JP2009140682A - Method for manufacturing flexible flat cable - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a flexible flat cable of which problems is prevented such as gaps between conductors are unequal or conductors are slant when manufacturing a flexible flat cable by welding of insulation films by supersonic vibration while a plurality of conductors are pinched by upper and lower insulation films. <P>SOLUTION: While a plurality of conductors are pinched by upper and lower insulation films, the method for manufacturing a flexible flat cable is provided by welding an insulation film by supersonic vibration when passing through between a supersonic horn and a rotatable roller anvil arranged in opposition to the supersonic horn with a concave groove formed at a part corresponding to a region of each conductor and a projected strip formed at a part other than the region of each conductor. On an entering side to the roller anvil, each conductor is housed in the concave groove of the roller anvil with the insulation film of one side, and supplied between the roller anvil and the supersonic horn while rolling is restrained. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a flexible flat cable, and more specifically, an ultrasonic horn and a roller anvil in a state where a plurality of conductors arranged in parallel at equal intervals are sandwiched between upper and lower insulating films. The present invention relates to a method of manufacturing a flexible flat cable by passing a gap therebetween and welding an insulating film by ultrasonic vibration.

  Conventionally, a flexible flat cable (FFC) that is thin and flexible has been proposed in order to save space and weight of the cable. As this FFC, for example, a structure in which two insulating films are welded by ultrasonic vibration with a plurality of parallel conductors sandwiched between two strip-like insulating films made of polyethylene terephthalate film or the like. A known one is known (see Patent Document 1 below).

  When manufacturing such an FFC, an FFC manufacturing apparatus 101 as shown in FIG. 4 is used. As shown in the figure, an upper ultrasonic horn 121 that conveys a plurality of conductors 103a to 103b arranged in parallel at equal intervals between upper and lower insulating films 107 and 108 and applies ultrasonic vibrations. And the ultrasonic welding device 120 composed of the lower roller anvil 122 disposed opposite to the ultrasonic horn 121, the insulating films 107 and 108 disposed above and below the conductors 103a, 103b, and 103c FFC112 is obtained by welding by sonic vibration.

  In this case, the roller anvil 122 has a rotatable cylindrical shape, and as shown in FIG. 5, a plurality of concave grooves 123 that are continuous in the circumferential direction are formed on the outer peripheral surface thereof. A plurality of ridges 124 that press the insulating films 107 and 108 are formed between the 123. The conductors 103a, 103b, and 103c and the insulating films 107 and 108 disposed above and below the conductors 103a, 103b, and 103c are welded by ultrasonic vibration while being sandwiched between the ultrasonic horn 121 and the protrusion 124 of the roller anvil 122. .

  On the uppermost stream side of the ultrasonic welding apparatus 120, there are provided three conductor supply rolls 102a, 102b, 102c in which a plurality of conductors 103a, 103b, 103c made of a copper or copper alloy linear body are wound and stored in advance. On the downstream side of these conductor supply rolls 102a, 102b, and 102c, a pair of upper and lower pitch guide rollers 104 that arrange the conductors 103a, 103b, and 103c in parallel at equal intervals are provided.

  Further, on the downstream side of the pitch guide roller 104, film supply rolls 106a and 106b for supplying the insulating films 107 and 108 are provided. In each film supply roll 106a, 106b, long strip-shaped insulating films 107, 108 are wound and stored in advance. A guide roller 109 that sandwiches the conductors 103a, 103b, and 103c between the upper and lower insulating films 107 and 108 is provided on the downstream side of the film supply rolls 106a and 106b.

  A cutter 111 is provided on the downstream side of the ultrasonic welding apparatus 120 to cut the ears at both ends in the width direction of the two insulating films 107 and 108 that are welded to a predetermined width. When cut by the cutter 111, an FFC 112 as shown in FIG. 6 or FIG. 7 is obtained. The FFC 112 cut to a predetermined width by the cutter 111 is wound and stored by a cable winding roll 113 provided on the downstream side of the cutter 111.

JP 2002-324444 A

  However, when manufacturing the FFC 112 in this way, before the welding by the ultrasonic horn 121, the vibration of the ultrasonic horn 121 is transmitted to the conductors 103a, 103b, 103c, and the conductors 103a, 103b, 103c are rolling. As a result, the FFC 112 with non-uniform spacing between the conductors 103a, 103b, and 103c may be manufactured.

  Such a problem will be described with reference to FIG. 5A shows a DD cross section of the roller anvil 122 shown in FIG. 4, and FIG. 5B shows an EE cross section of the roller anvil 122 shown in FIG.

  As shown in FIG. 5 (a), vibrations from the ultrasonic horn 121 are transmitted to the conductors 103a, 103b, 103c before ultrasonic welding, and horizontal rolls are generated respectively in the left and right directions. Further, as shown in FIG. 5B, immediately before the ultrasonic horn 121, the conductors 103a, 103b, 103c start to be accommodated in the concave groove 123 provided on the outer peripheral surface of the roller anvil 122 together with the lower insulating film 108. However, the conductors 103a, 103b, and 103c still roll in the left-right direction.

  And just before welding by the ultrasonic horn 121 in this way, the conductors 103a, 103b, and 103c roll, and before the conductors 103a, 103b, and 103c are accommodated in the center of the concave groove 123 of the roller anvil 122, When welding is performed, the FFC 112 in which the intervals P between the conductors 103a, 103b, and 103c are not uniform as shown in FIG. 6 and the conductors 103a and 103b are inclined as shown in FIG. The FFC 112 may be manufactured.

  Therefore, the problem to be solved by the present invention is to pass between an ultrasonic horn and a roller anvil in a state where a plurality of conductors arranged in parallel so as to be equally spaced are sandwiched between upper and lower insulating films. When manufacturing a flexible flat cable by welding an insulating film by ultrasonic vibration, a flat cable manufacturing method that prevents the spacing between conductors from becoming uneven or the conductor from tilting is prevented. Is to provide.

  In order to solve the above-mentioned problems, a flat cable manufacturing method according to the present invention includes an ultrasonic horn and an ultrasonic horn in a state where a plurality of conductors arranged in parallel at equal intervals are sandwiched between upper and lower insulating films. A groove is formed in a portion corresponding to the area of each conductor and is opposed to the sonic horn, and is passed between a rotatable roller anvil in which a protrusion is formed in a portion other than the area of each conductor. When the insulating film is welded by ultrasonic vibration, on the entry side to the roller anvil, each conductor is housed in the concave groove of the roller anvil together with one insulating film, and rolls are suppressed. The gist of the invention is that it is supplied between the roller anvil and the ultrasonic horn in a state.

  In this case, each of the conductors is housed together with one insulating film in the concave groove of the roller anvil, and the outer length of the roller anvil corresponding to the portion in which the roll is suppressed is 50 mm or more, and the arc angle of the roller anvil It is preferable that the length be 30 degrees or more and 90 degrees or less.

  According to the method of manufacturing a flexible flat cable having the above-described configuration, when welding the insulating film by ultrasonic vibration, each conductor is accommodated in the concave groove of the roller anvil along with the one insulating film on the entry side to the roller anvil. Since the roll is supplied between the roller anvil and the ultrasonic horn in a state in which the roll is suppressed, the roll of each conductor by the ultrasonic horn is suppressed, and the above-described problems are solved. Thereby, the flexible flat cable with a uniform space | interval between conductors is obtained.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a diagram showing a schematic configuration of an FFC manufacturing apparatus used in a method for manufacturing a flexible flat cable (FFC) according to the present invention. FIGS. 2A to 2C are cross-sectional views taken along line AA in FIG. It is the figure which showed B section and CC section in order.

  As shown in the figure, the FFC manufacturing apparatus 1 includes three conductor supply rolls 2a and 2b in which conductors 3a to 3c made of a copper or copper alloy wire are wound and stored in advance on the uppermost stream side of a predetermined transport path. 2c, and a pair of upper and lower pitch guide roller rollers 4 and 4 for guiding the conductors 3a to 3c so as to be arranged in parallel at a predetermined interval.

  As shown in FIG. 1, film rolls 6 a and 6 b for supplying insulating films 7 and 8 are further provided on the downstream side of the pitch guide rollers 4 and 4. In each of the film rolls 6a and 6b, long strip-shaped insulating films 7 and 8 are wound and stored in advance.

  A guide roller 9 is provided on the downstream side of the film rolls 6a and 6b. The guide roller 9 supplies the conductors 3a, 3b, and 3c to the ultrasonic welding apparatus 20 as a film laminate 10 that is sandwiched between the insulating films 7 and 8 supplied from the film rolls 6a and 6b (FIG. 2 ( b)).

  An ultrasonic welding device 20 is provided on the downstream side of the guide roller 9. The ultrasonic welding apparatus 20 is configured such that an ultrasonic horn 21 and a roller anvil 22 for applying vibration energy from an ultrasonic generator are arranged to face each other.

  As shown in FIG. 2 (b), the ultrasonic horn 21 and the roller anvil 22 are arranged so as to sandwich the film laminate 10 in which the conductors 3a, 3b, 3c are sandwiched between the upper and lower insulating films 7, 8 from above and below. Has been.

  The ultrasonic horn 21 of the ultrasonic welding device 20 is formed as a plate-like member that can be slidably contacted with the upper surface of the upper insulating film 7 over the entire width direction. The ultrasonic horn 21 is provided with ultrasonic vibration generated by an ultrasonic vibration generating mechanism (vibrator or the like) (not shown), and can vibrate in the vertical direction from the upper insulating film 7 to the lower insulating film 8. It is configured.

  The roller anvil 22 of the ultrasonic welding apparatus 20 has a rotatable cylindrical shape, and a plurality of concave grooves 23 and ridges 24 that are in contact with the lower surface of the insulating film 8 are formed on the outer peripheral surface thereof. Is formed.

  As shown in FIG. 2A, the roller anvil 22 of the ultrasonic welding apparatus 20 is in contact with the lower surface of the insulating film 8 at a portion corresponding to the region of the conductors 3a, 3b, 3c on the substantially cylindrical outer peripheral surface. A concave groove 23 is formed continuously in the circumferential direction of the roller anvil 22. The interval between the concave grooves 23 is formed in accordance with the interval P between the conductors 3a, 3b, 3c. Further, the width of each concave groove 23 is determined according to the width W of the conductors 3a, 3b, 3c.

  Further, on the roller anvil 22, a ridge 24 is formed continuously in the circumferential direction of the roller anvil 22 so as to come into contact with the lower surface of the insulating film 8 in a portion corresponding to a region other than the regions of the conductors 3 a, 3 b, 3 c. . Further, the ridges 24 are also formed at positions where they contact the lower surfaces of both outer edge portions of the insulating film 8.

  As shown in FIG. 1, on the downstream side of the ultrasonic welding device 20, a cutter 11 for cutting the ears at both ends in the width direction of the two insulating films 7 and 8 that are welded to a predetermined width. Is provided. When cut by the cutter 11, an FFC 12 as shown in FIG. 3 is obtained. The FFC 12 cut to a predetermined width by the cutter 11 is wound and stored by a cable take-up roll 13 provided on the downstream side of the cutter 11.

  As the insulating films 7 and 8, a resin film that is flexible and can be ultrasonically welded is used. As such insulating films 7 and 8, for example, a biaxially stretched polyethylene terephthalate (PET) film having a thickness of about 50 to 150 μm is used. In this case, the upper insulating film 7 and the lower insulating film 8 may have the same thickness or different thicknesses.

  As the conductors 3a, 3b, and 3c, for example, rectangular conductors having a rectangular cross section formed from copper or a copper alloy having a thickness of about 0.05 to 0.3 mm and a width of about 0.5 to 3 mm are used. In this case, the conductors 3a, 3a, 3c are arranged in parallel at intervals of about 1 to 5 mm.

  The manufacturing process of FFC13 using the FFC manufacturing apparatus 1 mentioned above is demonstrated. First, the conductors 3a, 3b, and 3c are supplied from the conductor supply rolls 2a, 2b, and 2c. The supplied conductors 3a, 3b, 3c are arranged in parallel by the pitch guide roller 4 so that the intervals between the conductors 3a, 3b, 3c become a predetermined interval.

  Next, the ultrasonic welding apparatus 20 is formed as a film laminate 10 in which the guide roller 9 is placed between the parallelly arranged conductors 3a, 3b, 3c between the insulating films 7, 8 supplied from the film rolls 6a, 6b. To supply.

  Then, when the film laminate 10 passes through the ultrasonic welding device 20, if ultrasonic vibration is applied while being sandwiched between the ultrasonic horn 21 and the roller anvil 22, the conductors 3a, 3b, 3c are connected. The sandwiched upper and lower insulating films 7 and 8 are ultrasonically welded at portions corresponding to the ridges 24 of the roller anvil 22.

  After the film laminated body 10 passes through the ultrasonic welding apparatus 20, the ear portions at both ends in the width direction are cut by the cutter 11, and formed into a predetermined dimension to form the FFC 12. Thereafter, when the FFC 12 is wound around the cable winding roll 13, the manufacture of the FFC 12 is completed.

  In this case, as shown in FIG. 1, the guide roller 9 is provided at a position below the roller anvil 22 on the entry side to the roller anvil 22. Thereby, the film laminated body 10 before the ultrasonic welding that has passed through the guide roller 9 enters the roller anvil 22 obliquely from below.

  Specifically, as shown in FIG. 1, the contact start point 17 between the vertical line 16 connecting the rotation axis center 14 of the roller anvil 22 and the vertex 15 where ultrasonic welding is performed, and the roller anvil 22 of the film laminate 10. The guide roller 9 is arranged so that an angle θ formed by a line 18 connecting the rotation axis center 14 of the roller anvil 22 is 60 degrees.

  FIG. 2 is a cross-sectional view showing the film laminate 10 and the roller anvil 22 in the order of processes from the roller anvil 22 to the ultrasonic welding before the ultrasonic welding. FIG. 2A shows an AA cross section of the roller anvil 22 and the film laminate 10 at the position 17 of the contact start point of the roller anvil 22 shown in FIG.

  As shown in the drawing, the conductors 3 a, 3 b, 3 c and the lower insulating film 8 of the film laminate 10 before ultrasonic welding are in a state of being accommodated in the concave groove 23 of the roller anvil 22. At this time, the vibration from the ultrasonic horn 21 is transmitted to the conductors 3a, 3b, and 3c. However, since they are accommodated in the concave groove 23 together with the insulating film 8, FIG. The rolling of the conductors 103a, 103b, 103c as shown in b) is suppressed.

  2B shows a BB cross section of the roller anvil 22 and the film laminate 10 at a position between the contact start point 17 position and the vertex 15 position of the roller anvil 22 shown in FIG. As shown in the drawing, the conductors 3 a, 3 b, 3 c and the lower insulating film 8 of the film laminate 10 before ultrasonic welding are still accommodated in the concave groove 23 of the roller anvil 22. Also at this time, the vibrations from the ultrasonic horn 21 are transmitted to the conductors 3a, 3b, 3c. However, since they are housed in the concave groove 23 together with the insulating film 8, FIG. The rolling of the conductors 3a, 3b, 3c as shown in (b) is suppressed.

  2C shows a CC cross section of the roller anvil 22 and the film laminate 10 at the position of the vertex 15 of the roller anvil 22 shown in FIG. As shown in the drawing, the conductors 3 a, 3 b, 3 c and the lower insulating film 8 of the film laminate 10 before ultrasonic welding are still accommodated in the concave groove 23 of the roller anvil 22. Also at this time, the vibrations from the ultrasonic horn 21 are transmitted to the conductors 3a, 3b, 3c. However, since they are housed in the concave groove 23 together with the insulating film 8, FIG. The rolling of the conductors 3a, 3b, 3c as shown in (b) is suppressed.

  Then, as shown in FIG. 2C, ultrasonic welding of the insulating films 7 and 8 by the ultrasonic horn 21 is performed. Specifically, when ultrasonic vibration is applied from the ultrasonic horn 21 to the portions of the insulating films 7 and 8 sandwiched between the ultrasonic horn 21 and the protrusion 24 of the roller anvil 22, the insulating films 7 and 8 are melted respectively. And will be welded.

  Thereafter, when the edge portions at both ends in the width direction of the two insulating films 7 and 8 that are welded are cut by the cutter 11, as shown in FIG. 3, the spacing P between the conductors 3a, 3b, and 3c is uniform. Is obtained.

  As described above, the conductor 3a, 3b, 3c is accommodated in the concave groove 23 of the roller anvil 22 together with the lower insulating film 8 on the entrance side of the roller anvil 22 in the film laminate 10 before ultrasonic welding. As shown in FIGS. 2 (a), 2 (b), and 2 (c), since the rolls are supplied between the roller anvil 22 and the ultrasonic horn 21 in a state in which the rolling of 3b and 3c is suppressed. Until the ultrasonic welding is completed, rolling of the conductors 3a, 3b, 3c is suppressed.

  Therefore, the distance between the conductors 103a, 103b, and 103c such as the FFC 112 shown in FIG. 6 due to the rolling of the conductors 103a, 103b, and 103c as shown in FIGS. It is possible to prevent P from becoming uneven and the conductors 103a and 103b such as the FFC 112 shown in FIG. 7 from being inclined.

  Incidentally, the outer peripheral length of the roller anvil 22 corresponding to the portion in which the conductors 3a, 3b, 3c are accommodated in the concave groove 23 of the roller anvil 22 together with the lower insulating film 8 and the roll is suppressed is 50 mm or more and is shown in FIG. If the arc angle θ of the roller anvil 22 shown in FIG. 2 is set to a length of 30 degrees or more and 90 degrees or less, the roll due to the vibration of the conductors 3a, 3b, 3c from the ultrasonic horn 21 can be sufficiently suppressed. .

  As mentioned above, although embodiment of the manufacturing method of the flexible flat cable which concerns on this invention was described, this invention is not limited to such embodiment at all, In the range which does not deviate from the summary of this invention, it is various aspects. Of course, it can be implemented.

  For example, in the above-described embodiment, the flexible flat cable has been described as having three conductors. However, the number of conductors is not limited to 2, 4 or 5, 6 conductors. The invention can be applied.

  In the above embodiment, a rectangular conductor having a rectangular cross section is used as the conductor of the flexible flat cable. However, a round conductor having a substantially circular cross section may be used, and conductors having various cross sectional shapes may be used. Can be applied.

It is the figure which showed schematic structure of the flexible flat cable manufacturing apparatus used for the manufacturing method of the flexible flat cable which concerns on this invention. It is the figure which showed each process of the manufacturing method of the flexible flat cable which concerns on this invention, (a) is AA cross section of FIG. 1, (b) is BB cross section of FIG. 1, (c) is FIG. It is the figure which showed CC cross section. It is sectional drawing which shows the flexible flat cable manufactured by the manufacturing method of the flexible flat cable which concerns on this invention. It is the figure which showed schematic structure of the flexible flat cable manufacturing apparatus used conventionally. It is the figure which showed each process of the manufacturing method of the flexible flat cable used conventionally, (a) is the DD cross section of FIG. 4, (b) is the figure which showed the EE cross section of FIG. . It is sectional drawing which shows the flexible flat cable manufactured by the manufacturing method of the flexible flat cable used conventionally. It is sectional drawing which shows the flexible flat cable similarly manufactured by the manufacturing method of the flexible flat cable conventionally used.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 FFC manufacturing apparatus 2a-2c Conductor supply roll 3a-3c Conductor 4 Pitch guide rollers 6a, 6b Film roll 7, 8 Insulating film 9 Guide roller 10 Laminated film 11 Cutter 12 FFC
13 Cable take-up roll 14 Roller anvil rotation axis center 15 Roller anvil apex 16 Vertical line 17 Roller anvil contact start point 18 Line connecting contact start point and rotation axis center θ Arc angle of the outer surface of the Roland anvil 20 Ultrasonic welding Device 21 Ultrasonic Horn 22 Roller Anvil 23 Groove 24 Convex

Claims (2)

  In a state where a plurality of conductors arranged in parallel so as to be equidistant are sandwiched between upper and lower insulating films, an ultrasonic horn, and a portion corresponding to the area of each of the conductors arranged opposite to the ultrasonic horn The insulating film is welded by ultrasonic vibration when passing through a rotatable roller anvil in which concave grooves are formed and convex portions are formed in portions other than the regions of the respective conductors. A method of manufacturing a cable, wherein, on the entry side to the roller anvil, each of the conductors is housed in a concave groove of the roller anvil together with one insulating film, and the roll anvil and the roll are controlled in a state where rolling is suppressed. A method for producing a flexible flat cable, characterized in that the flexible flat cable is supplied between an ultrasonic horn.   The outer length of the roller anvil corresponding to the portion in which each conductor is housed together with one insulating film in the concave groove of the roller anvil and the rolling is suppressed is 50 mm or more, and the arc angle of the roller anvil is 30 degrees or more. The length of 90 degrees or less, The manufacturing method of the flexible flat cable of Claim 1 or 2 characterized by the above-mentioned.

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