JPH1055726A - Manufacture of flat cable - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a flat cable capable of easily manufacturing the flat cable. SOLUTION: A flat cable continuous body 50 is formed in such a way that a lower side insulating film 36 is stuck to the lower surface side of a round conductive wire group formed by supplying in parallel a plurality of round conductive wires 10, and a belt-shaped upper side insulating film 30 in which conductive wire exposing windows 52 are formed at specified intervals along the length direction is stuck to the upper surface side. The regions corresponding to the conductive wire exposing windows 52 are pressed from the upper and lower sides with upper and lower side press parts, the round conductive wires 10 exposed to the region are pressed in a flat shape, then the flat cable continuous body 50 is cut in the conductive wire exposed window part 52, and a flat cable in which the round conductive wires 10 formed in a flat shape is exposed on the upper surface side at both ends is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a flat cable used for wiring various electric devices.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a flat cable, for example, as shown in FIG. 9, a copper foil attached to one surface of an insulating film 200 is etched to form a plurality of linear patterns 210. Therefore, there is a method of covering this with another insulating film cover 202.

In addition, instead of forming a linear pattern 210 by etching a copper foil, there is also a method of attaching a plurality of copper foil tapes cut in advance to a predetermined width to an insulating film in parallel.

However, in the former manufacturing method, since etching is performed by photolithography, the manufacturing cost is increased.

In the latter manufacturing method, it is difficult to process a narrow copper foil tape, and it is particularly difficult to manufacture a high-density flat cable.

Therefore, as disclosed in Japanese Patent Application Laid-Open No. 7-192541, a plurality of low-cost copper round conductors are arranged in parallel on the same plane, sandwiched between a pair of insulating sheets, and the end of each round conductor is flattened. A method of rolling into a shape has been proposed.

[0007]

By the way, in the flat cable disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 7-192541, in order to connect the terminal to another connection terminal, the end of each round conductor is rolled flat. Although it is processed, for this reason, after sandwiching round conductors arranged in parallel with a pair of insulating sheets, both ends of each round conductor are further rolled, which requires more complicated manufacturing steps. There is a problem.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problem, and has as its object to provide a method of manufacturing a flat cable that can more easily manufacture a flat cable.

[0009]

According to a first aspect of the present invention, there is provided a method of manufacturing a flat cable, comprising a plurality of round conductors arranged in parallel on the same plane by a pair of insulating films. A method of manufacturing a flat cable in which the ends of each of the round conductors that are sandwiched and formed flat at both ends are exposed, and wherein a plurality of round conductors are fed in parallel. Affixing a band-shaped lower insulating film on the lower surface side of the film, and attaching a band-shaped upper insulating film formed with conductive wire exposure windows at predetermined intervals along the longitudinal direction on the upper surface thereof, A rolling step of rolling the respective round conductors exposed in the region corresponding to the conductor exposure window portion from above and below by pressing the regions, and forming the group of round conductors in which the respective round conductors are flattened. Conductor exposure window Characterized in that it comprises a cutting step of Oite cutting.

[0010] Further, the rolling step is performed by a lower roller having a circular cross section and an upper roller having peripheral projections formed at predetermined intervals along an outer periphery. A pair of round conductors to which the lower insulating film is attached is sandwiched, and the two rollers are driven to rotate with the supply of the round conductors, so that the conductor exposure window is formed by the peripheral protrusion of the upper roller and the lower roller. The step of rolling each round conductor exposed at the portion into a flat shape may be performed.

According to a third aspect of the present invention, the rolling step includes a step of slightly lowering the diameter of the round conductor at each position corresponding to the lower press portion and each of the round conductors fed in parallel. An upper grooved press formed with a plurality of shallow grooves having large widths sandwiches the round conductor group to which the upper and lower insulating films are attached, and presses the respective round conductors with the respective shallow grooves to form a flat shape. It may be a step of rolling to

According to a fourth aspect of the present invention, there is provided a flat cable manufacturing method, wherein a plurality of round conductors arranged in parallel on the same plane are sandwiched by a pair of insulating films, and each round end is formed flat at both ends. A method for manufacturing a flat cable in which the ends of conductive wires are exposed, wherein a plurality of round conductive wires are fed in parallel to form a round conductive wire group. An insulating film affixing step, a rolling step of pressing the group of round conductors to which the lower insulating film is affixed from above and below at predetermined intervals along the longitudinal direction, and rolling each of the round conductors into a flat shape; A strip-shaped upper insulating film in which the conductive wire exposed windows are formed at the predetermined intervals along the wire, the conductive wire exposed windows are aligned with the area where each round conductive wire is rolled into a flat shape, and the upper surface of the round conductive wire group Upper insulation And Lum attaching step, characterized in that it comprises a cutting step of cutting the upper and lower round conductor groups insulating film is affixed in the conductor exposing window portion.

According to a fifth aspect of the present invention, in the rolling step, the lower roller is formed by a lower roller having a circular cross section and an upper roller having peripheral projections formed at predetermined intervals along an outer periphery. Insert the round conductor group with the insulating film attached,
In the step of rolling each of the round conductors into the flat shape at the predetermined intervals by the peripheral protrusions of the lower roller and the lower roller by rotating both rollers following the feeding of the round conductor group. There may be.

According to a sixth aspect of the present invention, the rolling step includes a step of slightly lowering the diameter of the round conductor at each position corresponding to the lower press portion and each of the round conductors fed in parallel. A step of sandwiching a group of round conductors to which the lower insulating film is attached by an upper press portion having a plurality of shallow groove portions having a large width dimension, and pressing each of the round conductor wires in each of the shallow groove portions so as to be flattened; It may be.

Furthermore, the lower insulating film may be formed of polypropylene or polyimide.

According to another aspect of the present invention, a natural rubber type, a synthetic rubber type, a vinyl acetate type, a polyvinyl acetal type, an acrylic type, or a vinyl ether type are used for bonding the round conductor to the lower insulating film. An adhesive may be used.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing a flat cable according to a first embodiment of the present invention will be described together with a manufacturing apparatus shown in FIG.

First, in this flat cable manufacturing apparatus, as shown in FIG. 1, a round conductor 10 made of copper or a copper alloy is wound and housed in a plurality of conductor bobbins 60, respectively. Round conductor 1 drawn from 60
The 0s are aligned in a parallel state at a predetermined pitch by the alignment guide unit 70.

The round conductor group 10A thus arranged in a side-by-side state is composed of a pair of upper and lower film sticking rollers 80a, 80a.
0b. Then, the upper insulating film 30 wound and housed in the upper film bobbin 86a is supplied to and adhered to the upper surface side of the round conductor group 10A via the film affixing roller 80a, and is attached to the lower film bobbin 86b. Lower insulating film 3 wound and housed
6 is a round conductor group 10A via a film sticking roller 80b.
Is supplied to and adhered to the lower surface of the flat cable, and thus the flat cable continuous body 50 shown in FIG. 2 is formed (film attaching step).

At this time, an adhesive is applied in advance to one surface of the upper insulating film 30 wound and accommodated in the film bobbin 86a, and the upper insulating film 30 is provided at predetermined intervals along the longitudinal direction. A conductor exposure window 52 having a shape is formed, and the round conductor 10 is exposed from the conductor exposure window 52 on the upper surface side of the flat cable continuous body 50. Also,
An adhesive is also applied in advance to one surface of the lower insulating film 36 wound and accommodated in the film bobbin 86b.

The flat cable continuum 50 is then formed by a pair of upper and lower press sections 90a and 9
0b.

Here, as shown in FIGS. 3 and 4, the area corresponding to the conductive wire exposure window 52 of the flat cable continuous body 50 is formed by an upper press section 90a and a lower press section 90b.
Pressed by. Then, in the conductive wire exposed window 52, each round conductive wire 10 is rolled into a flat shape over a predetermined length to form the flat portion 11 (rolling step).

At this time, for example, when rolling a round conductor 10 made of soft copper having a diameter of 0.2 mm to a width of 0.35 mm,
A load of 120 kg per 1 mm of the length of the round conductor 10 may be applied.

The flat cable continuum 50 in which each round conductor 10 is rolled into a flat shape at the conductor exposure window 52 in this manner is once wound around a storage drum 96.

Then, the flat cable continuous body 50 wound around the storage drum 96 is cut in the width direction at a substantially middle position in the longitudinal direction of the conductor exposure window 52 (two-dot chain line in FIG. 2) by another device not shown. And as shown in FIG.
A flat cable 1 in which a plurality of round conductors 10 arranged in parallel are sandwiched between upper and lower insulating films 30 and 36, and the round conductors 10 exposed at both upper end surfaces thereof are formed flat. Is done.

According to the method of manufacturing a flat cable as described above, the upper and lower insulating films 30 and 36 are attached to the upper and lower sides of the round conductor group 10A, respectively, and are exposed to the conductor exposure window 52 of the upper insulating film 30. Each round conductor 10
Is flattened and then cut at the wire exposure window 52 to produce the flat cable 1 in which the flat round conductor 10 is exposed at the upper surface of both ends. In the operation, two ends of the flat cable 1 are rolled together, and the flat cable 1 can be efficiently and easily manufactured.

Further, when the number of parallel wires of the flat cable 1 is changed, only the number of the conductor bobbins 60 and the alignment guide 70 need be changed.
It is possible to easily cope with the design change.

In the above rolling step, FIG.
As shown in FIG.
0a is pressed directly onto the flat pressing surface to finish it flat, but its lower surface is pressed by the lower insulating film 36 via the adhesive 38 applied to the upper surface of the lower insulating film 36. Become.

Therefore, in order that the pressing force of the lower pressing portion 90b acts more directly on the round conductor 10, the lower insulating film 36 is made of a material having less elastic deformation, for example, polypropylene or polyimide. Preferably, it is formed.

When a high-viscosity adhesive is used as the adhesive 38 applied to the lower insulating film 36, the resistance to the rolling deformation of the round conductor 10 becomes large, and a larger pressing force is required. In addition, there is a problem that the deformation and damage of the lower insulating film 36 due to the large pressing force are increased.

For this reason, as the adhesive 38, it is preferable to use a low-viscosity adhesive or a thermoplastic adhesive whose fluidity increases at a temperature at which the insulating films 30 and 36 are not softened. Examples of this type of adhesive include natural rubber-based, synthetic rubber-based (butyl rubber-based, etc.), vinyl acetate-based, polyvinyl acetal-based, acrylic-based, and vinyl ether-based adhesives.

By the way, as in the second embodiment shown in FIG. 6, the round conducting wire 10 is
The shallow groove 81 having a depth smaller than the diameter of the round conductor 10 and a width larger than the diameter of the round conductor 10 may be formed at a position corresponding to each of the round conductors 10 arranged in parallel.

In this case, since the round conducting wire 10 is rolled into a shape corresponding to the shallow groove portion 81, the flat portion 11 having a constant width and thickness is formed stably.

Further, the rolling step may be performed by roller rolling.

That is, as shown in FIG. 7, the flat cable continuous body 50 is sandwiched by upper rollers 82a and lower rollers 82b instead of the upper and lower press sections 90a and 90b of the first embodiment.

The length of the outer circumference of the upper roller 82a is determined by the length of each conductor exposure window 52 of the flat cable continuum 50.
It is formed in the same size as the interval between them, and a circumferential protrusion 83 is formed along the circumferential direction of the outer circumference. This peripheral projection 8
3 has a flat cable continuum 50
Is set slightly smaller than the opening dimension of the conductive wire exposure window 52 in the longitudinal direction of FIG. The lower roller 82b is a normal roller having a circular cross section. Then, both rollers 82a and 82b are driven to rotate in accordance with the feeding of the flat cable continuous body 50, and the flat cable continuous body 50 is rolled at the conductive wire exposure window 52 by the circumferential projection 83 to expose the round conductive wire there. 10 is rolled flat.

In this case, the round conductors 10 in the respective conductor exposure windows 52 are continuously rolled by the peripheral projections 83 of the upper roller 82a with the feeding of the flat cable continuous body 50, so that more efficiency is achieved. Rolling work can be performed well.

The length of the outer periphery of the upper roller 82a is set to N (integer) of a predetermined interval between the respective conductor exposure windows 52.
Even if the circumferential projections are provided at the above-described predetermined intervals along the circumferential direction on the outer periphery of the upper roller portion 82a, the round conductor 10 in each conductor exposure window 52 can be continuously rolled similarly. .

Next, a method for manufacturing a flat cable according to the fourth embodiment will be described with reference to FIG. In FIG. 8, the same components as those of the first embodiment are denoted by the same reference numerals, and the description thereof will be omitted.

That is, as shown in FIG. 8, the round conductor 10 pulled out from the plurality of conductor bobbins 60 is
By 0, they are arranged in a parallel state at a predetermined pitch and sent forward. Then, after the lower insulating film 36 supplied from the film bobbin 86b is attached to the lower surface side of the round conductor group 10A via the film attaching roller 80b (the lower film attaching step), the round presser unit 10A 9
Oa and 90b are intermittently pressurized so that the round conductors 10 are arranged at predetermined intervals along the longitudinal direction of the film 36.
Is rolled into a flat shape (rolling step).

Thereafter, the upper insulating film 30 in which the conductive wire exposure windows 52 are formed at predetermined intervals along the longitudinal direction.
However, the conductor exposure window 52 is aligned with the region where each of the above-mentioned round conductors 10 is rolled into a flat shape, and is adhered to the upper surface side of the circle conductor group 10A via a film application roller 80a, and thus shown in FIG. A continuous flat cable 50 having the same configuration as that of the flat cable is formed, and is once wound around the storage drum 96.

The flat cable continuum 50 wound around the storage drum 96 is, as in the case of the first embodiment, substantially at an intermediate position in the longitudinal direction of the conductive wire exposure window 52 by another device (not shown) (FIG. 2). (Two-dot chain line) is cut in the width direction to manufacture the flat cable 1 shown in FIG.

According to the method of manufacturing the flat cable of the fourth embodiment configured as described above, as in the case of the first embodiment, after the lower insulating film 36 is attached to the lower surface of the round conductor group 10A. At predetermined intervals in the longitudinal direction, the round conductor 10 is rolled into a flat shape, and the exposed wire window 52 is aligned with the rolled region, and the upper insulating film 30 is attached to the upper surface side of the round conductor group 10A to form a flat cable continuous wire. Body 50
The flat cable 1 in which the flat round conductor 10 is exposed at the upper surface of both ends is manufactured by cutting the wire at the conductor exposure window 52, so that the flat cable 1 is flattened by one rolling operation. Since the two ends of the cable 1 are rolled together, the flat cable 1 can be efficiently and easily manufactured.

In order to change the number of parallel wires of the flat cable 1, only the number of the copper bobbins 60 and the alignment guide 70 need be changed.
It is possible to easily cope with the design change.

In the fourth embodiment, as in the first embodiment, the lower insulating film 36 is formed of a material having less elastic deformation, for example, polypropylene or polyimide, or the lower insulating film 36 is formed on the lower insulating film 36. As the adhesive to be applied, a low-viscosity adhesive or a thermoplastic adhesive whose fluidity increases at a temperature at which the insulating films 30 and 36 do not soften, such as a natural rubber-based, synthetic rubber-based (butyl rubber-based, etc.), vinyl acetate-based , Polyvinyl acetal, acrylic, or vinyl ether adhesive may be used.

In the rolling step, a roller having a shallow groove formed on the press surface of the upper press portion 90a as in the second embodiment, or a roller having a circumferential protrusion formed along the outer periphery as in the third embodiment. May be applied.

Further, in each of the above-described embodiments, if the round conductor 10 that has been subjected to a surface treatment such as gold plating or tin plating is used in advance, the solderability of the end of the flat cable 1 and the end of the flat cable 1 The contact reliability when connecting with the connection terminal of the above is improved.

[0048]

As described above, according to the method of manufacturing a flat cable according to the first aspect of the present invention, the upper and lower insulating films are attached to the upper and lower sides of the round conductor group, respectively, and the conductor exposure window of the upper film. Since each round conductor exposed at the part is rolled into a flat shape, it is cut at the conductor exposure window, and a flat cable with a flat round conductor exposed at both upper surfaces is manufactured. In this rolling operation, the ends of the flat cable are rolled together at two places, so that the flat cable can be efficiently and easily manufactured.

According to a second aspect of the present invention, in the rolling step, an upper roller having a lower roller having a circular cross section and a peripheral protrusion formed on the outer periphery at the same interval as the distance between the conductive wire exposure windows. By sandwiching the group of round conductors to which the upper and lower insulating films are attached, the two rollers are driven to rotate with the supply of the group of round conductors, and the conductor is formed by the peripheral protrusion of the upper roller and the lower roller. If each round conductor exposed at the exposed window is rolled into a flat shape, each round conductor is continuously rolled at predetermined intervals, so that a flat cable can be manufactured more efficiently.

According to a third aspect of the present invention, in the rolling step, the width slightly larger than the diameter of the lower conducting portion and each round conducting wire fed in parallel at each position corresponding to the round conducting wire. By the upper press part which formed a plurality of shallow grooves of dimensions,
If the round conductive wire group to which the upper and lower insulating films are attached is sandwiched, and each of the round conductive wires is pressed and rolled into a flat shape at each of the shallow groove portions, each round wire is shaped according to the shape of the shallow groove portion. Since the conductor is rolled, the end of each round conductor exposed at the end of the flat cable becomes uniform.

Further, according to the flat cable manufacturing method of the present invention, the round conductor group to which the lower insulating film is adhered is pressed from above and below at predetermined intervals along the longitudinal direction, and each round conductor group is pressed. Rolled into a flat shape, the upper portion of the insulating film was affixed to the round wire group in accordance with the flat-rolled region of the conductive wire exposed window portion, and then cut at the conductive wire exposed window portion, and flattened on the upper surface of both ends. Since flat cables with rounded conductors are manufactured, the flat cable ends are rolled together at two locations in a single rolling operation, making it easier and more efficient to manufacture flat cables. Becomes possible.

According to a fifth aspect of the present invention, in the rolling step, the lower insulating roller is formed by a lower roller having a circular cross section and an upper roller having circumferential projections formed at predetermined intervals along an outer periphery. The round conductive wire group to which the film is attached is sandwiched, and both rollers are driven and rotated with the supply of the round conductive wire group, and the peripheral protrusions of the lower roller and the lower roller are used for the predetermined interval. When each round conductor is rolled into a flat shape, each round conductor is continuously rolled at predetermined intervals, so that a flat cable can be manufactured more efficiently.

According to a sixth aspect of the present invention, in the rolling step, the width slightly larger than the diameter of the round conductor at each position corresponding to the lower press part and each of the circle conductors fed in parallel. By the upper press part which formed a plurality of shallow grooves of dimensions,
If the round insulating wire group to which the lower insulating film is attached is sandwiched, and each of the round conductive wires is pressed and rolled into a flat shape in each of the shallow groove portions, each of the round conductive wires is shaped according to the shape of the shallow groove portion. Is rolled, so that the ends of each round conductor exposed at the ends of the flat cable are uniformly arranged.

When the lower insulating film is formed of a material having little elastic deformation, for example, polypropylene or polyimide, the pressing force is more directly increased when rolling the round conductor. To act on the conductor,
The round conductor is easily rolled.

Further, as a low-viscosity adhesive excellent in fluidity for bonding the round conductor to the lower insulating film, natural rubber, synthetic rubber, vinyl acetate, vinyl acetate, etc.
When a polyvinyl acetal-based, acrylic-based, or vinyl ether-based adhesive is used, the resistance to rolling of the round conductor is reduced, and the round conductor can be rolled with a smaller pressing force.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a method for manufacturing a flat cable according to a first embodiment of the present invention.

FIG. 2 is a view showing a flat cable continuum.

FIG. 3 is an enlarged view of a main part of a flat cable continuous body.

FIG. 4 is an enlarged sectional view of a main part showing an intermediate step in manufacturing a flat cable.

FIG. 5 is a view showing a flat cable.

FIG. 6 is an explanatory diagram of a method of manufacturing a flat cable according to a second embodiment of the present invention.

FIG. 7 is an explanatory diagram of a method of manufacturing a flat cable according to a third embodiment of the present invention.

FIG. 8 is an explanatory diagram of a method of manufacturing a flat cable according to a fourth embodiment of the present invention.

FIG. 9 is a diagram showing a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Flat cable 10 Round conductor 10A Round conductor group 30 Upper insulating film 36 Lower insulating film 52 Conductor exposure window part 90a Upper press part 90b Lower press part

Claims (8)

[Claims] 1. A flat cable in which a plurality of round conductors arranged in parallel on the same plane are sandwiched by a pair of insulating films, and the ends of each round conductor formed flat at both ends are exposed. A band-shaped lower insulating film is adhered to the lower surface of a group of round conductors in which a plurality of round conductors are fed in parallel, and the upper surface thereof is disposed at predetermined intervals along the longitudinal direction. A film sticking step of sticking a strip-shaped upper insulating film on which a conductor exposure window is formed, and flattening each of the round conductors exposed in the area corresponding to the conductor exposure window by applying pressure from above and below. A method of manufacturing a flat cable, comprising: a rolling step of rolling the round conductors; and a cutting step of cutting the round conductor group in which each of the round conductors is flattened at the conductor exposure window. 2. In the rolling step, the upper and lower insulating films are attached by a lower roller having a circular cross section and an upper roller having peripheral protrusions formed at predetermined intervals along an outer periphery. Each of the round conductors exposed to the conductor exposure window by the peripheral protrusion of the upper roller and the lower roller by rotating the two rollers following the feeding of the round conductor group by sandwiching the round conductor group. The flat cable manufacturing method according to claim 1, wherein the flat cable is rolled. 3. The rolling step includes a step of forming a plurality of lower press portions and a plurality of shallow grooves each having a width slightly larger than the diameter of the round conductor at each position corresponding to each of the round conductors fed in parallel. The formed upper grooved press section sandwiches the round conductor group on which the upper and lower insulating films are stuck, and presses each of the round conductors in each of the shallow grooves to roll it into a flat shape. The method for manufacturing a flat cable according to claim 1, wherein: 4. A flat cable in which a plurality of round conductors arranged in parallel on the same plane are sandwiched by a pair of insulating films, and the ends of each round conductor formed flat at both ends are exposed. A lower insulating film attaching step of attaching a band-shaped lower insulating film to the lower surface side of a group of round conductors in which a plurality of round conductors are fed in parallel, and wherein the lower insulating film is A rolling step of pressing the attached round conductor group from above and below at predetermined intervals along its longitudinal direction, and rolling each of the round conductors into a flat shape, and a conductor exposure window portion at each of the predetermined intervals along the longitudinal direction. The strip-shaped upper insulating film formed with
An upper insulating film attaching step of attaching each round conductor to the flat rolled region, and attaching the upper surface side of the round conductor group,
Cutting the round conductor group to which the upper and lower insulating films are attached at the conductor exposure window. 5. The round conducting wire to which the lower insulating film is affixed by a lower roller having a circular cross section and an upper roller having peripheral projections formed at predetermined intervals along an outer periphery in the rolling step. Each of the round conductors is flattened at a predetermined interval by the peripheral protrusions of the lower roller and the lower roller by sandwiching the group and rotating the two rollers following the feeding of the round conductor group. The method for producing a flat cable according to claim 4, wherein the flat cable is rolled. 6. The rolling step comprises: forming a plurality of shallow grooves having a width slightly larger than the diameter of the round conductor at each position corresponding to the lower press part and each of the round conductors fed in parallel. A step of sandwiching the group of round conductors to which the lower insulating film is affixed by the formed upper pressing portion, and pressing each of the round conductors in each of the shallow groove portions to roll it into a flat shape. Item 5. The method for manufacturing a flat cable according to Item 4. 7. The method according to claim 1, wherein the lower insulating film is made of polypropylene or polyimide. 8. A natural rubber-based, synthetic rubber-based, vinyl acetate-based, polyvinyl acetal-based, acrylic-based, or vinyl ether-based adhesive is used for bonding the round conductor to the lower insulating film. The method for manufacturing a flat cable according to claim 1.