【０００１】
【発明の属する技術分野】
本発明は、例えば、自動車等の電気配線系統に用いられるワイヤハーネス等に使用される平型配線材とフレキシブルプリント配線材の接続構造及びその製造方法に関するものである。
【０００２】
【従来の技術】
従来、例えば、自動車等の電気配線系統に用いられるワイヤハーネス等に電気的な分流、合流等の回路機能を持たせる手段としては、図７に示すようなジョイントコネクタ（ＪＣ）１が使用されている。このジョイントコネクタ１は、ワイヤハーネス等を構成する電線２を圧着した雌型の端子３を、格子状に形成された複数の端子挿入孔４ａを有するコネクタハウジング４にはめ込んで係合させ、端子３をコネクタハウジング４に固定する。また、前記コネクタハウジング４の端子挿入孔４ａに合致するように同じく格子状に形成された複数のバスバ挿入孔５ａを有するホルダ５を、コネクタハウジング４にはめ込んで固定すると共に、複数のタブ状接触片６ａを連結帯６ｂで連結してなる複数のバスバ６をホルダ５内にはめ込んでキャップ７で脱着しないように固定し、コネクタハウジング４に固定された端子３同士を前記バスバ６により電気的に接続し得るように構成される。そこで、例えば、３本の電線２を相互に接続すれば、これら電線２間で電気的な分流、合流等の回路機能を持たせることができる。
【０００３】
【発明が解決しようとする課題】
しかしながら、前記ジョイントコネクタ１による手段では、端子３、コネクタハウジング４、ホルダ５、バスバ６等、部品数が増え、また、電線２に端子３を取り付ける工数がかかり、更に、多様なワイヤハーネス等の配線材の回路パターンに適応するジョイントコネクタを成形して製作する工数がかかり、平型配線材とフレキシブルプリント配線材の接続構造が複雑になって、配線材を形成するコストが高くなるという問題があった。
【０００４】
また、ジョイントコネクタ１はコネクタハウジング４、ホルダ５等が樹脂成形品のため大型になることに加え、ジョイントコネクタ１の品番が増えないように、コネクタハウジング４及びホルダ５に未使用の端子挿入孔４ａ及びバスバ挿入孔５ａを予め形成しておくので、更に大型になり、配線材が嵩張って、自動車等への配索スペースが大きくなり、配索の作業性が低下するという問題もあった。
【０００５】
本発明は上記の課題を解決し、接続の構造が簡単で配線材のコストを低減させると共に、配線材を自動車等へ配索するスペースを小さくして配線材の配索の作業性を向上させることができる平型配線材とフレキシブルプリント配線材の接続構造及びその製造方法を提供することを目的とするものである。
【０００６】
【課題を解決するための手段】
上記の目的を達成するために、本発明の請求項１に記載された平型配線材とフレキシブルプリント配線材の接続構造は、平型導体が絶縁被覆材で被覆された平型配線材の前記絶縁被覆材が除去された導体露出部と、平型回路導体が所定の回路を形成するように配置され、絶縁被覆材で被覆されたフレキシブルプリント配線材の前記絶縁被覆材が除去された導体露出部と、両導体露出部を重ね合わせて接続する重合接続手段とを備え、前記重合接続手段は、一方の導体露出部が一側の絶縁被覆材を除去し、他側の除去されない絶縁被覆材を導体先端側から折り返される折り返し片として延出するように形成され、その導体露出部側における前記折り返し片に他方の導体露出部を挿通させる挿通穴が形成され、その挿通穴に挿通された他方の導体露出部を一方の導体露出部に重ね合わせた両導体露出部の重ね合わせ部分の外側に、一方の導体露出部側における他側の絶縁被覆材より折り返された前記折り返し片が被せられて、両導体露出部を接続するように構成されることを特徴とするものである。
【０００７】
このような構成によると、配線材に電気的な分流、合流等の回路機能を持たせる手段として、従来のジョイントコネクタの代わりに、所定の回路を形成したフレキシブルプリント配線材（ＦＰＣ）を用い、これと平型配線材とを前記重合接続手段により接続するので、接続構造が簡単になり、配線材の接続に要する部品数を減らすことができる。また、電線に端子を圧着等により取り付ける面倒な作業が不要になって工数を減らすことができる。更に、多様な配線材の回路パターンに適応する回路の形成が容易なフレキシブルプリント配線材で配線材の分流、合流等の回路機能を持たせるので、各種、各サイズのジョイントコネクタを予め製作する手間を省くことができる。よって、配線材の接続が容易になり、ワイヤハーネス等を形成するコストを低減させることができる。
【０００８】
また、大型なジョイントコネクタの代わりに軽量でスペースをとらず、多様な配線材の回路パターンに柔軟に対応可能なフレキシブルプリント配線材を用いるので、接続構造が小型化されて、配線材が嵩張らず、自動車等への配索スペースが小さくなり、配索の作業性を高めることができる。
【０００９】
更に、前記重合接続手段が、前記両導体露出部の重ね合わせ部分の外側に、一方の導体露出部側における他側の絶縁被覆材より折り返された前記折り返し片が被せられて、両導体露出部を接続するように構成されるので、接続構造が薄型になって、従来のコネクタを使用するものよりも一段と省スペース化をはかることができる。
【００１０】
本発明の請求項２に記載された平型配線材とフレキシブルプリント配線材の接続構造は、請求項１記載のものにおいて、前記重合接続手段における前記両導体露出部の重ね合わせ部分の両導体露出部間に導電性接着剤が設けられることを特徴とするものである。このような構成によると、両導体露出部の導電性が向上し、接続構造の信頼性をより高めることができるので好ましい。
【００１１】
本発明の請求項３に記載された平型配線材とフレキシブルプリント配線材の接続構造の製造方法は、平型導体が絶縁被覆材で被覆された平型配線材の前記絶縁被覆材が除去された導体露出部と、平型回路導体が所定の回路を形成するように配置され、絶縁被覆材で被覆されたフレキシブルプリント配線材の前記絶縁被覆材が除去された導体露出部のうち、一方の導体露出部は、一側の絶縁被覆材を除去し、他側の除去されない絶縁被覆材を導体先端側から折り返される折り返し片として延出するように形成し、折り返し片に他方の導体露出部が挿通する挿通穴を形成し、一方の導体露出部側における他側の前記折り返し片を導体先端側から折り曲げて起立させ、他方の導体露出部を前記起立させた折り返し片の挿通穴に挿通させて、一方の導体露出部に重ね合わせ、両導体露出部の重ね合わせ部分の外側に、前記折り返し片を更に折り曲げて折り返すことにより被せて、両導体露出部を接続することを特徴とするものである。
【００１２】
このような構成によると、前記絶縁被覆材で形成される折り返し片を折り返して、両導体露出部の重ね合わせ部分の外側に被せるので、その重ね合わせ部分に被せる絶縁被覆材を新たに準備しておく必要がなく、また、その絶縁被覆材である折り返し片を前記重ね合わせ部分に位置ずれを起こすことなく容易に被せることができる。また、その折り返し片に形成された挿通穴が、これに挿通される他方の導体露出部を案内する役目をして、その導体露出部を前記一方の導体露出部の上に迅速、且つ、容易に重ね合わせることができる。これにより、両導体露出部を接続する手間が省け、本接続構造を能率よく製造することができる。
【００１３】
【発明の実施の形態】
次に、本発明の実施形態を図面により詳細に説明する。図１は本発明の一実施形態を示す平型配線材とフレキシブルプリント配線材の接続構造で、（イ）はその斜視図、（ロ）はその主要部の拡大断面図である。
【００１４】
本実施形態の接続構造は、図１（イ）（ロ）に示すように、ワイヤハーネス等の配線材を構成する平型配線材１０の導体露出部１２と、フレキシブルプリント配線材（ＦＰＣ）１４の導体露出部１６と、両導体露出部１２、１６を重ね合わせて接続する重合接続手段１８とを備えて構成される。
【００１５】
平型配線材１０は、図２（イ）に示すように、導電性材料、例えば、銅材で出来た複数の平型導体２０が並列して配置され、絶縁性フイルム（シート、テープを含む）等の絶縁被覆材２２で被覆してなるフレキシブルフラットケーブル（ＦＦＣ）、テープ、リボン電線等で構成される。その導体露出部１２は、平型配線材１０の接続すべき端部側における絶縁被覆材２２を、接続に必要な長さだけ、例えば、図示のように上下両側にわたり除去して、各平型導体２０を露出させることにより形成される。
【００１６】
フレキシブルプリント配線材１４は、導電性材料、例えば、銅箔材を加工処理することにより、複数の平型回路導体２４が所定パターンの回路を形成するように配置され、絶縁性フイルム（シート、テープを含む）等の絶縁被覆材２６で被覆することにより構成される。その導体露出部１６は、フレキシブルプリント配線材１４の接続すべき端部側における一側（上側）、即ち、前記平型配線材１０の平型導体２０と接触する側の絶縁被覆材２６ａを接続に必要な長さだけ除去し、他側（下側）の絶縁被覆材２６ｂを、平型回路導体２４の導体先端側から、少なくとも露出される平型回路導体２４の長さに該導体２４の厚さを加えた長さに相当する分、折り返される折り返し片２８として延出するように残して、各平型回路導体２４を露出させることにより形成される。
【００１７】
重合接続手段１８は、前記導体露出部１６に、その導体露出部１６側における前記折り返し片２８の導体先端側部分に形成された挿通穴２８ａを挿通する前記導体露出部１２を重ね合わせた両導体露出部１２、１６の重ね合わせ部分３０の外側に、導体露出部１６側における下側の絶縁被覆材２６ｂより折り返された前記折り返し片２８が被せられて、前記導体露出部１６側における下側の絶縁被覆材２６ｂに、例えば、接着により固着され、両導体露出部１２、１６を接続するように構成される。
【００１８】
ところで、前記重ね合わせ部分３０の外側に被せられる折り返し片２８の長さを若干長く形成して、その先端が導体露出部１６側における上側の絶縁被覆材２６ａの上にまたがって該被覆材２６ａの方にも少し被せられるようにしてもよい。このように接続された両導体露出部１２、１６の重ね合わせ部分３０の絶縁被覆材２６ｂの上下両外側面には、必要に応じて、絶縁被覆材２２と２６ａ、また、絶縁被覆材２２にまたがるように絶縁保護カバー（図示せず）が被せられる。更に、平型配線材１０の導体露出部１２とフレキシブルプリント配線材１４の導体露出部１６との接続の組み合わせは回路構成に応じて任意に選択することができる。
【００１９】
なお、前記折り返し片２８を前記絶縁被覆材２６ｂに接着により固着させる手段としては、接着剤を用いる接着手段と接着剤を用いない接着手段を採用することができる。接着剤を用いる接着手段の場合には、例えば、ポリ酢酸ビニル系、ポリエステル系の接着剤、各種ホットメルト接着剤（ポリエステル系、ポリイミド系、ＥＶＣ（エチレンービニルエステル共重合体）系等）のような熱溶着型接着剤３２を用いる。熱溶着型接着剤３２を使用する場合には、前記折り返し片２８を熱プレスして熱溶着させることにより接着する。接着剤を用いない接着手段の場合には、例えば、折り返し片２８自体をヒータ又は超音波等により加熱溶着することにより接着する。
【００２０】
また、前記重合接続手段１８における前記両導体露出部１２、１６の重ね合わせ部分３０の両導体露出部１２、１６間に導電性接着剤３４を設ける構成にしてもよい。導電性接着剤３４は、例えば、エポキシ系樹脂（ポリイミド系、シリコーン系）をバインダーとし、銀、銅、その他の導電機能物をフィラーとして構成されるものが用いられ、両導体露出部１２、１６を重ね合わせる前に、いずれか一方の導体露出部１２、１６の導体接触面に、又は、両導体露出部１２、１６の導体接触面に塗布等して設けられ、加熱硬化させることにより接着力が得られる。ホットメルト接着剤等の熱溶着型接着剤３２を用いて折り返し片２８を熱プレスするときの熱を利用して、導電性接着剤３４を加熱硬化させるようにすると、接着工程を簡素化することができる。このように、両導体露出部１２、１６間に導電性接着剤３４が設けられていると、両導体露出部１２、１６の導電性が向上し、接続構造の信頼性をより高めることができるので好ましい。
【００２１】
次に本発明に係る平型配線材とフレキシブルプリント配線材の接続構造の製造方法を図２（イ）乃至図（ホ）及び図３乃至図６により説明する。
【００２２】
先ず、図２（イ）に示すように、平型配線材１０の接続すべき端部側における絶縁被覆材２２を、接続に必要な長さだけ、例えば、図示のように上下両側にわたり除去して、各平型導体２０を露出させることにより導体露出部１２を形成する。また、フレキシブルプリント配線材１４の接続すべき端部側における上側の絶縁被覆材２６ａを接続に必要な長さだけ除去し、下側の絶縁被覆材２６ｂを平型回路導体２４の導体先端側から、少なくとも露出される平型回路導体２４の長さに該導体２４の厚さを加えた長さに相当する分、折り返される折り返し片２８として延出するように残して、各平型回路導体２４を露出させることにより導体露出部１６を形成される。
【００２３】
そして、図２（ロ）、図３に示すように、各導体露出部１６側における折り返し片２８の導体先端側部分に、前記各導体露出部１２が挿通する挿通穴２８ａを形成し、平型回路導体２４の導体先端側から延出する該折り返し片２８の上面、若しくは、導体露出部１６側の下側の折り返されない絶縁被覆材２６ｂの上面、又は、図２（ロ）に示すように、双方の上面に、接着剤、例えば、ホットメルト接着剤である熱溶着型接着剤３２を塗布等して設ける。更に、平型配線材１０側における各導体露出部１２及びフレキシブルプリント配線材１４側における各導体露出部１６のいずれか一方、又は、図４に示すように、両導体露出部１２、１６の導体接触面に、導電性接着剤３４を塗布等して設ける。
【００２４】
次に、図２（ハ）、図４に示すように、各導体露出部１６側における各折り返し片２８を前記導体先端側から挿通穴２８ａと共に９０度折り曲げて起立させる。なお、前記熱溶着型接着剤３２及び導電性接着剤３２のいずれか一方又は双方は折り返し片２８を起立させた後、後記するように、各折り返し片２８の挿通穴２８ａに各導体露出部１２を挿通させる前に塗布等して設けるようにしてもよい。
【００２５】
次に、図２（ニ）及び図５に示すように、この起立させた各折り返し片２８の挿通穴２８ａに前記各導体露出部１２を挿通させて、これらを各導体露出部１６に重ね合わせる。そして、各両導体露出部１２、１６の重ね合わせ部分３０の外側に、前記各折り返し片２８を更に９０度折り曲げて折り返すことにより被せる。そして、図６に示すように、前記各重ね合わせ部分３０の上に被せられた折り返し片２８をその外側から熱プレス機３６の加熱ラム３８で熱プレスして各重ね合わせ部分３０に押し付けて密着させる。これにより、前記熱溶着型接着剤３２及び導電性接着剤３４を加熱硬化させ、各折り返し片２８を前記導体露出部１６側における下側の絶縁被覆材２６ｂの上面に接着させて固着すると共に、前記各重ね合わせ部分３０の両導体露出部１２、１６同士を導電性接着剤３４で接着させ、前記各両導体露出部１２、１６を接続して、図２（ホ）に示すような構成の平型配線材とフレキシブルプリント配線材の接続構造を製造する。
【００２６】
このような接続構造の製造方法によると、導体露出部１６側における前記絶縁被覆材２６ｂで形成される折り返し片２８を折り返して、両導体露出部１２、１６の重ね合わせ部分３０の外側に被せるので、その重ね合わせ部分３０に被せる絶縁被覆材２６ｂに相当する絶縁被覆材を新たに準備しておく必要がなく、また、その絶縁被覆材２６ｂである折り返し片２８を前記重ね合わせ部分３０に位置ずれを起こすことなく容易に被せることができる。また、その折り返し片２８に形成された挿通穴２８ａが、これに挿通される導体露出部１２を案内する役目をして、その導体露出部１２を前記導体露出部１６の上に、迅速、且つ、容易に重ね合わせることができる。これにより、両導体露出部１２、１６を接続する手間が省け、平型配線材１０とフレキシブルプリント配線材１４の接続構造を能率よく製造することができる。
【００２７】
なお、本接続構造における重合接続手段１８は、導体露出部１６側に折り返し片２８が形成され、導体露出部１２側には折り返し片２８が形成されない構成になっているが、これと反対に、導体露出部１２側に折り返し片２８が形成され、導体露出部１６側に折り返し片２８が形成されない構成になっていてもよい。
【００２８】
また、前記接続構造の製造方法では、平型配線材１０の導体露出部１２を、フレキシブルプリント配線材１４の導体露出部１６を形成する前に形成したが、フレキシブルプリント配線材１４の導体露出部１６を形成した後、前記折り返し片２８に挿通穴２８ａを形成し、折り返し片２８を折り曲げて起立させ、その挿通穴２８ａに挿通させるまでの適宜過程で形成してもよい。
【００２９】
更に、前記熱溶着型接着剤３２の接着剤や導電性接着剤３４を設ける時期は、接続すべき導体露出部１２、１６を形成した後、その一方又は双方を重ね合わせる前であれば、いずれの過程で設けるようにしてもよい。なお、導電性接着剤３４を設けると、両導体露出部１２、１６の導電性をより向上させることができるので好ましいが、両導体露出部１２、１６の接触、又は密着状態が良好な場合等においては、その導電性接着剤３４の使用を省くことができる。
【００３０】
【発明の効果】
以上説明したように、本発明の請求項１に記載された平型配線材とフレキシブルプリント配線材の接続構造は、配線材に電気的な分流、合流等の回路機能を持たせる手段として、従来のジョイントコネクタの代わりに、所定の回路を形成したフレキシブルプリント配線材（ＦＰＣ）を用い、これと平型配線材とを前記重合接続手段により接続するので、接続構造が簡単になり、配線材の接続に要する部品数を減らすことができる。また、電線に端子を圧着等により取り付ける面倒な作業が不要になって工数を減らすことができる。更に、多様な配線材の回路パターンに適応する回路の形成が容易なフレキシブルプリント配線材で配線材の分流、合流等の回路機能を持たせるので、各種、各サイズのジョイントコネクタを予め製作する手間を省くことができる。よって、配線材の接続が容易になり、配線材を形成するコストを低減させることができる。
【００３１】
また、大型なジョイントコネクタの代わりに軽量でスペースをとらず、多様な配線材の回路パターンに柔軟に対応可能なフレキシブルプリント配線材を用いるので、接続構造が小型化されて、配線材が嵩張らず、自動車等への配索スペースが小さくなり、配索の作業性を高めることができる。
【００３２】
更に、前記重合接続手段が、前記両導体露出部の重ね合わせ部分の外側に、一方の導体露出部側における他側の絶縁被覆材より折り返された前記折り返し片が被せられて、両導体露出部を接続するように構成されるので、接続構造が薄型になって、従来のコネクタを使用するものよりも一段と省スペース化をはかることができる。
【００３３】
本発明の請求項２に記載された平型配線材とフレキシブルプリント配線材の接続構造は、請求項１記載のものにおいて、前記重合接続手段における前記両導体露出部の重ね合わせ部分の両導体露出部間に導電性接着剤が設けられるので、両導体露出部の導電性が向上し、接続構造の信頼性をより高めることができ好ましい。
【００３４】
本発明の請求項３に記載された平型配線材とフレキシブルプリント配線材の接続構造の製造方法は、前記絶縁被覆材で形成される折り返し片を折り返して、両導体露出部の重ね合わせ部分の外側に被せるので、その重ね合わせ部分に被せる絶縁被覆材を新たに準備しておく必要がなく、また、その絶縁被覆材である折り返し片を前記重ね合わせ部分に位置ずれを起こすことなく容易に被せることができる。また、その折り返し片に形成された挿通穴が、これに挿通される他方の導体露出部を案内する役目をして、その導体露出部を前記一方の導体露出部の上に迅速、且つ、容易に重ね合わせることができる。これにより、両導体露出部を接続する手間が省け、本接続構造を能率よく製造することができる。
【図面の簡単な説明】
【図１】本発明に係る接続構造の一実施形態を示すもので、（イ）はその斜視図、（ロ）はその主要部の拡大断面図である。
【図２】図１の接続構造を製造する方法を作業工程順に示す斜視図で、（イ）は平型配線材とフレキシブルプリント配線材の各導体露出部を形成した状態を示すもの、（ロ）はフレキシブルプリント配線材の導体露出部側における折り返し片に平型配線材の導体露出部が挿通する挿通穴を形成した状態を示すもの、（ハ）は（ロ）における折り返し片を起立させた状態を示すもの、（ニ）はその折り返し片の挿通穴に平型配線材の導体露出部を挿通させて、両導体露出部を重ね合わせ、その重ね合わせ部分の外側に、折り返し片を折り返す状態を示すもの、（ホ）は両導体露出部の重ね合わせ部分に折り返し片が被せられて接続構造が製造された状態を示すものである。
【図３】フレキシブルプリント配線材の導体露出部側における折り返し片に挿通穴を形成した状態を示す拡大断面図である。
【図４】図３の状態から折り返し片を起立させた状態を示す拡大断面図である。
【図５】図４の状態から折り返し片の挿通穴に平型配線材の導体露出部を挿通させ、両導体露出部を重ね合わせた状態を示す拡大断面図である。
【図６】図５の状態から両導体露出部の重ね合わせ部分に折り返し片を被せ、熱プレス機することにより接着させて固着する状態を示す拡大断面図である。
【図７】従来の配線材の接続構造を構成するジョイントコネクタの概要を示す斜視図である。
【符号の説明】
１０ 平型配線材
１２ 導体露出部
１４ フレキシブルプリント配線材
１６ 導体露出部
１８ 重合接続手段
２０ 平型導体
２２ 絶縁被覆材
２４ 平型回路導体
２６ 絶縁被覆材
２６ａ 絶縁被覆材
２６ｂ 絶縁被覆材
２８ 折り返し片
２８ａ 挿通穴
３０ 重ね合わせ部分
３２ 熱溶着型接着剤
３４ 導電性接着剤
３６ 熱プレス機
３８ 加熱ラム[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a connection structure between a flat wiring member and a flexible printed wiring member used for a wire harness or the like used in an electric wiring system of an automobile or the like, and a method of manufacturing the same.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, for example, a joint connector (JC) 1 as shown in FIG. 7 has been used as a means for giving a circuit function such as an electric shunting and merging to a wire harness or the like used in an electric wiring system of an automobile or the like. I have. In this joint connector 1, a female terminal 3 to which an electric wire 2 constituting a wire harness or the like is crimped is engaged with a connector housing 4 having a plurality of terminal insertion holes 4a formed in a lattice shape. Is fixed to the connector housing 4. A holder 5 having a plurality of bus bar insertion holes 5a also formed in a lattice so as to match the terminal insertion holes 4a of the connector housing 4 is fitted into the connector housing 4 and fixed. The plurality of bus bars 6 formed by connecting the pieces 6 a with the connecting bands 6 b are fitted in the holder 5 and fixed so as not to be detached with the cap 7, and the terminals 3 fixed to the connector housing 4 are electrically connected by the bus bars 6. It is configured to be connectable. Therefore, for example, if the three electric wires 2 are connected to each other, it is possible to provide a circuit function such as electric shunting and merging between the electric wires 2.
[0003]
[Problems to be solved by the invention]
However, in the means using the joint connector 1, the number of components such as the terminal 3, the connector housing 4, the holder 5, the bus bar 6, etc. increases, and the man-hour for attaching the terminal 3 to the electric wire 2 is increased. It takes a lot of man-hours to form and manufacture a joint connector that adapts to the circuit pattern of the wiring material, complicates the connection structure between the flat wiring material and the flexible printed wiring material, and increases the cost of forming the wiring material. there were.
[0004]
In addition, the connector connector 4 and the holder 5 are made of resin molded products, so that the connector connector 4 and the holder 5 are large in size. Since the 4a and the bus bar insertion hole 5a are formed in advance, there is also a problem that the size is further increased, the wiring material is bulky, a wiring space for an automobile or the like is increased, and the workability of the wiring is reduced. .
[0005]
The present invention solves the above problems, reduces the cost of the wiring material with a simple connection structure, and improves the workability of wiring the wiring material by reducing the space for wiring the wiring material to an automobile or the like. It is an object of the present invention to provide a connection structure between a flat wiring member and a flexible printed wiring member, and a manufacturing method thereof.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, a connection structure between a flat wiring member and a flexible printed wiring member according to claim 1 of the present invention is a flat wiring member having a flat conductor covered with an insulating coating material. A conductor exposed portion from which the insulating coating material has been removed, and a conductor exposure where the flat circuit conductor is arranged so as to form a predetermined circuit, and the insulating coating material of the flexible printed wiring material covered with the insulating coating material has been removed. And an overlapping connecting means for overlapping and connecting both conductor exposed parts, wherein the overlapping connecting means is such that one of the exposed conductor parts removes the insulating coating material on one side and the other does not remove the insulating coating material on the other side. Is formed so as to extend as a folded piece folded from the conductor front end side, an insertion hole is formed through the folded piece on the conductor exposed portion side to insert the other conductor exposed portion, and the other inserted through the insertion hole is formed. Conductor On the outside of the overlapped portion of the two conductor exposed portions where the protruding portion is overlapped with one conductor exposed portion, the folded piece folded from the insulating coating material on the other side on one conductor exposed portion side is covered, and both ends are covered. It is characterized in that it is configured to connect the conductor exposed portion.
[0007]
According to such a configuration, a flexible printed wiring material (FPC) in which a predetermined circuit is formed is used in place of a conventional joint connector as a means for providing a wiring material with a circuit function such as electric branching and merging. Since this and the flat wiring material are connected by the overlapping connection means, the connection structure is simplified, and the number of components required for connecting the wiring material can be reduced. In addition, the troublesome work of attaching the terminal to the electric wire by crimping or the like becomes unnecessary, and the number of steps can be reduced. Furthermore, flexible printed wiring material that can easily form circuits adapted to the circuit patterns of various wiring materials has circuit functions such as shunting and merging of wiring materials, so it is troublesome to manufacture joint connectors of various sizes in advance. Can be omitted. Therefore, connection of the wiring members is facilitated, and the cost of forming the wire harness and the like can be reduced.
[0008]
In addition, instead of a large joint connector, a lightweight and space-saving flexible printed wiring material that can flexibly respond to the circuit patterns of various wiring materials is used, so the connection structure is downsized and the wiring material is not bulky. Thus, the space for wiring to a car or the like is reduced, and the workability of the wiring can be improved.
[0009]
Further, the overlapped connecting means covers the outside of the overlapped portion of the two conductor exposed portions with the folded piece folded from the insulating coating material on the other side on one conductor exposed portion side, and the two conductor exposed portions , The connection structure becomes thinner, and the space can be further reduced as compared with the conventional connector.
[0010]
The connection structure between the flat wiring member and the flexible printed wiring member according to claim 2 of the present invention is the connection structure according to claim 1, wherein the two conductor exposure portions of the overlapping portion of the two conductor exposure portions in the overlapping connection means are provided. A conductive adhesive is provided between the parts. According to such a configuration, the conductivity of the exposed portions of both conductors is improved, and the reliability of the connection structure can be further improved, which is preferable.
[0011]
According to a third aspect of the present invention, there is provided the method for manufacturing a connection structure between a flat wiring member and a flexible printed wiring member, wherein the insulating covering material is removed from the flat wiring member having the flat conductor covered with the insulating coating material. One of the exposed conductor portions where the insulating coating material of the flexible printed wiring member covered with the insulating coating material is removed, and the flat circuit conductor is arranged so as to form a predetermined circuit. The conductor exposed portion is formed so that the insulating coating material on one side is removed, and the insulating coating material not removed on the other side is extended as a folded piece folded from the conductor tip side, and the other conductor exposed portion is formed on the folded piece. An insertion hole to be inserted is formed, the folded piece on the other side on one conductor exposed portion side is bent from the conductor tip side to stand up, and the other conductor exposed portion is inserted into the insertion hole of the folded up piece. , One lead Superposed on the exposed portion, on the outside of the overlapping portions of the two conductor exposed portion, is covered by folding further folding said folded piece, and is characterized in that connecting both conductor exposed portion.
[0012]
According to such a configuration, since the folded piece formed of the insulating covering material is folded and covered outside the overlapped portion of the exposed portions of the two conductors, an insulating covering material to be covered on the overlapped portion is newly prepared. There is no need to place the folded portion, and it is possible to easily cover the folded portion, which is the insulating coating material, without causing a positional shift in the overlapped portion. Further, the insertion hole formed in the folded piece serves to guide the other conductor exposed portion inserted therein, and the conductor exposed portion is quickly and easily placed on the one conductor exposed portion. Can be superimposed. This saves the trouble of connecting the exposed portions of the two conductors, and the present connection structure can be manufactured efficiently.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, embodiments of the present invention will be described in detail with reference to the drawings. 1A and 1B show a connection structure between a flat wiring member and a flexible printed wiring member according to an embodiment of the present invention. FIG. 1A is a perspective view of the connection structure, and FIG.
[0014]
As shown in FIGS. 1A and 1B, the connection structure of the present embodiment includes a conductor exposed portion 12 of a flat wiring member 10 constituting a wiring member such as a wire harness, and a flexible printed wiring member (FPC) 14. And the overlapped connecting means 18 for overlapping and connecting the conductor exposed portions 12 and 16.
[0015]
As shown in FIG. 2A, a plurality of flat conductors 20 made of a conductive material, for example, a copper material, are arranged in parallel, and the flat wiring member 10 includes an insulating film (including a sheet and a tape). ), A flexible flat cable (FFC) coated with an insulating coating material 22, a tape, a ribbon electric wire, and the like. The conductor exposed portion 12 is formed by removing the insulating coating material 22 on the end side of the flat wiring member 10 to be connected by a length necessary for connection, for example, over both upper and lower sides as shown in the drawing. It is formed by exposing the conductor 20.
[0016]
The flexible printed wiring material 14 is formed by processing a conductive material, for example, a copper foil material, so that a plurality of flat circuit conductors 24 are arranged so as to form a circuit of a predetermined pattern, and an insulating film (sheet, tape) is formed. ). The exposed conductor portion 16 is connected to one side (upper side) of the end portion of the flexible printed wiring material 14 to be connected, that is, the insulating coating material 26a of the flat wiring material 10 which is in contact with the flat conductor 20. And remove the insulating coating material 26b on the other side (lower side) from the conductor tip side of the flat circuit conductor 24 to at least the length of the flat circuit conductor 24 that is exposed. The flat circuit conductors 24 are formed by exposing the respective flat-type circuit conductors 24, while leaving the folded pieces 28 to be folded back by the length corresponding to the length obtained by adding the thickness.
[0017]
The overlapping connection means 18 is formed by superposing the conductor exposed portion 12 on the conductor exposed portion 16 and the conductor exposed portion 12 which is inserted through the insertion hole 28a formed in the conductor tip side portion of the folded piece 28 on the conductor exposed portion 16 side. Outside the overlapped portion 30 of the exposed portions 12 and 16, the folded piece 28 folded back from the lower insulating coating material 26b on the conductor exposed portion 16 side is covered, and the lower folded portion 28 on the conductor exposed portion 16 side is covered. It is configured to be fixed to the insulating coating material 26b by, for example, an adhesive and to connect the conductor exposed portions 12 and 16 together.
[0018]
By the way, the length of the folded piece 28 to be covered on the outside of the overlapping portion 30 is formed to be slightly longer, and the tip of the folded piece 28 extends over the upper insulating covering material 26a on the conductor exposed portion 16 side. You may be able to cover a little. The outer and upper outer surfaces of the insulating covering material 26b of the overlapped portion 30 of the conductor exposed portions 12 and 16 connected in this way are provided with insulating covering materials 22 and 26a and, if necessary, the insulating covering material 22. An insulating protective cover (not shown) is placed so as to straddle. Furthermore, the combination of the connection between the conductor exposed portion 12 of the flat wiring member 10 and the conductor exposed portion 16 of the flexible printed wiring member 14 can be arbitrarily selected according to the circuit configuration.
[0019]
In addition, as the means for fixing the folded piece 28 to the insulating coating material 26b by bonding, a bonding means using an adhesive and a bonding means not using an adhesive can be adopted. In the case of the bonding means using an adhesive, for example, polyvinyl acetate-based, polyester-based adhesives, various hot melt adhesives (polyester-based, polyimide-based, EVC (ethylene-vinyl ester copolymer) -based, etc.) Such a heat welding type adhesive 32 is used. When using the heat welding type adhesive 32, the folded pieces 28 are bonded by hot pressing and heat welding. In the case of the bonding means that does not use an adhesive, for example, the folded piece 28 itself is bonded by heating and welding with a heater or ultrasonic waves.
[0020]
Further, a conductive adhesive 34 may be provided between the exposed portions 12 and 16 of the overlapped portion 30 of the exposed portions 12 and 16 in the overlapping connection means 18. The conductive adhesive 34 is, for example, an epoxy resin (polyimide or silicone) used as a binder and silver, copper, or another conductive material as a filler. Before overlapping, the adhesive is provided on the conductor contact surface of one of the exposed conductors 12 and 16 or on the conductor contact surface of both exposed conductors 12 and 16 by applying heat and curing. Is obtained. When the conductive adhesive 34 is heated and cured by using heat generated when the folded piece 28 is hot-pressed using a hot-melt adhesive 32 such as a hot-melt adhesive, the bonding process is simplified. Can be. Thus, when the conductive adhesive 34 is provided between the conductor exposed portions 12 and 16, the conductivity of the conductor exposed portions 12 and 16 is improved, and the reliability of the connection structure can be further improved. It is preferred.
[0021]
Next, a method of manufacturing a connection structure between a flat wiring member and a flexible printed wiring member according to the present invention will be described with reference to FIGS. 2A to 2E and FIGS.
[0022]
First, as shown in FIG. 2A, the insulating coating material 22 at the end of the flat wiring member 10 to be connected is removed by a length necessary for connection, for example, over the upper and lower sides as shown. Then, the exposed conductor 12 is formed by exposing each flat conductor 20. Further, the upper insulating coating material 26a at the end of the flexible printed wiring material 14 to be connected is removed by a length necessary for connection, and the lower insulating coating material 26b is removed from the conductor tip side of the flat circuit conductor 24. Each of the flat circuit conductors 24 is left so as to extend as a folded piece 28 by at least the length of the exposed flat circuit conductor 24 plus the thickness of the conductor 24. Is exposed to form a conductor exposed portion 16.
[0023]
Then, as shown in FIGS. 2B and 3, an insertion hole 28 a through which each conductor exposed portion 12 is inserted is formed in the conductor tip side portion of the folded piece 28 on each conductor exposed portion 16 side, and a flat mold is formed. As shown in FIG. 2B, the upper surface of the folded piece 28 extending from the conductor tip side of the circuit conductor 24, or the upper surface of the unfolded insulating coating material 26b below the conductor exposed portion 16 An adhesive, for example, a hot-melt adhesive 32, which is a hot-melt adhesive, is provided on both upper surfaces by coating or the like. Furthermore, one of the conductor exposed portions 12 on the flat wiring member 10 side and the conductor exposed portions 16 on the flexible printed wiring member 14 side, or, as shown in FIG. A conductive adhesive 34 is provided on the contact surface by coating or the like.
[0024]
Next, as shown in FIG. 2C and FIG. 4, each folded piece 28 on each conductor exposed portion 16 side is bent upright by 90 degrees together with the insertion hole 28a from the conductor front end side to be erected. After one or both of the heat-welding adhesive 32 and the conductive adhesive 32 erect the folded pieces 28, as will be described later, each conductor exposed portion 12 is inserted into an insertion hole 28 a of each folded piece 28. May be provided by coating or the like before insertion.
[0025]
Next, as shown in FIGS. 2D and 5, the conductor exposed portions 12 are inserted into the insertion holes 28 a of the standing folded pieces 28, and are superimposed on the conductor exposed portions 16. . Then, the folded pieces 28 are further folded at 90 degrees to cover the outside of the overlapped portion 30 of the conductor exposed portions 12 and 16, respectively. Then, as shown in FIG. 6, the folded piece 28 covered on each of the overlapping portions 30 is hot-pressed from the outside thereof with a heating ram 38 of a hot press machine 36 and pressed against each of the overlapping portions 30 to be in close contact therewith. Let it. Thereby, the heat-welding adhesive 32 and the conductive adhesive 34 are heated and cured, and each folded piece 28 is adhered and fixed to the upper surface of the lower insulating covering material 26b on the conductor exposed portion 16 side, The conductor exposed portions 12 and 16 of the respective overlapping portions 30 are adhered to each other with a conductive adhesive 34, and the conductor exposed portions 12 and 16 are connected to each other to form a structure as shown in FIG. Manufactures a connection structure between a flat wiring material and a flexible printed wiring material.
[0026]
According to the manufacturing method of such a connection structure, the folded piece 28 formed of the insulating covering material 26b on the conductor exposed portion 16 side is folded and covered on the outside of the overlapped portion 30 of the conductor exposed portions 12 and 16. It is not necessary to newly prepare an insulating coating material corresponding to the insulating coating material 26b to be placed on the overlapped portion 30, and the folded piece 28, which is the insulating coating material 26b, is misaligned to the overlapped portion 30. It can be easily covered without causing. In addition, the insertion hole 28a formed in the folded piece 28 serves to guide the conductor exposed portion 12 inserted therein, and the conductor exposed portion 12 is quickly and quickly placed on the conductor exposed portion 16. , Can be easily superimposed. This saves the labor of connecting the conductor exposed portions 12 and 16, and can efficiently manufacture the connection structure between the flat wiring member 10 and the flexible printed wiring member 14.
[0027]
The overlapping connection means 18 in the present connection structure has a configuration in which the folded piece 28 is formed on the conductor exposed portion 16 side and the folded piece 28 is not formed on the conductor exposed portion 12 side. The folded piece 28 may be formed on the conductor exposed portion 12 side, and the folded piece 28 may not be formed on the conductor exposed portion 16 side.
[0028]
In the method of manufacturing the connection structure, the conductor exposed portion 12 of the flat wiring member 10 is formed before the conductor exposed portion 16 of the flexible printed wiring member 14 is formed. After forming the 16, an insertion hole 28 a may be formed in the folded piece 28, and the folded piece 28 may be formed in an appropriate process from being bent upright to being inserted into the insertion hole 28 a.
[0029]
Further, the timing of providing the adhesive of the heat welding type adhesive 32 or the conductive adhesive 34 may be any time after forming the conductor exposed portions 12 and 16 to be connected and before overlapping one or both of them. May be provided in the process. In addition, it is preferable to provide the conductive adhesive 34 because the conductivity of the conductor exposed portions 12 and 16 can be further improved, but it is preferable that the contact or the close contact state of the conductor exposed portions 12 and 16 be good. In this case, the use of the conductive adhesive 34 can be omitted.
[0030]
【The invention's effect】
As described above, the connection structure between the flat wiring member and the flexible printed wiring member according to the first aspect of the present invention is a conventional method for providing a wiring member with a circuit function such as electrical branching or merging. In place of the joint connector described above, a flexible printed wiring (FPC) having a predetermined circuit is used, and this is connected to the flat wiring by the overlapping connection means. The number of components required for connection can be reduced. In addition, the troublesome work of attaching the terminal to the electric wire by crimping or the like becomes unnecessary, and the number of steps can be reduced. Furthermore, flexible printed wiring material that can easily form circuits that adapt to the circuit patterns of various wiring materials has circuit functions such as branching and merging of wiring materials. Can be omitted. Therefore, connection of the wiring member is facilitated, and the cost of forming the wiring member can be reduced.
[0031]
In addition, instead of a large joint connector, a lightweight and space-saving flexible printed wiring material that can flexibly respond to the circuit patterns of various wiring materials is used, so the connection structure is downsized and the wiring material is not bulky. Thus, the space for wiring to a car or the like is reduced, and the workability of the wiring can be improved.
[0032]
Further, the overlapped connecting means covers the outside of the overlapped portion of the two conductor exposed portions with the folded piece folded from the insulating coating material on the other side on one conductor exposed portion side, and the two conductor exposed portions , The connection structure becomes thinner, and the space can be further reduced as compared with the conventional connector.
[0033]
The connection structure between the flat wiring member and the flexible printed wiring member according to claim 2 of the present invention is the connection structure according to claim 1, wherein the two conductor exposure portions of the overlapping portion of the two conductor exposure portions in the overlapping connection means are provided. Since the conductive adhesive is provided between the portions, the conductivity of the exposed portions of both conductors is improved, and the reliability of the connection structure can be further improved, which is preferable.
[0034]
According to a third aspect of the present invention, there is provided a method of manufacturing a connection structure between a flat wiring material and a flexible printed wiring material, wherein a folded piece formed of the insulating coating material is folded back to form a superposed portion of both conductor exposed portions. Since it is placed on the outside, there is no need to prepare a new insulating covering material to cover the overlapped portion, and the folded piece, which is the insulating covering material, can be easily placed on the overlapped portion without causing displacement. be able to. Further, the insertion hole formed in the folded piece serves to guide the other conductor exposed portion inserted therein, and the conductor exposed portion is quickly and easily placed on the one conductor exposed portion. Can be superimposed. This saves the trouble of connecting the exposed portions of the two conductors, and the present connection structure can be manufactured efficiently.
[Brief description of the drawings]
FIGS. 1A and 1B show an embodiment of a connection structure according to the present invention, wherein FIG. 1A is a perspective view thereof, and FIG. 1B is an enlarged sectional view of a main part thereof.
FIGS. 2A and 2B are perspective views showing a method of manufacturing the connection structure of FIG. 1 in the order of operation steps, and FIG. 2A shows a state in which conductor exposed portions of a flat wiring material and a flexible printed wiring material are formed; ) Shows a state in which an insertion hole through which the conductor exposed portion of the flat wiring material is inserted is formed in the folded piece on the conductor exposed portion side of the flexible printed wiring material, and (c) shows the folded piece in (b) raised (D) shows a state in which the conductor exposed portion of the flat wiring material is inserted into the insertion hole of the folded piece, the conductor exposed portions are overlapped, and the folded piece is folded outside the overlapped portion. (E) shows a state in which a folded piece is put on the overlapped portion of the exposed portions of both conductors to produce a connection structure.
FIG. 3 is an enlarged cross-sectional view showing a state where an insertion hole is formed in a folded piece on a conductor exposed portion side of a flexible printed wiring material.
FIG. 4 is an enlarged cross-sectional view showing a state in which a folded piece is erected from the state of FIG.
5 is an enlarged cross-sectional view showing a state in which a conductor exposed portion of a flat wiring member is inserted into an insertion hole of a folded piece from the state of FIG. 4 and both conductor exposed portions are overlapped.
FIG. 6 is an enlarged cross-sectional view showing a state in which a folded piece is put on a superposed portion of the exposed portions of both conductors from the state of FIG. 5 and adhered and fixed by hot pressing.
FIG. 7 is a perspective view showing an outline of a joint connector constituting a conventional connection structure of wiring members.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Flat wiring material 12 Conductor exposed part 14 Flexible printed wiring material 16 Conductor exposed part 18 Overlapping connection means 20 Flat conductor 22 Insulating coating material 24 Flat circuit conductor 26 Insulating coating material 26a Insulating coating material 26b Insulating coating material 28 Folded piece 28a insertion hole 30 overlapping portion 32 heat welding type adhesive 34 conductive adhesive 36 heat press machine 38 heating ram
