JP3959981B2 - Flat cable manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a flat cable manufacturing method for manufacturing a flat cable by sandwiching and laminating a plurality of conductors with an insulating film.
[0002]
[Prior art]
For the purpose of space saving and weight reduction, as shown in FIG. 6, there is a flat cable 3 in which a plurality of rectangular conductors 1 are arranged in parallel and sandwiched between thin insulating films 2a and 2b from both sides (first prior art). .
[0003]
However, in the flat cable 3 (first prior art) shown in FIG. 6, the insulating films 2a and 2b are set to be thin, and the conductor 1 is also a flat shape. (Not shown) increases the capacitance between the ground and the ground via the metal body, and lowers the characteristic impedance. If the distance between the flat cable 3 and the surrounding metal body varies, the characteristic impedance of the flat cable 3 varies.
[0004]
Of course, the same can be said even when the flat cables 3 are separated from each other. That is, as shown in FIGS. 7 and 8, when the conductor 1 of the other flat cable 3b is connected to or disconnected from one flat cable 3a, the characteristic impedance of the one flat cable 3a varies. The same applies to the other flat cable 3b. Therefore, when a plurality of flat cables 3 shown in FIG. 6 are installed, it is easily affected by external noise.
[0005]
In consideration of this, by using the flat cable 6 having a structure in which the conductors 4 and 5 are arranged in a pair as shown in FIG. 9, the capacitance between the pair of conductors 4 and 5 is set large, (2nd prior art) is carried out to reduce the influence of different electromagnetic fields on individual conductors.
[0006]
According to such a configuration, the pair of conductors 4 and 5 are very close to each other, so that the electromagnetic field can be confined between the two conductors 4 and 5, and thus is not easily affected by external noise or the like.
[0007]
[Problems to be solved by the invention]
In the second prior art, polyester films such as PET having good insulation are used as the insulating films 2a and 2b. Then, as shown in FIG. 9, in order to bond the two insulating films 2a and 2b to each other in the non-conductor portion where the conductors 4 and 5 are not disposed, an adhesive layer is provided in advance on the surfaces of the insulating films 2a and 2b. It has a structure.
[0008]
And in 2nd prior art, in order to insulate each conductor 4 and 5 and to ensure adhesiveness with both insulation films 2a and 2b, the intervening film 7 in which the adhesive layer was formed on both surfaces is used. It was.
[0009]
However, the intervening film 7 in which the adhesive layers are formed on both sides has to be expensive due to its structure.
[0010]
The subject of this invention is providing the flat cable manufacturing method which can manufacture cheaply and easily the laminated flat cable of the structure which arrange | positions a pair of upper and lower conductors closely.
[0011]
[Means for Solving the Problems]
In order to solve the above problem, the invention according to claim 1 is a first insulating film in which an adhesive layer is formed only on one surface, the adhesive surface on which the adhesive layer is formed, and the adhesive layer is not formed on both surfaces. A plurality of conductors are sandwiched between two surfaces of the two insulating films, and the non-conductive portions of the first insulating film and the non-conductive portion of the second insulating film are heated and pressed by a heating roller to temporarily A plurality of conductors are arranged in parallel between the first step of bonding, the bonding surface of the third insulating film in which the bonding layer is formed only on one surface, and the other surface of the second insulating film. The second insulating film is sandwiched between the upper and lower conductors in a state and a plurality of conductors sandwiched in parallel between the adhesive surface of the first insulating film and one surface of the second insulating film. The other side of the third insulating film Free conductor portions each other Chakumen, in which and a second step of temporarily adhered by hot-pressing by the heating roller.
[0012]
Invention of Claim 2 is a flat cable manufacturing method of Claim 1, Comprising: The non-conductive parts of the adhesive surface of said 1st insulating film and one surface of said 2nd insulating film, and said 2nd insulating film The method further includes a third step of ultrasonically welding the non-conductive portions of the other surface and the bonding surface of the third insulating film.
[0013]
Invention of Claim 3 is a flat cable manufacturing method of Claim 1 or Claim 2, Comprising: The said non-conductive part of said 1st insulating film and / or said 3rd insulating film is provided in the said heating roller. What is provided with a ridge projecting to press in the direction of the second insulating film is used.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a sectional view showing a concept of a flat cable applied in one embodiment of the present invention. The flat cable 6 manufactured in this embodiment is the same as the second prior art shown in FIG. 9, and therefore, the flat cable 6 is assigned the same reference numeral as the second prior art. In an actual flat cable, the insulating films 2a and 2b and the intervening film 7a are bonded to each other at a portion (non-conductor portion) 21 where the conductors 4 and 5 are not disposed. The state of non-adhesion is shown for ease.
[0015]
As shown in FIG. 1, the flat cable 6 is a laminated flat cable having a structure in which conductors 4 and 5 are arranged in a pair, and an intervening film (second insulating film) for insulating the conductors 4 and 5 from each other. ) As 7a, the adhesive layer is not formed on either side, and the insulating films 2a and 2b located on the outer side are only about 0.6 to 3.0 μm on one side (adhesive side). Are used in which adhesive layers 8a and 8b having a thickness of 5 are previously formed (primer treatment).
[0016]
And the flat cable manufacturing apparatus for performing this flat cable manufacturing method, as shown in FIG. 2, the 1st film supply roller 11 which supplies the 1st insulating film 2a, and the intervening film (2nd insulating film) 7a A second film supply roller 12, a first temporary bonding portion 13 for temporarily bonding a plurality of parallel conductors of the first conductors 4 between the first insulating film 2a and the intervening film 7a, and a third insulation A plurality of parallels are provided between the third film supply roller 15 for supplying the film 2 b, the intermediate product 16 primarily laminated at the first temporary bonding portion 13, and the third insulating film 2 b supplied from the third film supply roller 15. Ultrasonic welding is performed on the second temporary bonding portion 17 that is temporarily bonded by sandwiching the second conductor 5 in parallel and the intermediate product 18 that is temporarily bonded by the temporary bonding portions 13 and 17. And a ultrasonic welds 19 to complete the flat cable by.
[0017]
The first temporary bonding portion 13 is formed as shown in FIG. 1 while heating and melting the flat roller 20 formed of an elastic body such as rubber and having a smooth outer peripheral surface and the adhesive layer 8a formed on the first insulating film 2a. The portion of the first insulating film 2a shown where the conductors 4 and 5 are not disposed (that is, between the adjacent conductors and the portion where the conductors 4 and 5 are not disposed at the end in the width direction of the flat cable is included: And a first forming roller (heating roller) 22 (FIG. 3) that presses the non-conductor portion 21) against the intervening film 7a.
[0018]
The reason why the surface of the flat roller 20 is formed smoothly is to contact the intervening film 7a and keep the intervening film 7a smooth as shown in FIG.
[0019]
The first forming roller 22 (FIG. 3) uses a metal having high heat conductivity so as to transmit heat from a heating device (not shown) to the first insulating film 2a. A plurality of metal ridges 23 for pressing the non-conductor portion 21 against the intervening film 7a side are formed. The first forming roller 22 is disposed immediately above the flat roller 20, and temporarily bonds (temporary lamination) by sandwiching the first insulating film 2a, the first conductor 4, and the intervening film 7a in the vertical direction.
[0020]
Similarly to the first molding roller 22, the second temporary bonding portion 17 is formed with a flange 23 (FIG. 3) on which the non-conductive portion 21 is pressed while the adhesive layer 8a formed on the first insulating film 2a is heated and melted. A second forming roller (heating roller) 24 and a third forming roller (heated) formed with a flange 23 (FIG. 3) for pressing the non-conductive portion 21 while heating and melting the adhesive layer 8b formed on the second insulating film 2b. Roller) 25.
[0021]
The second molding roller 24 and the third molding roller 25 are each made of a metal having high heat conductivity so as to transmit heat from a heating device (not shown) to the first insulating film 2a and the second insulating film 2b. As shown in FIG. 3, a collar 23 is formed on the outer periphery. Then, as shown in FIG. 5, the second molding roller 24 and the third molding roller 25 are arranged in the vertical direction, while pressing the non-conductive portion 21 of the intermediate product 16 from the vertical direction by the respective flanges 23, The adhesive layers 8a and 8b are melted by heat transfer from the second molding roller 24 and the third molding roller 25, and the non-conductive portions 21 of both the insulating films 2a and 2b are both temporarily bonded (temporarily laminated) to the intervening film 7a. .
[0022]
The ultrasonic welding portion 19 includes a columnar anvil 27, and an ultrasonic oscillator 28 that emits ultrasonic waves from the horn 28a to the intermediate product 18 on the anvil 27 to melt and bond the non-conductive portion 21 to the adhesive layers 8a and 8b. Is provided.
[0023]
Note that reference numerals 31, 32, and 33 in FIG. 2 denote the temporary bonding portions 13, 17 while adjusting the tensions of the insulating films 2a, 2b, 7a supplied from the film supply rollers 11, 12, 15, respectively. The relay guide roller for guiding to the nipping positions of the rollers 20, 22, 24, 25 is shown.
[0024]
The flat cable manufacturing method using the flat cable manufacturing apparatus of the said structure is demonstrated.
[0025]
First, the first insulating film 2 a is supplied from the first film supply roller 11, and this first insulating film 2 a is interposed between the flat roller 20 and the first molding roller 22 of the first temporary bonding portion 13 by the relay guide roller 31. Guide to the pinching position. At this time, the adhesive surface on which the adhesive layer 8a of the first insulating film 2a is formed is directed downward. Further, an intervening film (second insulating film) 7 a is supplied from the second film supply roller 12, and the intervening film 7 a is guided to the sandwiching position of the first temporary bonding portion 13 by the relay guide roller 32. At the same time, the first conductor 4 supplied from the outside is guided to the sandwiching position of the first temporary bonding portion 13 and sandwiched between the first insulating film 2a and the intervening film 7a.
[0026]
At this time, as shown in FIG. 4, the flange 23 of the first forming roller 22 faces the non-conductive portion 21 of the first insulating film 2 a toward the interposition film 7 a in contact with the flat roller 20 (downward). Press. At the same time, the heat transfer from the flange 23 of the first forming roller 22 melts the adhesive layer 8a formed on the lower surface of the first insulating film 2a, and the non-conductive portion 21 of the first insulating film 2a becomes the intervening film 7a. Temporary bonding (first step). The intermediate product 16 in this state is supplied from the first temporary bonding portion 13 to the second temporary bonding portion 17.
[0027]
In the second temporary bonding portion 17, the intermediate product 16 supplied from the first temporary bonding portion 13 is sandwiched between the second forming roller 24 and the third forming roller 25. Further, between the second forming roller 24 and the third forming roller 25, the third insulating film 2 b that has passed through the relay guide roller 33 from the third film supply roller 15 is supplied to the lower side of the intermediate product 16. At this time, the bonding surface on which the bonding portion 8b of the third insulating film 2b is formed is set upward. At the same time, between the second forming roller 24 and the third forming roller 25, the second conductor 5 supplied from the outside is sandwiched between the intermediate product 16 and the third insulating film 2b.
[0028]
At this time, as shown in FIG. 5, the flange 23 of the second forming roller 24 presses the non-conductive portion 21 of the first insulating film 2a toward the intervening film 7a (downward), and the third forming roller 25 of the flanges 23 press the non-conductive portion 21 of the third insulating film 2b toward the intervening film 7a (upward). In this way, each of the forming rollers 24, 25 is pressed against the intervening film 7a by the flanges 23 of the molding rollers 24, 25, and the heat transfer from the flanges 23 of the molding rollers 24, 25 causes each The adhesive layers 8a and 8b formed on one side of the insulating films 2a and 2b are melted, and the non-conductive portions 21 of the insulating films 2a and 2b are temporarily bonded to the intervening film 7a (second step). The intermediate product 18 in this state is discharged from the second temporary bonding portion 17.
[0029]
Here, the intermediate product 18 having the configuration shown in FIG. 5 does not have an adhesive layer formed in advance on the intervening film 7a side, so it is compared with the second prior art in which the adhesive layer is formed on both surfaces of the intervening film 7 in advance. And the adhesion | attachment with respect to the intervening film 7a in the non-conductor part 21 of each insulating film 2a, 2b is not made | formed completely. For this reason, this intermediate product 18 is supplied to the ultrasonic welding part 19, and the ultrasonic welding part 19 is securely bonded. Specifically, in the ultrasonic welded portion 19, the intermediate product in a state where the insulating films 2a and 2b on both sides are temporarily bonded by sandwiching the conductors 4 and 5 between the intervening film 7a by the temporary bonding portions 13 and 17. 18, the ultrasonic wave is emitted from the horn 28a of the ultrasonic oscillator 28 on the anvil 27, and the adhesive layers 8a and 8b are surely melted and bonded by the non-conductive portion 21 to complete the flat cable 6 (third). Process).
[0030]
Thus, since the thing without the adhesive layer previously formed can be used as the intervening film 7a, the two insulating films 2a and 2b having the adhesive layer formed on one side and the adhesive layer formed on both sides 1 The manufacturing cost can be reduced as compared with the second prior art, which is very expensive because the intervening film 7 is used.
[0031]
In this case, since the non-conductive portion 21 of each insulating film 2a, 2b can be reliably bonded to both surfaces of the intervening film 7a in the ultrasonic welded portion 19, it is possible to prevent the quality of the flat cable 6 from being impaired.
[0032]
In the above-described embodiment, the both insulating films 2a and 2b used the primer-treated ones, but any material can be used as long as the adhesive layers 8a and 8b are formed on one side in advance. May be.
[0033]
Further, the flat cable manufacturing apparatus is not limited to that shown in FIG. For example, in the case of the flat cable manufacturing apparatus shown in FIG. 2, in the first temporary bonding part 13, the bonding surface of the first insulating film 2a and the non-conductive portion 21 on one surface of the intervening film 7a are temporarily bonded (first step). After that, in the second temporary bonding portion 17, the non-conductive portions 21 on the other surface of the intervening film 7 a and the bonding surface of the third insulating film 2 b were temporarily bonded (second step). 13 and the second temporary bonding portion 17 are combined to provide a single temporary bonding portion. In this single temporary bonding portion, the first step and the second step are performed simultaneously, and all the insulation is performed at once. The non-conductive portion 21 of the films 2a, 2b, 7a may be temporarily bonded.
[0034]
【The invention's effect】
According to the first aspect of the present invention, as the second insulating film (intervening film), one having no adhesive layer formed in advance can be used, so one intervening film having an adhesive layer formed on both sides is used. Therefore, the manufacturing cost can be reduced as compared with the second prior art which has become very expensive because of the above.
[0035]
In this case, since the adhesive layer is not formed in advance on the second insulating film (intervening film) side, the first insulating film and the first insulating film are compared with the second prior art in which the adhesive layer is formed on both surfaces of the intervening film in advance. Although the adhesion to the intervening film at the non-conductive portion of the three insulating films is not completely achieved, according to the invention of claim 2, the non-conductive portions of the first insulating film and the third insulating film are bonded by ultrasonic welding. It can be securely bonded to both sides of the second insulating film. Therefore, it can prevent impairing the quality of the flat cable.
[0036]
According to the invention described in claim 3, the heating roller having a protrusion for pressing the non-conductive portion of the first insulating film and / or the third insulating film toward the second insulating film is used. Therefore, the insulating films can be reliably temporarily bonded to each other in the non-conductor portion that is thinner than the portion where the conductor is disposed.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view showing the concept of a flat cable manufactured according to an embodiment of the present invention.
FIG. 2 is a schematic diagram showing a flat cable manufacturing apparatus used in an embodiment of the present invention.
FIG. 3 is a view showing a forming roller (heating roller) with a flange protruding therefrom.
FIG. 4 is a diagram showing an operation of welding the non-conductive portions of the first insulating film and the intervening film at the first temporary bonding portion.
FIG. 5 is a diagram showing an operation of pressing a non-conductive portion of the first insulating film and the third insulating film against an intervening film layered in the second temporary bonding portion.
FIG. 6 is a schematic diagram showing a flat cable of the first prior art.
FIG. 7 is a schematic diagram showing an example of the positional relationship between a pair of flat cables according to the first prior art.
FIG. 8 is a schematic diagram showing an example of the positional relationship between a pair of flat cables according to the first prior art.
FIG. 9 is a schematic diagram showing a flat cable manufactured in the second prior art.
[Explanation of symbols]
2a First insulating film 2b Third insulating film 4 First conductor 5 Second conductor 7a Second insulating film (intervening film)
8a, 8b Adhesive layer 11 First film supply roller 12 Second film supply roller 13 First temporary adhesive portion 15 Third film supply roller 16 Intermediate product 17 Second temporary adhesive portion 18 Intermediate product 19 Ultrasonic welding portion 20 Flat roller 21 Non-conductive portion 22 First forming roller 23 鍔 24 Second forming roller 25 Third forming roller 27 Anvil 28 Ultrasonic oscillator 28a Horn

Claims (3)

A plurality of conductors are arranged in parallel between the adhesive surface of the first insulating film having the adhesive layer formed on only one surface and the one surface of the second insulating film in which the adhesive layer is not formed on both surfaces. A first step of temporarily adhering the non-conductive portions of the first insulating film and the non-conductive portion of the second insulating film with a heating roller;
A plurality of conductors are arranged in parallel between the adhesive surface of the third insulating film having the adhesive layer formed only on one surface and the other surface of the second insulating film, and the second insulating film . A plurality of conductors sandwiched in parallel between an adhesive surface of one insulating film and one surface of the second insulating film are sandwiched so as to form a pair, and the other surface of the second insulating film and the third surface A flat cable manufacturing method provided with the 2nd process of heat-pressing the non-conductive parts of the adhesive surface of an insulating film with a heating roller, and temporarily bonding. It is a flat cable manufacturing method of Claim 1, Comprising:
The non-conductive portions of the first insulating film and the non-conductive portion of the second insulating film are ultrasonically welded together and the non-conductive portions of the second insulating film and the non-conductive portion of the third insulating film are ultrasonically welded. A flat cable manufacturing method further comprising a third step. The flat cable manufacturing method according to claim 1 or 2,
Flat cable manufacturing in which the heating roller is provided with a ridge protruding to press the non-conductive portion of the first insulating film and / or the third insulating film toward the second insulating film Method.

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