JP3457764B2 - Manufacturing method of sheet circuit body - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet circuit in which a round bare wire is crushed into a flat shape to improve adhesiveness between insulating sheets and weldability to a mating connecting portion.
The present invention relates to a method for manufacturing a body .

[0002]

2. Description of the Related Art FIGS.
It shows a method of manufacturing a sheet circuit body proposed in No. 1729. In FIG. 11, reference numeral 3 denotes a wiring board, and an electric wire (bare wire) 5 is arranged in a required circuit pattern shape by a wiring head (not shown) between a plurality of pins 4 on the wiring board 3. . The wiring plate 3 can be freely moved in the two-dimensional directions by the screw shafts 6 and 27 in the XY directions. The pin 4 penetrates the wiring plate 3 and is erected on a lower base plate 11, and the base plate 11 is integrated with the pin 4 along a guide bar 29 against a push spring (not shown). It can descend and separate from the wiring board 3.

After the electric wires 5 are routed to the wiring board 3, the insulating resin sheet 7 is positioned on the wiring board 3 by a supply means (not shown). A plurality of connection holes 12 are formed in advance in the insulating resin sheet 7 at required locations by a punching machine (not shown). The connection hole 12 is for exposing the electric wire 5 and bringing it into contact with a mating connecting portion. A thermoplastic adhesive is attached to the inner surface of the insulating sheet 7.

Then, the heating unit 9 is positioned with respect to the insulating sheet 7 on the wiring board 3, and the heated heating unit 9 is pressed against the insulating sheet 7 by the elevating cylinder 10. The pin 4 pushed by the heating unit 9 descends and only the electric wire 5 is adhered to the insulating sheet 7 with the wiring board 3 in a circuit pattern shape.

FIG. 12 shows a state in which the electric wire 5 is adhered to the inner surface of the insulating sheet 7, and the electric wire 5 is arranged at the center of each connection hole 12. Another insulating resin sheet 15 is adhered to the insulating sheet 7 and the electric wire 5 from below with a heating unit (not shown) similar to the above. A connection hole 12 is formed in the lower insulating sheet 15 at the same position as the upper insulating sheet 7. The electric wire 5 is sandwiched between two insulating sheets 7 and 15 as shown in FIG.

Further, as shown in FIG. 14, the electric wire 5 is cut (26) together with the insulating sheets 7 and 15 between the two connection holes 12 to make a plurality of circuits independent. The cutting hole 26 is the connection hole 12
It is formed by the same punching machine. And the seat circuit body 2
8 is completed. The sheet circuit body 28 is connected and fixed by welding the exposed electric wire 5a in the connection hole 12 to the bent base portion 21a of the bus bar terminal 21 provided on the insulating substrate 20 such as an electric connection box (not shown). To be done.

FIGS. 15 to 16 show a state in which the electric wire 5 in the connection hole 12 is ultrasonically welded to the terminal 21. Terminal 2
1 is inserted into the slit hole 30 of the insulating substrate 20,
As shown in FIG. 15, the lower welding horn 23 ′ is opposed to the round hole 24 adjacent to the insertion hole 30 so that the tip of the horn can contact the bent base portion 21 a of the terminal 21, and the connection hole is formed on the bent base portion 21 a. Position the exposed electric wire 5a in 12 to expose the exposed electric wire 5a.
Position the upper welding horn 22 'on top. Then, the electric wire 5 and the bent base portion 21a of the terminal 21 are sandwiched and pressed by the upper and lower welding horns 22 'and 23', and as shown in FIG.
5 ')

[0008]

However, in the above-mentioned conventional method for manufacturing a sheet circuit body, when the electric wire 5 is bonded between the insulating sheets 7 and 15 as shown in FIG. If used, the wire 5 and sheets 7, 15
There is a concern that a large gap 31 is likely to be formed between the wire and the wire, which adversely affects the fixing of the electric wire 5 and the insulating property. Further, as shown in FIG. 15, when the exposed electric wire 5a in the connection hole 12 is connected to the mating connecting portion such as the terminal 21, the welding horns 22 'and 2'
If a large pressure is not applied to 3 ', the electric wire 5 is not firmly welded, and there is a problem that the welding machine becomes large and the equipment cost increases accordingly. In view of the above points, the present invention can reliably bond the electric wire between both insulating sheets without a gap even when using a thick electric wire, and exposes the electric wire in the connection hole to the mating connection portion of the welding horn. An object of the present invention is to provide a method for manufacturing a sheet circuit body that can be reliably welded with a small pressing force.

[0009]

In order to achieve the above object, the present invention is to adhere a circuit pattern-shaped circular electric wire to the surface of an insulating sheet and then press the circuit pattern-shaped circular electric wire together. Then, the method of manufacturing the sheet circuit body is characterized in that the sheet circuit body is crushed integrally with the insulating sheet. Also, arrange the round electric wire in the circuit pattern shape on the wiring board,
A method for manufacturing a sheet circuit body in which the round electric wire having the circuit pattern shape is transferred to one of the insulating sheets and adhered thereto, and the other insulating sheet is adhered to the one insulating sheet from above the circular electric wire having the circuit pattern shape In, after adhering the circular electric wire having the circuit pattern shape to the one insulating sheet, the circular electric wire is crushed by a press in the thickness direction of the insulating sheet to form a flat shape, and then the electric wire having the flat shape. A method of adhering the other insulating sheet to the one insulating sheet from above, or exposing the flat-shaped electric wire from the connection holes formed in both the insulating sheets, and exposing the flat exposed electric wire in the connecting hole. A method is also possible in which a large contact area is brought into contact with the mating connecting portion to enable welding .

[0010]

[Operation] A round electric wire is crushed by a press and transformed into a flat electric wire. The flat electric wire reliably adheres to the insulating sheet with no gap between the two insulating sheets and a large contact area. The flat electric wire contacts a mating connecting portion such as a terminal over a large area, and can be reliably welded even with a small pressing force of the ultrasonic welding horn.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows an embodiment of a method for manufacturing a sheet circuit body according to the present invention. In FIG. 1, reference numeral 1 denotes a wiring device similar to the conventional one (see Japanese Patent Application No. 6-91729), and a round head (bare wire) 5 is required for a pin 4 on a wiring plate 3 by a wiring head 2. The wiring board 3 is arranged in a different circuit pattern shape, and the wiring board 3 on which wiring has been completed is moved by the screw shaft 6 to be positioned below one of the insulating resin sheets 7. The insulating resin sheet 7 is obtained by winding a roll-shaped material through a guide roller 8 and leading it into a strip shape.

A heating unit 9 is located above the wiring plate 3, and the heating unit 9 is mounted on the wiring plate 3 by an elevating cylinder 10.
And the insulating sheet 7 is pressed against the wiring board 3 by the heating unit 9, and the insulating sheet 7 is moved as shown in FIGS.
The circular electric wire 5 having a circuit pattern shape is adhered to the inner surface 7a of the. A thermoplastic adhesive is applied to the inner surface 7a of the insulating sheet 7 as in the conventional case, and the pins 4 on the wiring plate 3 can be lowered together with the base plate 11. A connection hole 12 (FIG. 2) is formed at a required position in the insulating sheet 7 by a hole punching machine (not shown) before the heat bonding, and the round electric wire 5 is exposed at the center of the connection hole 12 as shown in FIG. And located.

By repeatedly arranging the electric wires 5 on the wiring board 3 and transferring them to the insulating sheet 7, a plurality of circuit patterns of the round electric wires 5 are formed on the belt-shaped insulating sheet 7 as shown in FIG. It The strip-shaped insulating sheet 7 is sent forward by a pulling roll or the like (not shown).

On the upper and lower sides of the insulating sheet 7 after the transfer of electric wires, a vertically movable press 13 and a press base 14 facing the press 13 are installed. The press table 14 is located directly below the insulating sheet 7. The circular electric wire 5 on the insulating sheet 7 is pressed by the press 13 on the press table 14
Press it up and crush it into a flat shape as shown in Figs. The crushing of the electric wire 5 is performed integrally with the insulating sheet 7. The insulating sheet 7 will not be damaged even if the electric wire 5 is crushed.
It is made of a resin material that does not damage it. It is a feature of the method for manufacturing a sheet circuit body of the present invention that the round electric wire 5 adhered to the insulating sheet 7 is crushed by the presses 13 and 14 to have a flat shape or a substantially elliptical cross section.

To the electric wire 5'crushed into a flat shape, another insulating resin sheet 15 is adhered from the lower side of the insulating sheet 7 by a heating unit 16 in FIG. A pressing plate 17 is located above the heating unit 16,
The flat electric wire 5 ′ is adhered by the pressing plate 17 and the heating unit 16 between the two insulating sheets 7 and 15 as shown in FIGS. 6 and 7 with almost no gap, and the sheet circuit body 18 is completed.

In FIG. 1, the lower insulating sheet 15 is wound in a roll shape like the upper insulating sheet 7, and is heated by a pulling roller or the like (not shown) via a guide roller 19 to heat the lower insulating sheet. Derived on unit 16. A connection hole 12 is also formed in the lower insulating sheet 15 at the same position as the upper insulating sheet 7 by a punching machine (not shown) before the heat bonding. Then, as shown in FIG. 6, the connection holes 12 of both insulating sheets 7 and 15 are located at the same position, and the flat exposed wire 5a 'is located in both connection holes 12. Since the electric wire 5'is flattened, even when a thick electric wire is used, the upper and lower insulating sheets 7 and 15 are close to each other at the position of the flat electric wire 5'as shown in FIG. The upper and lower insulating sheets 7 and 15 are in close contact with each other on both sides, and almost no gap is formed.

8 to 10 show a state in which the flat exposed electric wire 5a 'of the sheet circuit body 18 is welded and connected to the bus bar terminal 21 on the insulating substrate 20 such as an electric junction box. That is, as shown in FIG. 9, the exposed electric wire 5a 'in the connection hole 12 is positioned on the bent base portion 21a of the terminal 21, the upper ultrasonic welding horn 22 is opposed to the exposed electric wire 5a', and the lower ultrasonic welding horn is placed. 23 is positioned so that it can be inserted into the hole 24 of the substrate 21 below the bent base portion 21a of the terminal 21, and the exposed electric wire 5a 'and the bent base portion 21a of the terminal 21 are sandwiched and pressed by both welding horns 22 and 23. Then, ultrasonic welding (25) is performed as shown in FIG. In FIG. 8, reference numeral 26 indicates a cutting hole similar to the conventional one.

In FIG. 9, the electric wire 5'of the sheet circuit body 18
Since the sheet has a flat shape, the sheet circuit body 1 is mounted on the substrate 20.
8 is set, the exposed electric wire 5a 'in the connection hole 12
Has a large contact area with a lower contact surface of the bent base portion 21a of the terminal 21, and the tip of the upper welding horn 22 has the exposed electric wire 5
It contacts the upper surface of a'with a large contact area, so that the electric wire 5'and the terminal 21 can be reliably welded to each other without applying a large pressing force as in the conventional case.

Although the embodiment of ultrasonic welding for connecting the electric wire terminals has been described above, the same can be done by changing the welding means to spot welding or resistance welding.

[0020]

As described above, according to the present invention, the flat electric wire which has been crushed is bonded between the two insulating sheets with no gap and with a large contact area. Therefore, the thick electric wire is used. Even in this case, the adhesion of the electric wire to the sheet is improved, the electric wire is firmly fixed to the insulating sheet, and the deterioration of the insulating property due to the gap is prevented. Also, the contact area of the mating side such as the terminal is large, and the tip of the ultrasonic welding horn is also large area, so even if the welding horn has a small pressing force, it surely welds, thereby downsizing the welding machine. It is possible to reduce the equipment cost. Further, since the electric wire is crushed in the manufacturing process of the sheet circuit body, the crushing process can be performed in a short time without impairing the productivity.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a method for manufacturing a sheet circuit body according to the present invention.

FIG. 2 is a perspective view showing a state where a round electric wire is bonded to one insulating sheet.

FIG. 3 is likewise a longitudinal sectional view of an essential part.

FIG. 4 is a perspective view showing a state in which a round electric wire on an insulating sheet is crushed.

FIG. 5 is a vertical cross-sectional view of the same main part.

FIG. 6 is a perspective view showing a flat circuit body formed by adhering the other insulating sheet to a crushed electric wire.

FIG. 7 is likewise a longitudinal sectional view of an essential part.

FIG. 8 is a perspective view showing a state in which the flat circuit body is connected to a substrate such as an electric junction box.

FIG. 9 is a vertical cross-sectional view showing a state in which a flat electric wire is welded to a bus bar terminal with an ultrasonic welding horn.

FIG. 10 is a vertical cross-sectional view of a state in which welding is completed similarly.

FIG. 11 is a perspective view showing a conventional method for manufacturing a sheet circuit body.

FIG. 12 is a perspective view showing a state in which a round electric wire is similarly bonded between insulating sheets.

FIG. 13 is a vertical cross-sectional view of the same bonded state.

FIG. 14 is a perspective view showing a state in which a conventional flat circuit body is connected to a substrate such as an electric junction box.

FIG. 15 is a vertical cross-sectional view showing a state where a round electric wire is welded to a bus bar terminal by a welding horn.

FIG. 16 is a vertical cross-sectional view showing a state in which welding is also completed.

[Explanation of symbols]

5a 'Exposed wire 5 round electric wire 7,15 Insulation sheet 12 connection holes 13,14 Press 18 sheet circuit 21 terminals

Claims (3)

(57) [Claims] 1. A sheet comprising a circuit pattern-shaped round electric wire adhered to the surface of an insulating sheet, and the circuit pattern-shaped round electric wire being crushed integrally with the insulating sheet by a press. Circuit body manufacturing method. 2. A round electric wire having a circuit pattern shape is arranged on a wiring board in a circuit pattern shape, and the round electric wire having the circuit pattern shape is transferred to one of the insulating sheets and bonded to the insulating sheet. In the method for manufacturing a sheet circuit body, in which the other insulating sheet is adhered to the one insulating sheet from above, the circular electric wire having the circuit pattern shape is adhered to the one insulating sheet, and then the circular electric wire is pressed. A method for manufacturing a sheet circuit body, comprising: crushing an insulating sheet in a plate thickness direction to form a flat shape, and then bonding the other insulating sheet to the one insulating sheet from above the flat-shaped electric wire. 3. The flat-shaped electric wire is exposed from the connection holes formed in both of the insulating sheets, and the flat exposed electric wire in the connection hole can be welded by contacting the mating connection portion with a large contact area. 3. The method according to claim 2, wherein
A method for manufacturing the described sheet circuit body.