a flat shape cannot be obtained.
  • the thicknesses of the extrusion coating layers 8 in contact with the upper and lower faces of the rectangular conductor are set at 0.02 to 0.5 mm. If the thickness is less than 0.02 mm, the property to materialize an insulating layer is insufficient. If the thickness is larger than 0.5 mm, the flat cable itself becomes resistant to flection, so that the function for a flat cable lessens, and, depending on the material used, cracks occur at the time of repeated flection and stretch, which degrades the flexibility.
  • water bathing or hot water bathing may be applied to supplement control over the temperature at which the flat cable is reeled around the spool finally.
  • a preheating device is interposed between the bobbin 4 and the cross-head 10, by which the rectangular conductors 1 may be preheated before being fed to the cross-head 10.
  • the preheat temperature is selected depending on the resin used, but it is set usually in the temperature range of 100 to 350°C, specifically in the temperature range of 120 to 280°C.
  • a gas heating device or a commercially available conductor heating device or high frequency induction heating device can be used.
  • the rectangular conductors 1 may be led to the cross-head 10 without being preheated. Alternatively, they may be led to the cross-head 10 after being heated to a temperature not exceeding the temperature of resin supplied to the cross-head 10. Such methods can improve the shape stability of flat cable.
  • a silane coupling agent is applied onto the surface of the rectangular conductor before being extrusion coated, the adhesion property of the rectangular conductor with an extrusion coating layer is improved, so that the flexibility of the flat cable can be enhanced.
  • silane coupling agent an agent having at least one type of functional group selected from a group of epoxy group, methacryloxy group, amino group, chloro group, and mercapto group and a hydrolyzable group such as alkoxy group such as methoxy group and ethoxy group can be cited as an example.
  • an epoxy type agent such as 3-glycidoxypropyltrimethoxysilane and 2-(3,4-epoxycyclohexyl) ethyltrimethoxysilane
  • a methacryloxy type agent such as 3-methacrylopropyltrimethoxysilane
  • an amino type agent such as 3-aminopropyltriethoxysilane, 3-aminopropylmethyldimethoxysilane, N-(2-aminoethyl)3-aminopropyltriethoxysilane, and N-(2-aminoethyl)3-aminopropylmethyldimethoxysilane
  • a chloro type agent such as 3-chloropropyltrimethoxysilane
  • a mercapto type agent such as 3-mercaptopropyltrimethoxysilane
  • the application method may be such that the silane coupling agent is diluted with a solvent such as water, methanol, ethanol, and toluene, and the resultant solution is applied by using a brush or application roll, or dipping in the same solution, followed by drying is performed.
  • a solvent such as water, methanol, ethanol, and toluene
  • FIG. 8 shows another flat cable B2.
  • This flat cable B2 is formed further with an extrusion coating layer 13 on the outside of the extrusion coating layer 8 of the flat cable B1.
  • This extrusion coating layer 13 may be formed of the same material as that of the extrusion coating layer 8, or formed of another material such as polvinylchloride, polyethylene, polystyrene, polycarbonate, polyethyleneterephthalate, polyacetal, polybutyleneterephthalate, modified polyphenyleneether, fluororesin, and rubber. Also, the extrusion coating layer 13 is not limited to the case where the whole periphery of the extrusion coating layer 8 is covered, and a part of periphery, for example, one face of cable or both ends thereof may be covered.
  • the extrusion coating layer is not limited to the two-layer construction as shown in FIG. 8, and more numbers of layers may be formed.
  • the extrusion coating layer directly covering the rectangular conductors 1 needs to be formed of the aforementioned thermoplastic resin.
  • FIG. 9 shows one more flat cable B3.
  • the thickness of the extrusion coating layer 8 between the rectangular conductors 1 arranged in parallel and at both sideends is decreased.
  • This flat cable B3 can be manufactured by making the shape of the die hole 12a of the die 12 shown in FIGS. 6 and 7 the same as the external form of the cable B3 shown in FIG. 9. Alternatively, it can be manufactured by adjusting the amount of molten resin into the internal space 12b of the cross-head 10 in which the extruding die 12 and the extruding nipple 11, for example, shown in FIGS. 6 and 7 are disposed and by making the molten resin shrink naturally.
  • the rectangular conductors 1 are too thin, handling is difficult to perform, and specifically extrusion coating is difficult to perform. Also, the mass-producibility of rectangular conductor decreases.
  • the thickness of the rectangular conductor used should preferably be 0.02 to 0.5 mm, and particularly the thickness of 0.03 to 0.2 mm is preferable. Also, the width of the rectangular conductor 1 is determined appropriately considering the intended application of the flat cable, but it is usually about 0.9 to 4 mm.
  • the thicknesses of an upper face portion 8a and a lower face portion 8b of the extrusion coating layer located above and below the rectangular conductor 1 each should preferably be 0.02 to 0.5 mm. If this thickness is smaller than 0.02 mm, it is difficult to perform extrusion coating and at the same time the reliability of the extrusion coating layer as an insulating layer is reduced. If this thickness is larger than 0.5 mm, the bending property is decreased remarkably, so that the function as a flat cable is reduced.
  • the thicknesses of the extrusion coating layers 8a and 8b should more specifically be 0.030 to 0.2 mm.
  • a flat cable was manufactured using the production line shown in FIG. 5 in the following manner.
  • the mutual intervals of the nipple holes 11a of the extrusion nipple 11 in the cross-head 10 had been set at 1.0 mm.
  • Nylon 12 (Daiamide L2140 manufactured by DAICEL-HÜLS LTD., having a flexural modulus of 1200 MPa under the measuring conditions of a temperature of 23°C and a relative humidity of 50%) was supplied to the cross-head 10 at a temperature of 240°C, thereby performing extrusion coating of the rectangular conductors, and was cooled by air.
  • the line speed at this time is given in Table 1.
  • Example 1 a flat cable B3 having a cross-sectional construction shown in FIG. 9 was continuously obtained.
  • the respective thicknesses of the upper face portion 8a and the lower face portion 8b were 0.08 mm, and the thickness of the central portion between the rectangular conductors was 0.23 mm.
  • the width of the obtained flat cable B3 was 9 mm.
  • the obtained flat cable is referred to as Example 1.
  • a flat cable was manufactured in the same way as Example 1 except that the resin used for forming the extrusion coating layer 8 was polypropylene (Chissopolypro 2038 manufactured by Chisso Corporation, having a flexural modulus of 1200 MPa), and the temperature of resin supplied to the cross-head was 210°C.
  • the obtained flat cable is referred to as Example 2.
  • a flat cable was manufactured in the same way as Example 2 except that the resin used for forming the extrusion coating layer 8 was polypropylene (Chissopolypro 2527 manufactured by Chisso Corporation, having a flexural modulus of 1960 MPa).
  • the obtained flat cable is referred to as Example 3.
  • a flat cable was manufactured in the same way as Example 1 except that the obtained epoxy-modified polypropylene pellet of 30 wt% and Ubenylon 1013NU2 (trade name, manufactured by Ube Industries, Ltd.) of 70 wt% were mixed, and the mixture was supplied to the cross-head at a temperature of 260°C.
  • the obtained flat cable is referred to as Example 4.
  • the flexural modulus of the aforesaid mixture was 1640 MPa (measured value under the conditions of a temperature of 23°C and a relative humidity of 50%).
  • a flat cable was manufactured in the same way as Example 1 except that the resin used for forming the extrusion coating layer 8 was a polymer alloy (Zairon 540Z manufactured by Asahi Chemical Industry Co., Ltd., having a flexural modulus of 2450 MPa) of polystyrene and polyphenylene ether, and the temperature of the resin supplied to the cross-head was 270°C.
  • the obtained flat cable is referred to as Comparative Example 1.
  • a flat cable was manufactured in the same way as Example 1 except that the resin used for forming the extrusion coating layer 8 was high-density polyethylene (J-REX-HD-C3502E manufactured by Nippon Polyolefin, having a flexural modulus of 780 MPa), and the temperature of the resin supplied to the cross-head was 210°C.
  • the obtained flat cable is referred to as Comparative Example 2.
  • polyethyleneterephthalate films 3a and 3b with a thickness of 38 ⁇ m, to each of which polyester film 2,2 with a thickness of 47 ⁇ m is laminated on the inside, were supplied to the heating rolls 6a, 6b after being adhered to the upper and lower faces of the rectangular conductors 1.
  • the whole structure was heat-compressed under the conditions of a heating roll surface temperature of 150°C and a roll surface pressure of 5 kg/cm 2 .
  • the line speed at this time is given in Table 1.
  • This flat cable is referred to as Conventional Example 1.
  • the operation was performed under the same conditions as those of Conventional Example 1 except that the heating rolls 6c and 6d disposed on the downstream side of the heating rolls 6a and 6b were operated under the conditions of a surface temperature of 120°C and a roll surface pressure of 5 kg/cm 2 , and the line speed was increased as given in Table 1.
  • the obtained flat cable is taken as Conventional Example 2.
  • Each flat cable was cut to a length of 400 mm to get a specimen, and the specimen was placed in a U shape with a bending diameter of 10 mm. One end thereof is fixed, and the other end was subjected to flexing motion of 100 cycles per minute with a stroke of 200 mm. The number of cycles before the first electrical breakage (including momentary breakage) occurred in the rectangular conductor was measured. The higher the value is, the longer the useful life at the time of flection of the flat cable is. The results are given in Table 1.
  • Example 1 In manufacturing the flat cable of Example 1, a flat cable was manufactured by changing the thickness of the rectangular conductor used, the thicknesses of upper and lower face portions of the extrusion coating layer formed, and the line speed as shown in Table 2, and the flexing property of the obtained flat cable was investigated. The results are given in Table 2. Thickness of rectangular conductor (mm) Thickness of upper or lower face portion of extrusion coating layer (mm) Line speed (m/min) No. of cycles of flexing motion (cycle) Example 5 0.14 0.04 20 140,000 Example 6 0.14 0.08 20 190,000 Example 7 0.14 0.35 20 400,000 Example 8 0.25 0.25 20 70,000
  • the flat cable in accordance with the present invention has very excellent life characteristics at the time of repeated flection.
  • the line speed can be made ten or more times as high as that of the conventional production line, so that functional flat cables can be manufactured at a low cost with high productivity.
  • the flat cable in accordance with the present invention can be attached with a very high industrial value as a cable for applications, which force a heavy repetition of flexing motion, such as various kinds of communication equipment, household electrical appliances, photocopy equipment, computers, printers, image scanners, word processors, CD players, automotive steering-wheel roll connectors, and other automotive wires. Also, this flat cable can be used as an automotive wire harness and the like.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulated Conductors (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
EP98919609A 1997-05-16 1998-05-15 Flachkabel und sein herstellungsverfahren Withdrawn EP0938099A1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP12738497 1997-05-16
JP12738497 1997-05-16
PCT/JP1998/002145 WO1998052199A1 (fr) 1997-05-16 1998-05-15 Cable plat et procede de fabrication

Publications (1)

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EP0938099A1 true EP0938099A1 (de) 1999-08-25

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EP (1) EP0938099A1 (de)
JP (1) JP3700861B2 (de)
KR (1) KR20000023728A (de)
CN (1) CN1226993A (de)
WO (1) WO1998052199A1 (de)

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EP1389784A1 (de) * 2002-08-15 2004-02-18 Panta GmbH Verfahren zur Herstellung klebstofffreier Flachleiter-Bandkabel
EP1453068A1 (de) * 2003-02-26 2004-09-01 I & T Flachleiter Produktions-Ges.m.b.h. Flachleiterkabel
US6954983B2 (en) 2000-11-20 2005-10-18 Reifenhäuser GmbH & Co Maschinenfabrik Method for producing flat cables
US7989701B2 (en) 2007-11-27 2011-08-02 Sabic Innovative Plastics Ip B.V. Multiconductor cable assembly and fabrication method therefor
WO2012154256A1 (en) * 2011-02-17 2012-11-15 Advanced Bionics Ag Wire constructs
US20130000950A1 (en) * 2010-03-12 2013-01-03 Yazaki Corporation Extruded flexible flat cable
WO2013014903A1 (en) * 2011-07-27 2013-01-31 Yazaki Corporation Flat cable and method for preparing the same
EP2879248A4 (de) * 2012-07-26 2016-03-23 Furukawa Electric Co Ltd Drehbare verbindervorrichtung
DE102016114944A1 (de) * 2016-08-11 2018-02-15 Lisa Dräxlmaier GmbH Elektrische Flachleiteranordnung und Herstellungsverfahren für eine solche

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DE10103367C2 (de) * 2000-11-20 2002-10-24 Reifenhaeuser Masch Verfahren zum Herstellen von Flachbandkabeln
JP2002358837A (ja) 2001-06-01 2002-12-13 Teijin Ltd フラットケーブルおよび被覆用ポリエステル樹脂組成物
JP4618536B2 (ja) * 2004-07-01 2011-01-26 株式会社潤工社 平坦状ケーブル
CN1327456C (zh) * 2005-01-04 2007-07-18 天津竹内装璜有限公司 挠性扁平电缆母材和挠性扁平电缆及其制造方法
CN100433201C (zh) * 2005-09-08 2008-11-12 新普科技股份有限公司 片状柔性导体制造方法
JP2008123755A (ja) * 2006-11-09 2008-05-29 Auto Network Gijutsu Kenkyusho:Kk フラットケーブル
CN101236799B (zh) * 2007-01-30 2011-06-08 住友电气工业株式会社 平型电线及其制造方法
JP5111890B2 (ja) * 2007-02-28 2013-01-09 タツタ電線株式会社 可動用フラットケーブル
JP5144955B2 (ja) * 2007-05-01 2013-02-13 株式会社オートネットワーク技術研究所 フレキシブルフラットケーブル
KR100846862B1 (ko) * 2007-12-21 2008-07-17 한국봉제기술연구소 스마트 의류의 전도선 제조장치
CN101494096B (zh) * 2008-01-25 2011-01-26 莱尔德电子材料(深圳)有限公司 屏蔽扁平柔性线缆
JP5218291B2 (ja) * 2009-06-15 2013-06-26 住友電気工業株式会社 フラットケーブルの製造装置および製造方法
CN101973106A (zh) * 2010-10-11 2011-02-16 南君洲 一种用于制造软排线的注塑装置
CN102024516A (zh) * 2010-10-11 2011-04-20 南君洲 一种制造软排线的方法和一种软排线
CN102945714B (zh) * 2012-11-21 2017-05-31 领亚电子科技股份有限公司 多对双层折叠式扁平线及其同步挤出设备、挤出方法
DE102014011180B4 (de) * 2014-07-31 2020-09-03 Auto-Kabel Management Gmbh Elektrischer Flachleiter für Kraftfahrzeuge
KR101947223B1 (ko) 2015-07-28 2019-04-22 주식회사 두산 절연필름 및 플렉서블 플랫 케이블(ffc)
CN114446522A (zh) * 2020-11-04 2022-05-06 进营全球株式会社 柔性扁平电缆与包含柔性扁平电缆的叠层母排
CN114446523A (zh) * 2020-11-04 2022-05-06 进营全球株式会社 柔性扁平电缆与包含柔性扁平电缆的叠层母排
CN113380461A (zh) * 2021-04-30 2021-09-10 上海空间电源研究所 一种扁平电缆排气装置及方法
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Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6954983B2 (en) 2000-11-20 2005-10-18 Reifenhäuser GmbH & Co Maschinenfabrik Method for producing flat cables
WO2004019349A1 (de) * 2002-08-15 2004-03-04 Panta Gmbh Verfahren zur herstellung klebstofffreier flachleiter-bandkabel
DE10238188A1 (de) * 2002-08-15 2004-03-04 Panta Gmbh Verfahren zur Herstellung klebstofffreier Flachleiter-Bandkabel
EP1389784A1 (de) * 2002-08-15 2004-02-18 Panta GmbH Verfahren zur Herstellung klebstofffreier Flachleiter-Bandkabel
EP1453068A1 (de) * 2003-02-26 2004-09-01 I & T Flachleiter Produktions-Ges.m.b.h. Flachleiterkabel
US7989701B2 (en) 2007-11-27 2011-08-02 Sabic Innovative Plastics Ip B.V. Multiconductor cable assembly and fabrication method therefor
US9793030B2 (en) * 2010-03-12 2017-10-17 Yazaki Corporation Extruded flexible flat cable
US20130000950A1 (en) * 2010-03-12 2013-01-03 Yazaki Corporation Extruded flexible flat cable
US10147516B2 (en) 2010-03-12 2018-12-04 Yazaki Corporation Extruded flexible flat cable
WO2012154256A1 (en) * 2011-02-17 2012-11-15 Advanced Bionics Ag Wire constructs
US9263172B2 (en) 2011-02-17 2016-02-16 Advanced Bionics Ag Wire constructs
WO2013014903A1 (en) * 2011-07-27 2013-01-31 Yazaki Corporation Flat cable and method for preparing the same
EP2879248A4 (de) * 2012-07-26 2016-03-23 Furukawa Electric Co Ltd Drehbare verbindervorrichtung
DE102016114944A1 (de) * 2016-08-11 2018-02-15 Lisa Dräxlmaier GmbH Elektrische Flachleiteranordnung und Herstellungsverfahren für eine solche

Also Published As

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WO1998052199A1 (fr) 1998-11-19
CN1226993A (zh) 1999-08-25
JP3700861B2 (ja) 2005-09-28
KR20000023728A (ko) 2000-04-25

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