JP4560185B2

JP4560185B2 - Conductor thin film sheet with electric wire and method for producing conductor thin film sheet with electric wire

Info

Publication number: JP4560185B2
Application number: JP2000238287A
Authority: JP
Inventors: 和宏村上; 健一花崎; 嘉彦渡邊; 晃馬場
Original assignee: Yazaki Corp
Current assignee: Yazaki Corp
Priority date: 2000-08-07
Filing date: 2000-08-07
Publication date: 2010-10-13
Anticipated expiration: 2020-08-07
Also published as: JP2002050236A

Description

【０００１】
【発明の属する技術分野】
本発明は、薄い導体層と薄い絶縁層とを有し該導体層に電線の芯線が接合した電線付き導体薄膜シート及び該電線付き導体薄膜シートの製造方法に関する。
【０００２】
【従来の技術】
移動体としての自動車には、搭載される種々のランプや種々のモータなどの電子機器にバッテリなどの電源から電極を供給したり制御装置から制御信号を送ったりするためにワイヤハーネスが配索されている。前述したワイヤハーネスは複数の電線などを備えている。
【０００３】
これらの電線には、それぞれの芯線に外部からのノイズが侵入することを防止するために、シールド電線が用いられることがある。シールド電線は、導電性を有する編組からなるシールド部を備えている。このシールド部が、前記芯線内にノイズが侵入することを防止する。
【０００４】
ここで、近年、前述したワイヤハーネスの低コスト化を図ることが望まれている。このために、前記シールド部を備えない電線を複数本束ね、これらの複数本の電線に薄膜の導体層を有する導体薄膜シートを巻き付けて、ワイヤーハーネスを構成することが提案されている。このような構成にすることによって、低コスト化とノイズの侵入防止とを図ることが提案されている。また、このような構成においても、前記ノイズを取り出すために、前記導体層にアース電線または端子などを取り付ける必要がある。
【０００５】
【発明が解決しようとする課題】
前記導体層は、電線に巻き付けるために可撓性を有する必要が生じ、比較的薄く形成されることが望まれる。このため、前記導体層にアース電線などを取り付けるために、導体薄膜シートに孔を開けて、該孔に前述したアース電線などの端部を通した後、ワッシャ、ボルト、ナットなどを用いて導体薄膜シートとアース電線とを接続することが考えられる。
【０００６】
この場合、前記アース電線の被覆部の一部を除去するなどの皮むき作業が必要となるなどの、組み立てにかかる工数が増加することが考えられる。また、ワッシャ、ボルト、ナットなどの部品が必要になるので、部品点数が増加する。したがって、コストが高騰することが考えられる。さらに、前述したボルトとナットなどを締め付ける際に、導体層が破損して、確実に前述したアース電線を導体層に接続できないことが考えられる。
【０００７】
したがって、本発明の目的は、薄膜の導体層に電線を確実に接続できかつ低コストな電線付き導体薄膜シート及び該電線付き導体薄膜シートの製造方法を提供することにある。
【０００８】
【課題を解決するための手段】
前記課題を解決し目的を達成するために、請求項１に記載の本発明の電線付き導体薄膜シートは、導体層と前記導体層に積層された絶縁層とを有する導体薄膜シートと、導電性を有する一本の芯線と前記芯線を被覆する絶縁性を有する被覆部とを備えた電線と、を備え、前記電線の端部が導体薄膜シートの平面上でＵ字状に曲げられて当該導体薄膜シートに重ねられ、かつＵ字状に曲げられた部分を挟んだ２箇所で前記電線の芯線と前記導体薄膜シートの導体層とが互いに接合していることを特徴としている。
【０００９】
請求項２に記載の本発明の電線付き導体薄膜シートは、請求項１に記載の電線付き導体薄膜シートにおいて、前記Ｕ字状に曲げられた部分を挟んだ２箇所で前記導体薄膜シートの絶縁層と前記電線の被覆部とが互いに溶着していることを特徴としている。
【００１１】
請求項３に記載の本発明の電線付き導体薄膜シートは、請求項１又は請求項２に記載の電線付き導体薄膜シートにおいて、前記導体薄膜シートの導体層がアルミまたはアルミニウム合金を含んでおり、前記電線の芯線が銅または銅合金を含んでおり、前記導体薄膜シートの絶縁層と前記電線の被覆部とはそれぞれ合成樹脂からなることを特徴としている。
【００１２】
請求項４に記載の本発明の電線付き導体薄膜シートは、請求項１又は請求項２に記載の電線付き導体薄膜シートにおいて、前記導体薄膜シートの導体層は銅または銅合金を含みかつ外表面にすずまたはすず合金からなるメッキ層が形成されており、前記電線の芯線が銅または銅合金を含んでおり、前記導体薄膜シートの絶縁層と前記電線の被覆部とはそれぞれ合成樹脂からなることを特徴としている。
【００１３】
請求項５に記載の本発明の電線付き導体薄膜シートの製造方法は、請求項１ないし請求項４のうちいずれか一項に記載の電線付き導体薄膜シートの製造方法において、前記導体薄膜シートの絶縁層に前記電線の被覆部を重ねて超音波溶着を行うことで、前記導体薄膜シートの導体層と前記電線の芯線とを互いに接合することを特徴としている。
【００１４】
請求項６に記載の本発明の電線付き導体薄膜シートの製造方法は、請求項５に記載の電線付き導体薄膜シートの製造方法において、前記絶縁層と前記被覆部とを互いに近づける方向に加圧した後、徐々に加圧した力を弱めながら前記超音波溶着を行うことを特徴としている。
【００１５】
請求項１に記載した本発明の電線付き導体薄膜シートによれば、導体薄膜シートの導体層に電線の芯線が接合されているので、部品点数が増加することを防止できる。
電線の端部がＵ字状に曲げられかつ前記端部に位置する被覆部と芯線とが、それぞれ絶縁層に溶着しているとともに導体層に接合している。このように、導体層と芯線との接合箇所の面積を増加させているので、導体層と芯線との接合箇所の機械的な強度をより一層向上させる。
【００１６】
請求項２に記載した本発明の電線付き導体薄膜シートによれば、導体薄膜シートの絶縁層と電線の被覆部とが互いに溶着しているので、導体層と芯線との接合箇所の機械的な強度を向上させる。
【００１８】
請求項３及び請求項４に記載した本発明の電線付き導体薄膜シートによれば、導体薄膜シートの導体層に電線の芯線が接合されているので、部品点数が増加することを防止できる。
【００１９】
請求項５に記載した本発明の電線付き導体薄膜シートの製造方法によれば、導体薄膜シートの絶縁層に電線の被覆部を重ねて超音波溶着を行うので、導体薄膜シートに電線を取り付ける際に電線の被覆部を皮むきするなどの作業を行う必要が生じない。
【００２０】
また、超音波溶着を行って、導体層と芯線とを接合させるので、導体薄膜シートに電線を取り付ける際に必要な部品点数が増加することを防止できる。さらに、超音波溶着を行って導体薄膜シートに電線を取り付けるので、超音波溶着を行う際に生じる摩擦熱によって、絶縁層と被覆部とが溶けて互いに溶着する。なお、超音波溶着中では、薄膜導体シートと電線とを互いに近づける方向に加圧する力を一定に保っても良く、変化させても良い。
【００２１】
請求項６に記載した本発明の電線付き導体薄膜シートの製造方法によれば、絶縁層と被覆部とを互いに近づける方向に加圧する力を弱めながら超音波溶着を行うので、超音波溶着によって生じる摩擦熱が高くなると前述した加圧する力を徐々に弱くすることとなる。
【００２２】
【発明の実施の形態】
以下、本発明の第１の実施形態にかかる電線付き導体薄膜シートを、図１ないし図４を参照して説明する。電線付き導体薄膜シート１は、図１及び図２に示すように、導体薄膜シートとしてのアルミラミネートシート（以下ＡＬＳと呼ぶ）２と、電線としての被覆電線３と、を備えている。
【００２３】
ＡＬＳ２は、薄い導体層４と、薄い絶縁層７と、を備えて、比較的薄いシート状に形成されている。導体層４は、導電性を有する金属からなる。導体層４は、可撓性を有している。導体層４は、少なくともアルミニウムまたはアルミニウム合金を含んでいる。絶縁層７は、第１絶縁層５と、第２絶縁層６と、を備えている。
【００２４】
第１絶縁層５は、絶縁性を有する合成樹脂からなりかつＡＬＳ２に積層されている。第１絶縁層５は、可撓性を有しかつポリエチレンテレフタレート（Polyethyleneterephthalate：ＰＥＴ）などからなる。第２絶縁層６は、絶縁性を有する合成樹脂からなりかつ第１絶縁層５に積層されている。第２絶縁層６は、可撓性を有しかつポリ塩化ビニル（Polyvinylchloride：ＰＶＣ）などからなる。
【００２５】
被覆電線３は、断面形状が丸形に形成されている。被覆電線３は、断面丸形の芯線１０と、この芯線１０を被覆する被覆部１１と、を備えている。芯線１０は、導電性を有する金属からなる。芯線１０は、可撓性を有している。芯線１０は、少なくとも銅または銅合金を含んでいる。被覆部１１は、絶縁性を有する合成樹脂からなる。被覆部１１は、可撓性を有しかつポリ塩化ビニル（Polyvinylchloride：ＰＶＣ）などからなる。
【００２６】
電線付き導体薄膜シート１は、被覆電線３の一部分３ａに位置する被覆部１１が絶縁層７と溶着し、かつ前記一部分３ａに位置する芯線１０が導体層４に金属結合した状態で接合している。電線付き導体薄膜シート１は、被覆電線３の一部分３ａと、ＡＬＳ２とが、超音波溶着機によって互いに固定されて得られる。なお、図示例では、前記一部分３ａは、被覆電線３の端部に位置しており、本明細書に記した端部をなしている。
【００２７】
超音波溶着機は、図３及び図４に示すように、チップ２０と、このチップ２０に相対するアンビル２１と、図示しない発振機と、振動子と、コーンと、ホーンなどを備えている。超音波溶着機は、チップ２０とアンビル２１との間に互いに溶着する溶着対象物を挟み、これらのチップ２０とアンビル２１とを互いに近づける方向に加圧した状態で、発振機で振動子を振動させてこの振動をコーン、ホーン経由でチップ２０に伝える。そして、超音波溶着機は、チップ２０とアンビル２１との間に挟んだ溶着対象物に超音波振動を加えて摩擦熱で該対象物を溶着させる。
【００２８】
前記電線付き導体薄膜シート１を製造する際、即ち、ＡＬＳ２と被覆電線３とを互いに固定する際には、まず、図３に示すように、チップ２０とアンビル２１との間にＡＬＳ２と被覆電線３とを挟む。このとき、絶縁層７に被覆部１１を重ね、かつアンビル２１にＡＬＳ２を載置し、被覆電線３にチップ２０を当接させる。
【００２９】
そして、図３中の矢印Ｐ１，Ｐ２に沿ってチップ２０とアンビル２１とを互いに近づける方向に加圧した後、発振機で振動子を振動させてこの振動をコーン、ホーン経由でチップ２０に伝える。前述した加圧する力を一定に保ったまま、発振機の振動をチップ２０に伝える。ＡＬＳ２被覆電線３との間に、前述した振動に応じた摩擦熱が生じて、まず、絶縁層７及び被覆部１１が溶ける。
【００３０】
チップ２０とアンビル２１とが互いに近づく方向に加圧されているので、絶縁層７及び被覆部１１が溶けると、導体層４と芯線１０が接触する。互いに接触すると、導体層４と芯線１０とは前述した摩擦熱によって溶融しない状態で固相のまま互いに金属結合する。
【００３１】
即ち、導体層４と芯線１０とは、いわゆる超音波溶着（超音波溶接または超音波接合ともいう）によって互いに接合される。絶縁層７と被覆部１１とが互いに溶着し、かつ導体層４と芯線１０とが互いに接合した前述した構成の電線付き導体薄膜シート１を得る。
【００３２】
このように得られた電線付き導体薄膜シート１は、ワイヤハーネスを構成する複数束ねられた電線にＡＬＳ２が巻かれるなどして、前記複数束ねられた電線のシールドを行う。また、前記被覆電線３は、所望のアース回路などと接続される。
【００３３】
本実施形態によれば、超音波溶着によって導体層４と芯線１０とが互いに接合されているので、ＡＬＳ２に被覆電線３を取り付ける際にかかる工数及び部品点数の増加を抑制できる。したがって、電線付き導体薄膜シート１のコストの高騰を抑制できる。
【００３４】
また、絶縁層７に被覆部１１即ち被覆電線３を重ねているため、ＡＬＳ２に取り付ける際に、被覆電線３の一部分３ａなどの被覆部１１を除去する必要が生じない。即ち、被覆電線３を皮むきする必要が生じないので、ＡＬＳ２に被覆電線３を取り付ける際にかかる工数をより一層抑制できる。したがって、電線付き導体薄膜シート１のコストの高騰をより一層抑制できる。
【００３５】
超音波溶着によって導体層４と芯線１０を接合する際に、絶縁層７に被覆部１１即ち被覆電線３を重ねている。このため、導体層４に被覆電線３を重ねて超音波溶着を行う場合と比較して、導体層４が破損することを防止できる。したがって、被覆電線３をＡＬＳ２に確実に接続できる。
【００３６】
また、絶縁層７に被覆部１１即ち被覆電線３を重ねているため、超音波溶着を行う際の摩擦熱によって絶縁層７と被覆部１１とが溶けて互いに溶着している。
このため、導体層４と芯線１０とを例えばワイヤボンディングなどによって互いに電気的に接続する場合などと比較して、導体層４と芯線１０との接合箇所の機械的な強度を向上させることができる。したがって、被覆電線３をＡＬＳ２に確実に接続できる。
【００３７】
さらに、絶縁層７に被覆部１１即ち被覆電線３を重ねて絶縁層７と被覆部１１とを互いに溶着させているため、互いに接合しずらいアルミニウムまたはアルミニウム合金からなる導体層４と、銅または銅合金からなる芯線１０とを、確実に固定できる。したがって、被覆電線３をＡＬＳ２により確実に接続できる。
【００３８】
さらに、被覆電線３が断面丸形に形成されているので、チップ２０とアンビル２１とを互いに近づける力が、ＡＬＳ２と被覆電線３とが互いに接触する箇所に集中することとなる。このため、摩擦熱によって溶けた絶縁層４及び被覆部１１とが、導体層４と芯線１０との間から速やかに除去される。導体層４と芯線１０とが確実に接合する。したがって、ＡＬＳ２に被覆電線３をより一層確実に接続できる。
【００３９】
また、被覆電線３は、図５に示すように、その一部分３ａがＵ字状に曲げられた状態で、超音波溶着機によって、ＡＬＳ２に取り付けられても良い。図５に示す場合では、Ｕ字状に曲げられた一部分３ａの二箇所に、導体層４と芯線１０とが互いに接合された接合箇所を形成している。この場合でも、絶縁層７に被覆電線３を重ねて、超音波溶着が行われる。さらに、前述した二箇所の接合箇所のうち一箇所ずつ接合が行われても良く、二箇所同時に接合が行われても良い。
【００４０】
この場合、部品点数と所要の工数を抑制してコストを抑制でき、かつ被覆電線３をＡＬＳ２に確実に接続できることにくわえ、被覆電線３の一部分３ａがＵ字状に曲げられているので、ＡＬＳ２と被覆電線３との接合箇所の面積を増加させることが可能となる。したがって、ＡＬＳ２と被覆電線３との接合箇所の機械的な強度をより一層向上させることが可能となって、ＡＬＳ２に被覆電線３をより一層確実に固定できる。
【００４１】
次に、本発明の第２の実施形態にかかる電線付き導体薄膜シート１を、図６を参照して説明する。なお、前述した第１の実施形態と同一構成部分には同一符号を付して説明を省略する。
【００４２】
本実施形態では、導体薄膜シートとしてすずメッキ付き銅ラミネートシート２ａを用いている。すずメッキ付き銅ラミネートシート２ａは、互いに積層された導体層４とメッキ層１２と前述した絶縁層７を備えている。
【００４３】
導体層４は、少なくも銅又は銅合金を含んでいる。メッキ層１２は導体層４の外表面に形成されている。メッキ層１２は少なくもすず又はすず合金を含んでいる。すずメッキ付き銅ラミネートシート２ａは、図６では、下から順にメッキ層１２と導体層４と第１絶縁層５と第２絶縁層６とが積層されて形成されている。
【００４４】
本実施形態の電線付き導体薄膜シート１も、前述した第１の実施形態と同様にチップ２０とアンビル２１とを備えた超音波溶着機を用いて、すずメッキ付き銅ラミネートシート２ａと被覆電線３とが接続される。このとき、電線付き導体薄膜シート１は、第２絶縁層６に被覆部１１即ち被覆電線３が重ねられる。超音波溶着されて、導体層４と芯線１０とが互いに接合しかつ絶縁層７と被覆部１１とが互いに溶着する。
【００４５】
本実施形態によれば、前述した第１の実施形態と同様に、超音波溶着によって導体層４と芯線１０とが互いに接合されているので、すずメッキ付き銅ラミネートシート２ａに被覆電線３を取り付ける際にかかる工数及び部品点数の増加を抑制できる。したがって、電線付き導体薄膜シート１のコストの高騰を抑制できる。
【００４６】
また、絶縁層７に被覆部１１即ち被覆電線３を重ねているため、すずメッキ付き銅ラミネートシート２ａに取り付ける際に、被覆電線３の一部分３ａなどの被覆部１１を除去する必要が生じない。即ち、被覆電線３を皮むきする必要が生じないので、すずメッキ付き銅ラミネートシート２ａに被覆電線３を取り付ける際にかかる工数をより一層抑制できる。したがって、電線付き導体薄膜シート１のコストの高騰をより一層抑制できる。
【００４７】
超音波溶着によって導体層４と芯線１０を接合する際に、絶縁層７に被覆部１１即ち被覆電線３を重ねている。このため、導体層４に被覆電線３を重ねて超音波溶着を行う場合と比較して、導体層４が破損することを防止できる。さらに、絶縁層７に被覆部１１即ち被覆電線３を重ねているため、導体層４の表面に芯線１０と接合しずらいすずなどからなるメッキ層１２が形成されていても、このメッキ層１２の影響を受けることなく被覆電線３をすずメッキ付き銅ラミネートシート２ａに確実に接続できる。
【００４８】
また、絶縁層７に被覆部１１即ち被覆電線３を重ねているため、超音波溶着を行う際の摩擦熱によって絶縁層７と被覆部１１とが溶けて互いに溶着している。
このため、導体層４と芯線１０とを例えばワイヤボンディングなどによって互いに電気的に接続する場合などと比較して、導体層４と芯線１０との接合箇所の機械的な強度を向上させることができる。したがって、被覆電線３をすずメッキ付き銅ラミネートシート２ａに確実に接続できる。
【００４９】
さらに、被覆電線３が断面丸形に形成されているので、チップ２０とアンビル２１とを互いに近づける力が、すずメッキ付き銅ラミネートシート２ａと被覆電線３とが互いに接触する箇所に集中することとなる。このため、摩擦熱によって溶けた絶縁層４及び被覆部１１とが、導体層４と芯線１０との間から速やかに除去される。導体層４と芯線１０とが確実に接合する。したがって、すずメッキ付き銅ラミネートシート２ａに被覆電線３をより一層確実に接続できる。
【００５０】
また、被覆電線３は、前述した第１の実施形態と同様に、一部分３ａがＵ字状に曲げられた状態で、超音波溶着機によって、すずメッキ付き銅ラミネートシート２ａに取り付けられても良い。
【００５１】
また、前述した第１及び第２の実施形態では、一本の芯線１０を有する被覆電線３とＡＬＳ２またはすずメッキ付き銅ラミネートシート２ａとを互いに固定しているが、本発明では、複数の導線が互いに撚られてなる撚線とこの撚線を被覆する被覆部とを有する被覆電線をＡＬＳ２またはすずメッキ付き銅ラミネートシート２ａに固定するようにしても良い。なお、この場合、導体層４と前記撚線とが互いに接合されることとなる。
【００５２】
さらに、前述した第１及び第２の実施形態では、超音波溶着中にチップ２０とアンビル２１とを加圧する力を一定に保っている。しかしながら、本発明では、超音波溶着中に、時間の経過とともに前述した力を徐々に弱めても良い。この場合、摩擦熱によって薄い導体層４が溶けるなどの破損することを防止できる、したがって、ＡＬＳ２またはすずメッキ付き銅ラミネートシート２ａに被覆電線３をより確実に接続できる。
【００５３】
【発明の効果】
以上説明したように、請求項１に記載の本発明によれば、導体薄膜シートの導体層に電線の芯線が接合されているので、部品点数が増加することを防止できる。したがって、コストの高騰を抑制できる。導体薄膜シートの導体層に電線の芯線が接合されているので、導体薄膜シートの導体層に確実に電線を接続できる。
電線の端部がＵ字状に曲げられかつ前記端部に位置する被覆部と芯線とが、それぞれ絶縁層に溶着しているとともに導体層に接合している。このように、導体層と芯線との接合箇所の面積を増加させているので、導体層と芯線との接合箇所の機械的な強度をより一層向上させる。したがって、コストの高騰を抑制できることにくわえ、導体薄膜シートの導体層により一層確実に電線を接続することができる。
【００５４】
請求項２に記載の本発明によれば、導体薄膜シートの絶縁層と電線の被覆部とが互いに溶着しているので、導体層と芯線との接合箇所の機械的な強度を向上させる。したがって、コストの高騰を抑制できることにくわえ、導体薄膜シートの導体層により確実に電線を接続することができる。
【００５６】
請求項３に記載の本発明によれば、導体薄膜シートの導体層に電線の芯線が接合されているので、部品点数が増加することを防止できる。したがって、コストの高騰を抑制できるとともに、導体薄膜シートの導体層に確実に電線を接続できる。
【００５７】
請求項４に記載の本発明によれば、導体薄膜シートの導体層に電線の芯線が接合されているので、部品点数が増加することを防止できる。したがって、コストの高騰を抑制できるとともに、導体薄膜シートの導体層に確実に電線を接続できる。
【００５８】
請求項５に記載の本発明によれば、導体薄膜シートの絶縁層に電線の被覆部を重ねて超音波溶着を行うので、導体薄膜シートに電線を取り付ける際に電線の被覆部を皮むきするなどの作業を行う必要が生じない。このため、製造にかかる工数を抑制できる。また、超音波溶着を行って、導体層と芯線とを接合させるので、導体薄膜シートに電線を取り付ける際に必要な部品点数が増加することを防止できる。したがって、電線付き導体薄膜シートのコストの高騰を抑制できる。
【００５９】
また、超音波溶着を行って導体薄膜シートに電線を取り付けるので、超音波溶着を行う際に生じる摩擦熱によって、絶縁層と被覆部とが溶けて互いに溶着する。したがって、導体層と芯線との接合箇所の機械的な強度を向上でき、導体薄膜シートの導体層に確実に電線を接続できる。
【００６０】
さらに、超音波溶着を行って導体薄膜シートに電線を取り付けるので、導体層がアルミニウムまたはアルミニウム合金からなり、芯線が銅または銅合金からなって、融接法及びろう付けなどの溶接方法によって互いに固定しずらい場合でも、導体層と芯線とを確実に接合できる。導体層の外表面に、前記芯線が接合しずらいすずなどを含んだメッキ層が形成されていても、導体層と芯線とを確実に接合できる。
【００６１】
請求項６に記載の本発明によれば、絶縁層と被覆部とを互いに近づける方向に加圧する力を弱めながら超音波溶着を行うので、超音波溶着によって生じる摩擦熱が高くなると前述した加圧する力を徐々に弱くすることとなる。このため、超音波溶着を行う際に生じる摩擦熱などによって、導体層が溶けるなどして破損することを防止できる。したがって、導体薄膜シートの導体層により一層確実に電線を接続することができる。
【図面の簡単な説明】
【図１】本発明の第１の実施形態にかかる電線付き導体薄膜シートを示す斜視図である。
【図２】図１中のＩＩ−ＩＩ線に沿った断面図である。
【図３】同実施形態の被覆電線と導体薄膜シートとを互いに固定する前の状態を示す断面図である。
【図４】同実施形態の被覆電線と導体薄膜シートとを互いに固定した後の状態を示す断面図である。
【図５】同実施形態の電線付き導体薄膜シートの変形例を示す斜視図である。
【図６】本発明の第２の実施形態にかかる電線付き導体薄膜シートの断面図である。
【符号の説明】
１電線付き導体薄膜シート
２ＡＬＳ（導体薄膜シート）
２ａすずメッキ付き銅ラミネートシート（導体薄膜シート）
３被覆電線（電線）
３ａ一部分（端部）
４導体層
７絶縁層
１０芯線
１１被覆部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a conductor thin film sheet with electric wires having a thin conductor layer and a thin insulating layer, and a core wire of an electric wire joined to the conductor layer, and a method for producing the conductor thin film sheet with electric wires.
[0002]
[Prior art]
In a car as a moving body, a wire harness is routed to supply electrodes from a power source such as a battery to a mounted electronic device such as various lamps and various motors or to send a control signal from a control device. ing. The wire harness described above includes a plurality of electric wires.
[0003]
For these electric wires, shielded electric wires may be used in order to prevent external noise from entering the respective core wires. The shielded electric wire includes a shield part made of a braid having conductivity. This shield portion prevents noise from entering the core wire.
[0004]
In recent years, it has been desired to reduce the cost of the wire harness described above. For this reason, it has been proposed that a plurality of electric wires not provided with the shield part are bundled, and a conductive thin film sheet having a thin conductive layer is wound around these electric wires to constitute a wire harness. It has been proposed to reduce the cost and prevent the intrusion of noise by adopting such a configuration. Also in such a configuration, it is necessary to attach a ground wire or a terminal to the conductor layer in order to extract the noise.
[0005]
[Problems to be solved by the invention]
The conductor layer needs to have flexibility in order to be wound around the electric wire, and is desirably formed to be relatively thin. For this reason, in order to attach a ground wire or the like to the conductor layer, a hole is formed in the conductor thin film sheet, and the end of the ground wire or the like is passed through the hole, and then a conductor is used using a washer, a bolt, a nut, or the like. It is conceivable to connect the thin film sheet and the ground wire.
[0006]
In this case, it is conceivable that the number of man-hours required for assembly increases, for example, a peeling operation such as removing a part of the covering portion of the ground wire is required. In addition, since parts such as washers, bolts, and nuts are required, the number of parts increases. Therefore, it can be considered that the cost will rise. Further, when the bolts and nuts described above are tightened, the conductor layer may be damaged, and the above-described ground wire cannot be reliably connected to the conductor layer.
[0007]
Accordingly, an object of the present invention is to provide a conductor thin film sheet with electric wires and a method for producing the conductor thin film sheet with electric wires, which can reliably connect electric wires to a thin film conductor layer and are low in cost.
[0008]
[Means for Solving the Problems]
In order to solve the problems and achieve the object, the conductor thin film sheet with electric wire according to claim 1 of the present invention includes a conductor thin film sheet having a conductor layer and an insulating layer laminated on the conductor layer, and a conductive property. And an electric wire provided with an insulating covering for covering the core wire, and the end of the electric wire is bent in a U shape on the plane of the conductive thin film sheet, and the conductor. It is characterized in that the core wire of the electric wire and the conductor layer of the conductive thin film sheet are bonded to each other at two positions sandwiching the U - shaped bent portion on the thin film sheet.
[0009]
The conductor thin film sheet with electric wire of the present invention according to claim 2 is the conductor thin film sheet with electric wire according to claim 1, wherein the conductor thin film sheet is insulated at two locations sandwiching the U - shaped bent portion. The layer and the covering portion of the electric wire are welded to each other.
[0011]
The conductor thin film sheet with electric wire according to claim 3 of the present invention is the conductor thin film sheet with electric wire according to claim 1 or 2 , wherein the conductor layer of the conductor thin film sheet contains aluminum or an aluminum alloy, The core wire of the electric wire contains copper or a copper alloy, and the insulating layer of the conductive thin film sheet and the covering portion of the electric wire are each made of a synthetic resin.
[0012]
The conductor thin film sheet with electric wires of the present invention according to claim 4 is the conductor thin film sheet with electric wires according to claim 1 or 2 , wherein the conductor layer of the conductor thin film sheet contains copper or a copper alloy and has an outer surface. A plating layer made of tin or tin alloy is formed, the core wire of the electric wire contains copper or a copper alloy, and the insulating layer of the conductive thin film sheet and the covering portion of the electric wire are made of synthetic resin, respectively It is characterized by.
[0013]
The manufacturing method of the conductor thin film sheet with an electric wire of this invention of Claim 5 is a manufacturing method of the conductor thin film sheet with an electric wire as described in any one of Claim 1 thru | or 4 . The conductor layer of the conductor thin film sheet and the core wire of the electric wire are bonded to each other by performing ultrasonic welding with the covering portion of the electric wire superimposed on an insulating layer.
[0014]
The method for producing a conductor thin film sheet with electric wire according to a sixth aspect of the present invention is the method for producing a conductor thin film sheet with electric wire according to the fifth aspect , wherein the insulating layer and the covering portion are pressed toward each other. Then, the ultrasonic welding is performed while gradually decreasing the pressure applied.
[0015]
According to the conductor thin film sheet with electric wire of the present invention described in claim 1, since the core wire of the electric wire is joined to the conductor layer of the conductor thin film sheet, it is possible to prevent the number of parts from increasing.
The end portion of the electric wire is bent in a U-shape, and the covering portion and the core wire located at the end portion are welded to the insulating layer and joined to the conductor layer. As described above, since the area of the joint portion between the conductor layer and the core wire is increased, the mechanical strength of the joint portion between the conductor layer and the core wire is further improved.
[0016]
According to the conductor thin film sheet with an electric wire of the present invention described in claim 2, since the insulating layer of the conductor thin film sheet and the covering portion of the electric wire are welded to each other, the mechanical location of the joint portion between the conductor layer and the core wire is reduced. Improve strength.
[0018]
According to the conductor thin film sheet with electric wire of the present invention described in claim 3 and claim 4 , since the core wire of the electric wire is joined to the conductor layer of the conductor thin film sheet, it is possible to prevent the number of parts from increasing.
[0019]
According to the method for manufacturing a conductor thin film sheet with electric wire of the present invention described in claim 5 , since the ultrasonic welding is performed by superposing the coating portion of the electric wire on the insulating layer of the conductor thin film sheet, when attaching the electric wire to the conductor thin film sheet Therefore, it is not necessary to perform work such as peeling the sheath of the electric wire.
[0020]
In addition, since the conductor layer and the core wire are joined by ultrasonic welding, it is possible to prevent an increase in the number of parts required when attaching the electric wire to the conductor thin film sheet. Further, since the electric wires are attached to the conductor thin film sheet by performing ultrasonic welding, the insulating layer and the covering portion are melted and welded to each other by frictional heat generated when ultrasonic welding is performed. In addition, during ultrasonic welding, the force which pressurizes a thin film conductor sheet and an electric wire in the direction which mutually approaches may be kept constant, and may be changed.
[0021]
According to the manufacturing method of the conductor thin film sheet with electric wire of the present invention described in claim 6 , since ultrasonic welding is performed while weakening the force of pressing the insulating layer and the covering portion in a direction to bring them closer to each other, it is caused by ultrasonic welding. When the frictional heat is increased, the aforementioned pressing force is gradually weakened.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the conductor thin film sheet with an electric wire concerning the 1st Embodiment of this invention is demonstrated with reference to FIG. As shown in FIGS. 1 and 2, the conductor thin film sheet 1 with electric wires includes an aluminum laminate sheet (hereinafter referred to as ALS) 2 as a conductor thin film sheet and a covered electric wire 3 as an electric wire.
[0023]
The ALS 2 includes a thin conductor layer 4 and a thin insulating layer 7 and is formed in a relatively thin sheet shape. The conductor layer 4 is made of a conductive metal. The conductor layer 4 has flexibility. The conductor layer 4 contains at least aluminum or an aluminum alloy. The insulating layer 7 includes a first insulating layer 5 and a second insulating layer 6.
[0024]
The first insulating layer 5 is made of an insulating synthetic resin and laminated on the ALS 2. The first insulating layer 5 is flexible and made of polyethylene terephthalate (PET) or the like. The second insulating layer 6 is made of a synthetic resin having an insulating property and is laminated on the first insulating layer 5. The second insulating layer 6 is flexible and made of polyvinyl chloride (PVC) or the like.
[0025]
The covered electric wire 3 has a round cross section. The covered electric wire 3 includes a core wire 10 having a round cross section and a covering portion 11 that covers the core wire 10. The core wire 10 is made of a conductive metal. The core wire 10 has flexibility. The core wire 10 contains at least copper or a copper alloy. The covering portion 11 is made of an insulating synthetic resin. The covering portion 11 has flexibility and is made of polyvinyl chloride (PVC).
[0026]
The conductor thin film sheet 1 with an electric wire is joined in a state in which the covering portion 11 located on the portion 3 a of the covered electric wire 3 is welded to the insulating layer 7 and the core wire 10 located on the portion 3 a is metal-bonded to the conductor layer 4. Yes. The conductor thin film 1 with electric wire is obtained by fixing a part 3a of the covered electric wire 3 and the ALS 2 to each other by an ultrasonic welding machine. In the illustrated example, the portion 3a is located at the end of the covered electric wire 3 and forms the end described in the present specification.
[0027]
As shown in FIGS. 3 and 4, the ultrasonic welder includes a chip 20, an anvil 21 opposed to the chip 20, an oscillator (not shown), a vibrator, a cone, a horn, and the like. In the ultrasonic welding machine, an object to be welded is sandwiched between the tip 20 and the anvil 21, and the vibrator is vibrated by the oscillator in a state in which the tip 20 and the anvil 21 are pressurized in a direction approaching each other. Then, this vibration is transmitted to the chip 20 via a cone and a horn. Then, the ultrasonic welding machine applies ultrasonic vibration to the welding object sandwiched between the tip 20 and the anvil 21 and welds the object with frictional heat.
[0028]
When manufacturing the conductor thin film sheet 1 with electric wires, that is, when fixing the ALS 2 and the covered electric wire 3 to each other, first, as shown in FIG. 3, the ALS 2 and the covered electric wire are placed between the chip 20 and the anvil 21. 3 is sandwiched. At this time, the covering portion 11 is overlaid on the insulating layer 7, the ALS 2 is placed on the anvil 21, and the chip 20 is brought into contact with the covered electric wire 3.
[0029]
Then, after pressurizing the chip 20 and the anvil 21 along the arrows P1 and P2 in FIG. 3 so as to approach each other, the vibrator is vibrated by an oscillator and this vibration is transmitted to the chip 20 via a cone and a horn. . The vibration of the oscillator is transmitted to the chip 20 while keeping the above-described pressurizing force constant. Friction heat corresponding to the vibration described above is generated between the ALS2 covered electric wire 3 and the insulating layer 7 and the covering portion 11 are first melted.
[0030]
Since the tip 20 and the anvil 21 are pressurized in a direction approaching each other, when the insulating layer 7 and the covering portion 11 are melted, the conductor layer 4 and the core wire 10 come into contact with each other. When they are in contact with each other, the conductor layer 4 and the core wire 10 are metal-bonded to each other in a solid phase without being melted by the frictional heat.
[0031]
That is, the conductor layer 4 and the core wire 10 are bonded to each other by so-called ultrasonic welding (also referred to as ultrasonic welding or ultrasonic bonding). The conductor thin film sheet with electric wire 1 having the above-described configuration in which the insulating layer 7 and the covering portion 11 are welded to each other and the conductor layer 4 and the core wire 10 are joined to each other is obtained.
[0032]
The thus obtained conductor thin film sheet 1 with electric wires shields the plural bundled wires by, for example, winding ALS2 around the plural bundled wires constituting the wire harness. The covered wire 3 is connected to a desired ground circuit or the like.
[0033]
According to this embodiment, since the conductor layer 4 and the core wire 10 are joined to each other by ultrasonic welding, it is possible to suppress an increase in the number of man-hours and the number of parts required when attaching the covered electric wire 3 to the ALS 2. Therefore, an increase in cost of the conductor thin film 1 with electric wires can be suppressed.
[0034]
Further, since the covering portion 11, that is, the covered electric wire 3 is overlapped on the insulating layer 7, it is not necessary to remove the covering portion 11 such as the portion 3 a of the covered electric wire 3 when attaching to the ALS 2. That is, since it is not necessary to peel off the covered electric wire 3, the man-hour required when attaching the covered electric wire 3 to ALS2 can be suppressed further. Therefore, the cost increase of the conductor thin film 1 with electric wires can be further suppressed.
[0035]
When joining the conductor layer 4 and the core wire 10 by ultrasonic welding, the covering portion 11, that is, the covered electric wire 3 is overlapped on the insulating layer 7. For this reason, it can prevent that the conductor layer 4 is damaged compared with the case where the covered electric wire 3 is overlapped on the conductor layer 4 and ultrasonic welding is performed. Therefore, the covered electric wire 3 can be reliably connected to the ALS 2.
[0036]
In addition, since the covering portion 11, that is, the covered electric wire 3 is overlapped on the insulating layer 7, the insulating layer 7 and the covering portion 11 are melted and welded to each other by frictional heat when performing ultrasonic welding.
For this reason, compared with the case where the conductor layer 4 and the core wire 10 are mutually electrically connected by wire bonding etc., the mechanical strength of the junction location of the conductor layer 4 and the core wire 10 can be improved, for example. . Therefore, the covered electric wire 3 can be reliably connected to the ALS 2.
[0037]
Further, since the insulating layer 7 and the covered electric wire 3 are overlapped on the insulating layer 7 and the insulating layer 7 and the covering portion 11 are welded to each other, the conductor layer 4 made of aluminum or aluminum alloy which is difficult to be bonded to each other, and copper or The core wire 10 made of a copper alloy can be reliably fixed. Therefore, the covered electric wire 3 can be reliably connected by the ALS 2.
[0038]
Furthermore, since the covered electric wire 3 is formed in a round cross section, the force that brings the tip 20 and the anvil 21 closer to each other concentrates on the place where the ALS 2 and the covered electric wire 3 are in contact with each other. For this reason, the insulating layer 4 and the covering portion 11 melted by the frictional heat are quickly removed from between the conductor layer 4 and the core wire 10. The conductor layer 4 and the core wire 10 are reliably joined. Therefore, the covered electric wire 3 can be more reliably connected to the ALS 2.
[0039]
Further, as shown in FIG. 5, the covered electric wire 3 may be attached to the ALS 2 by an ultrasonic welding machine in a state where a part 3 a thereof is bent in a U shape. In the case illustrated in FIG. 5, joint portions where the conductor layer 4 and the core wire 10 are joined to each other are formed at two portions of the portion 3 a bent into a U shape. Even in this case, ultrasonic welding is performed with the covered electric wire 3 overlaid on the insulating layer 7. Further, one of the two joints described above may be joined one by one, or two parts may be joined at the same time.
[0040]
In this case, since the number of parts and required man-hours can be suppressed, the cost can be reduced, and the covered wire 3 can be securely connected to the ALS 2, and the portion 3 a of the covered wire 3 is bent in a U-shape. It is possible to increase the area of the joint portion between the wire and the covered electric wire 3. Therefore, it is possible to further improve the mechanical strength of the joint portion between the ALS 2 and the covered electric wire 3, and the covered electric wire 3 can be more securely fixed to the ALS 2.
[0041]
Next, the conductor thin film 1 with electric wires according to the second embodiment of the present invention will be described with reference to FIG. In addition, the same code | symbol is attached | subjected to the same component as 1st Embodiment mentioned above, and description is abbreviate | omitted.
[0042]
In the present embodiment, a tin-plated copper laminate sheet 2a is used as the conductor thin film sheet. The tin-plated copper laminate sheet 2 a includes a conductor layer 4, a plating layer 12, and the insulating layer 7 described above, which are laminated with each other.
[0043]
The conductor layer 4 contains at least copper or a copper alloy. The plating layer 12 is formed on the outer surface of the conductor layer 4. The plating layer 12 includes at least tin or a tin alloy. In FIG. 6, the tin-plated copper laminate sheet 2 a is formed by laminating a plating layer 12, a conductor layer 4, a first insulating layer 5, and a second insulating layer 6 in order from the bottom.
[0044]
Similarly to the first embodiment, the conductor thin film sheet 1 with electric wire of the present embodiment is also prepared by using an ultrasonic welding machine having a chip 20 and an anvil 21 and using a tin-plated copper laminate sheet 2a and a covered electric wire 3 as shown in FIG. And are connected. At this time, the conductor thin film sheet 1 with electric wires has the covering portion 11, that is, the covered electric wire 3, superimposed on the second insulating layer 6. By ultrasonic welding, the conductor layer 4 and the core wire 10 are joined to each other, and the insulating layer 7 and the covering portion 11 are welded to each other.
[0045]
According to this embodiment, since the conductor layer 4 and the core wire 10 are joined to each other by ultrasonic welding, as in the first embodiment described above, the covered electric wire 3 is attached to the copper laminate sheet 2a with tin plating. It is possible to suppress an increase in the number of man-hours and parts required. Therefore, an increase in cost of the conductor thin film 1 with electric wires can be suppressed.
[0046]
In addition, since the covering portion 11, that is, the covered electric wire 3 is overlapped on the insulating layer 7, it is not necessary to remove the covering portion 11 such as the portion 3 a of the covered electric wire 3 when attaching to the copper laminate sheet 2 a with tin plating. That is, since it is not necessary to peel the covered electric wire 3, the man-hour required when attaching the covered electric wire 3 to the tin-plated copper laminate sheet 2a can be further suppressed. Therefore, the cost increase of the conductor thin film 1 with electric wires can be further suppressed.
[0047]
When joining the conductor layer 4 and the core wire 10 by ultrasonic welding, the covering portion 11, that is, the covered electric wire 3 is overlapped on the insulating layer 7. For this reason, it can prevent that the conductor layer 4 is damaged compared with the case where the covered electric wire 3 is overlapped on the conductor layer 4 and ultrasonic welding is performed. Further, since the covering portion 11, that is, the covered electric wire 3, is overlapped on the insulating layer 7, even if the plating layer 12 made of tin that is difficult to join the core wire 10 is formed on the surface of the conductor layer 4, The coated wire 3 can be reliably connected to the tin-plated copper laminate sheet 2a without being affected.
[0048]
In addition, since the covering portion 11, that is, the covered electric wire 3 is overlapped on the insulating layer 7, the insulating layer 7 and the covering portion 11 are melted and welded to each other by frictional heat when performing ultrasonic welding.
For this reason, compared with the case where the conductor layer 4 and the core wire 10 are mutually electrically connected by wire bonding etc., the mechanical strength of the junction location of the conductor layer 4 and the core wire 10 can be improved, for example. . Therefore, the covered electric wire 3 can be reliably connected to the tin-plated copper laminate sheet 2a.
[0049]
Furthermore, since the covered electric wire 3 is formed in a round cross section, the force for bringing the chip 20 and the anvil 21 closer to each other is concentrated on the portion where the tin-plated copper laminate sheet 2a and the covered electric wire 3 are in contact with each other. Become. For this reason, the insulating layer 4 and the covering portion 11 melted by the frictional heat are quickly removed from between the conductor layer 4 and the core wire 10. The conductor layer 4 and the core wire 10 are reliably joined. Therefore, the covered electric wire 3 can be more reliably connected to the tin-plated copper laminate sheet 2a.
[0050]
Similarly to the first embodiment described above, the covered wire 3 may be attached to the tin-plated copper laminate sheet 2a by an ultrasonic welding machine with a portion 3a bent in a U-shape. .
[0051]
In the first and second embodiments described above, the covered electric wire 3 having one core wire 10 and the ALS 2 or tin-plated copper laminate sheet 2a are fixed to each other. You may make it fix the covered electric wire which has the strand wire formed by mutually twisting and the coating | coated part which coat | covers this strand wire to ALS2 or the copper laminate sheet 2a with a tin plating. In this case, the conductor layer 4 and the stranded wire are joined to each other.
[0052]
Furthermore, in the first and second embodiments described above, the force for pressing the tip 20 and the anvil 21 during ultrasonic welding is kept constant. However, in the present invention, during the ultrasonic welding, the above-described force may be gradually weakened over time. In this case, it is possible to prevent the thin conductor layer 4 from being damaged due to frictional heat. Therefore, the covered electric wire 3 can be more reliably connected to the ALS 2 or the tin-plated copper laminate sheet 2a.
[0053]
【The invention's effect】
As described above, according to the present invention described in claim 1, since the core wire of the electric wire is joined to the conductor layer of the conductor thin film sheet, it is possible to prevent the number of parts from increasing. Therefore, the increase in cost can be suppressed. Since the core wire of the electric wire is joined to the conductor layer of the conductor thin film sheet, the electric wire can be reliably connected to the conductor layer of the conductor thin film sheet.
The end portion of the electric wire is bent in a U-shape, and the covering portion and the core wire located at the end portion are welded to the insulating layer and joined to the conductor layer. As described above, since the area of the joint portion between the conductor layer and the core wire is increased, the mechanical strength of the joint portion between the conductor layer and the core wire is further improved. Therefore, in addition to suppressing an increase in cost, the electric wire can be more reliably connected to the conductor layer of the conductor thin film sheet.
[0054]
According to the second aspect of the present invention, since the insulating layer of the conductor thin film sheet and the covering portion of the electric wire are welded to each other, the mechanical strength of the joint portion between the conductor layer and the core wire is improved. Therefore, in addition to suppressing an increase in cost, the electric wire can be reliably connected by the conductor layer of the conductor thin film sheet.
[0056]
According to this invention of Claim 3 , since the core wire of the electric wire is joined to the conductor layer of the conductor thin film sheet, it can prevent that a number of parts increases. Therefore, an increase in cost can be suppressed and an electric wire can be reliably connected to the conductor layer of the conductor thin film sheet.
[0057]
According to this invention of Claim 4 , since the core wire of the electric wire is joined to the conductor layer of the conductor thin film sheet, it can prevent that a number of parts increases. Therefore, an increase in cost can be suppressed and an electric wire can be reliably connected to the conductor layer of the conductor thin film sheet.
[0058]
According to the fifth aspect of the present invention, since the wire coating portion is overlapped on the insulating layer of the conductor thin film sheet and ultrasonic welding is performed, the wire coating portion is peeled when the wire is attached to the conductor thin film sheet. It is not necessary to perform such work. For this reason, the man-hour concerning manufacture can be suppressed. In addition, since the conductor layer and the core wire are joined by ultrasonic welding, it is possible to prevent an increase in the number of parts required when attaching the electric wire to the conductor thin film sheet. Therefore, an increase in the cost of the conductor thin film with wires can be suppressed.
[0059]
Further, since the electric wire is attached to the conductor thin film sheet by performing ultrasonic welding, the insulating layer and the covering portion are melted and welded to each other by frictional heat generated when performing ultrasonic welding. Therefore, the mechanical strength of the joint portion between the conductor layer and the core wire can be improved, and the electric wire can be reliably connected to the conductor layer of the conductor thin film sheet.
[0060]
Furthermore, since the wires are attached to the conductive thin film sheet by ultrasonic welding, the conductor layer is made of aluminum or an aluminum alloy, the core wire is made of copper or a copper alloy, and they are fixed to each other by a welding method such as fusion welding or brazing. Even when it is difficult, the conductor layer and the core wire can be reliably joined. Even if a plating layer including tin that is difficult to bond the core wire is formed on the outer surface of the conductor layer, the conductor layer and the core wire can be bonded reliably.
[0061]
According to the sixth aspect of the present invention, since the ultrasonic welding is performed while weakening the force of pressing the insulating layer and the covering portion toward each other, the above-described pressure is applied when the frictional heat generated by the ultrasonic welding becomes high. The power will gradually weaken. For this reason, it can prevent that a conductor layer melt | dissolves by the frictional heat etc. which arise at the time of performing ultrasonic welding, and is damaged. Therefore, the electric wire can be more reliably connected to the conductor layer of the conductor thin film sheet.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a conductor thin film sheet with electric wires according to a first embodiment of the present invention.
2 is a cross-sectional view taken along line II-II in FIG.
FIG. 3 is a cross-sectional view showing a state before the covered electric wire and the conductor thin film sheet of the embodiment are fixed to each other.
FIG. 4 is a cross-sectional view showing a state after the covered electric wire and the conductor thin film sheet of the embodiment are fixed to each other.
FIG. 5 is a perspective view showing a modification of the conductor thin film sheet with electric wires of the same embodiment.
FIG. 6 is a cross-sectional view of a conductor thin film sheet with electric wires according to a second embodiment of the present invention.
[Explanation of symbols]
1 Conductor thin film sheet with electric wire 2 ALS (conductor thin film sheet)
2a Tin-plated copper laminate sheet (conductor thin film sheet)
3 Covered wire (wire)
3a Partial (end)
4 Conductor layer 7 Insulating layer 10 Core wire 11 Covering portion

Claims

A conductor thin film sheet having a conductor layer and an insulating layer laminated on the conductor layer;
An electric wire comprising a single core wire having conductivity and a covering portion having an insulating property to cover the core wire;
An end portion of the wire is bent into a U shape on the conductive thin film sheet plane superimposed on the conductive thin film sheet, and the core wire and the conductor of the electric wire at two points sandwiching the bent portion in a U-shape A conductor thin film sheet with electric wires, wherein the conductor layer of the thin film sheet is bonded to each other.

The conductor thin film sheet with electric wire according to claim 1, wherein the insulating layer of the conductor thin film sheet and the covering portion of the electric wire are welded to each other at two positions sandwiching the U - shaped bent portion. .

The conductor layer of the conductor thin film sheet contains aluminum or an aluminum alloy,
The core wire of the electric wire contains copper or a copper alloy,
The conductor thin film sheet with electric wire according to claim 1 or 2, wherein the insulating layer of the conductive thin film sheet and the covering portion of the electric wire are each made of a synthetic resin.

The conductor layer of the conductive thin film sheet contains copper or a copper alloy, and a plating layer made of tin or tin alloy is formed on the outer surface,
The core wire of the electric wire contains copper or a copper alloy,
The conductor thin film sheet with electric wire according to claim 1 or 2, wherein the insulating layer of the conductive thin film sheet and the covering portion of the electric wire are each made of a synthetic resin.

The conductor layer of the said conductor thin film sheet and the core wire of the said electric wire are mutually joined by superposing | stacking the coating | coated part of the said electric wire on the insulating layer of the said conductor thin film sheet, and performing ultrasonic welding. The manufacturing method of the conductor thin film sheet with an electric wire as described in any one of Claims 4.

6. The method of manufacturing a conductor thin film with wires according to claim 5, wherein the ultrasonic welding is performed while gradually weakening the pressure applied after pressing the insulating layer and the covering portion toward each other. Method.