WO2015152261A1 - 圧延銅箔、圧延銅箔の製造方法、フレキシブルフラットケーブル、フレキシブルフラットケーブルの製造方法 - Google Patents
圧延銅箔、圧延銅箔の製造方法、フレキシブルフラットケーブル、フレキシブルフラットケーブルの製造方法 Download PDFInfo
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/08—Flat or ribbon cables
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
- B21C1/02—Drawing metal wire or like flexible metallic material by drawing machines or apparatus in which the drawing action is effected by drums
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/02—Alloys based on copper with tin as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/04—Alloys based on copper with zinc as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/10—Alloys based on copper with silicon as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/08—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/026—Alloys based on copper
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0003—Apparatus or processes specially adapted for manufacturing conductors or cables for feeding conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/42—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes polyesters; polyethers; polyacetals
- H01B3/421—Polyesters
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/02—Single bars, rods, wires, or strips
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
Definitions
- the present invention relates to a rolled copper foil obtained by rolling a round wire made of copper or a copper alloy, a method for producing the rolled copper foil, a flexible flat cable, and a method for producing the rolled copper foil.
- the present invention relates to a rolled copper foil used for a flat cable or the like and a method for producing the same.
- a flexible flat cable has a high degree of freedom in mounting form on an electronic device or the like because of its thin thickness and excellent flexibility, and is used in various applications.
- steering roll connectors SRC
- SRC steering roll connectors
- movable parts such as digital cameras and printer heads
- HDD Hard Disk Drive
- DVD Digital Versatile
- Blu-ray registered trademark
- CD Compact Disc
- a rolled copper foil is generally used for the conductor portion of such a flexible flat cable.
- the integrated intensity of (200) plane obtained by X-ray diffraction of copper foil is I
- the integrated intensity of (200) plane obtained by X-ray diffraction of fine powder copper is I (0).
- Patent Document 1 a rolled copper foil having a cubic texture satisfying I / I (0)> 20 is disclosed (Patent Document 1).
- a long life can be realized by using a copper foil having a texture excellent in bending resistance, and a flexible printed circuit board (FPC) can be miniaturized and enhanced in function.
- Patent Document 2 a rolled copper foil that is manufactured by rolling a round wire rod and defines the crystal average grain size with respect to the foil thickness is disclosed (Patent Document 2).
- the bending resistance is improved by making the surface layer crystal where fracture due to fatigue starts to be finer.
- JP 2006-326684 A Japanese Patent No. 5342712
- Patent Document 1 since a copper foil is manufactured by rolling a plate material, when FFC is manufactured using a copper foil, it is premised on slitting the copper foil, which increases the cost. Cause. In recent years, there has been an increasing demand for narrowing the FFC, but it has been difficult to sufficiently narrow the width of the copper foil by the slit processing method. Patent Document 1 does not disclose a technique for producing a copper foil based on a round wire. On the other hand, in the technique of Patent Document 2, a copper wire is manufactured by rolling a round wire, and it is disclosed that the bending resistance is high, but texture control is not performed, and in recent years, For example, further improvements in characteristics have been sought for the high flex resistance requirement required by the SRC.
- the object of the present invention is to provide a rolled copper foil that is excellent in bending resistance, and can be easily processed and reduced in cost, even when a narrow-width copper foil is produced. It is to provide a flat cable and a manufacturing method thereof.
- a crystal grain having a Cube orientation ⁇ 001 ⁇ ⁇ 100> is formed as a texture of a copper foil when a round wire having a circular cross section is rolled. It can be controlled, and an industrially excellent control method is found. Further, when the crystal grains are accumulated in an area ratio of 6% or more, it has excellent bending resistance, and buckling occurs when applied to FFC. It has been found that rolled copper foil that is difficult to be manufactured can be produced at low cost.
- the present invention produces copper foil by a round wire rolling process, when the width is narrowed to several millimeters or less, the conventional slit process greatly increases the processing difficulty, while the round wire is rolled. It has been found that easy workability can be realized by producing a copper foil.
- the above-mentioned (1) characterized in that in both end regions corresponding to 10% width in the width direction, crystal grains oriented within 13 ° of deviation angle from the Cube orientation have an area ratio of 15% or more.
- a total of one or more elements selected from Mg, Zn, Sn, Ag, P, Cr, Si, Zr, Ti, and Fe is 0.005% by mass or more and 1.0% by mass or less.
- a flexible flat cable comprising an insulating film disposed on both surfaces of the rolled copper foil.
- the insulating film is made of a resin that can be laminated at a temperature lower than the recrystallization temperature of the rolled copper foil. .
- a rolled copper foil manufacturing method comprising: a second rolling treatment step. (10) The method for producing a rolled copper foil according to (9), further comprising a third heat treatment step for subjecting the foil material to strain relief annealing after the second rolling treatment step.
- a method for producing a flexible flat cable characterized by: (12) The method for producing a flexible flat cable according to (11) above, wherein an insulating film is formed on the side surface adjacent to the rolled surface of the rolled copper foil without slitting.
- the rolled copper foil of the present embodiment is not only SRC with FFC mounted, but also mobile phone bending parts, digital camera, movable parts such as a printer head, HDD, DVD, Blu-ray (registered trademark) Disc, CD For example, it can be used for wiring of movable parts of disk-related equipment.
- FIG. 1 It is a perspective view (partial sectional view) of a rolled copper foil according to an embodiment of the present invention. It is an electron microscope image of the rolled copper foil which concerns on embodiment of this invention, (a) is sectional drawing of a TD direction, (b) is an expanded sectional view of the edge part, (c) is slit-processing a board
- the rolled copper foil which becomes one Embodiment of this invention is a rolled copper foil obtained by rolling the round wire which consists of copper or a copper alloy. As shown in FIG. 1, the rolled copper foil 1 has a rolled surface 1 ⁇ / b> A and a side surface 1 ⁇ / b> B composed of a non-sheared surface adjacent thereto.
- the rolled copper foil 1 has a rolled surface 1 ⁇ / b> A and a side surface 1 ⁇ / b> B composed of a non-sheared surface adjacent thereto.
- the XYZ axis is an orthogonal coordinate system
- RD being the X axis indicates the rolling direction
- ND being the Z axis indicates the rolling normal direction perpendicular to the rolling surface 1A
- Y TD which is an axis
- shaft is a rolling width direction
- Reference numeral 1C denotes a cross section perpendicular to the rolling direction RD, which is also referred to as an RD plane.
- reference numerals 1Ca and 1Cb are rectangular area regions (both end regions) each corresponding to a width of 10% on both sides, and are hereinafter simply referred to as both end portions 1Ca and 1Cb.
- non-sheared surface means that a sheared surface produced by slitting with a slitter does not occur, and characterizes the rolled copper foil 1 manufactured from a round wire.
- FIG. 2A The whole cross-sectional photograph of the RD surface in the rolled copper foil 1 of this embodiment is shown in FIG. 2A, and an enlarged view (also RD surface) in the vicinity of the side surface 1B, which is a non-sheared surface, is shown in FIG. .
- Side surfaces 1B located on both sides in the width direction of the rolled copper foil 1 are formed as non-sheared surfaces, and the non-sheared surfaces are curved surfaces having a predetermined curvature. No burr or sag (shear breakage) is formed at the corners of the non-sheared surface and the rolled surface.
- FIG. 2A The whole cross-sectional photograph of the RD surface in the rolled copper foil 1 of this embodiment is shown in FIG. 2A, and an enlarged view (also RD surface) in the vicinity of the side surface 1B, which is a non-sheared surface, is shown in FIG.
- side surfaces located on both sides in the width direction are formed by shearing surfaces, and the shearing surfaces are formed on the rolling surface.
- the plane is almost perpendicular to the plane. Further, burrs and sagging are formed at the corners of the sheared surface and the rolled surface.
- the width and thickness of the rolled copper foil 1 are not particularly limited and can be appropriately determined depending on the application, but the width is 0.300 to 2.000 mm and the thickness is 0.010 to 0.200 mm. preferable.
- the rolled copper foil 1 of the present embodiment is a rolled copper foil obtained by rolling a round wire, it can be made narrower than a conventional case where the rolled foil is simply slit and manufactured.
- the copper or copper alloy used for the rolled copper foil 1 is tough pitch copper (TPC), oxygen-free copper (OFC: Oxygen-Free Copper), or a dilute copper alloy obtained by adding a trace element to them.
- TPC tough pitch copper
- OFC oxygen-free copper
- dilute copper alloy defines the accumulation rate and strength of the texture in a predetermined direction of the rolled sheet. Therefore, the copper or copper alloy used in the present invention only needs to have the above-described integration rate and strength as a material, and the final shape after processing does not necessarily have to be a thin plate shape.
- 1 type or 2 types selected from pure copper such as tough pitch copper and an oxygen free copper, Mg, Zn, Sn, Ag, P, Cr, Si, Zr, Ti, and Fe.
- a dilute copper alloy containing 1.0% by mass or less of the above elements and the balance of copper and inevitable impurities is used.
- the addition of the above elements is intended to increase the strength and heat resistance while not excessively reducing the conductivity, and the total addition amount is preferably 1.0% by mass or less.
- the lower limit value of the addition amount is not particularly specified, but when it is positively added, it is set to 0.005% by mass or more.
- the conductivity of such a dilute copper alloy is desirably 90% or more when the conductivity of standard soft copper is 100%.
- the additive elements are not limited to those described above as long as the above-described main purpose can be achieved.
- the area ratio of crystal grains oriented within a deviation angle of 13 ° from the Cube orientation is 6% or more
- the area ratio of the crystal grains in which the deviation angle from the Cube orientation ⁇ 001 ⁇ ⁇ 100> is within 13 ° is 6% or more.
- the Cube orientation is the crystal orientation of the copper or copper alloy matrix in the material (in the rolled copper foil). This orientation is a crystal in which the ⁇ 001 ⁇ plane of a copper or copper alloy matrix crystal (face-centered cubic lattice) is parallel to the rolling surface and the ⁇ 100> direction is parallel to the rolling direction (RD direction). It is an azimuth.
- the rolled copper foil of the present embodiment includes not only crystal grains strictly oriented in the Cube orientation, but also crystal grains oriented in a three-dimensionally rotated orientation within plus or minus 13 ° from the Cube orientation. In addition, these crystal grains are present at an area occupation ratio (area ratio) of 6% or more when observed on the RD plane.
- the direction including a deviation angle within 13 ° from the Cube direction may be simply referred to as a Cube direction.
- the area ratio of the crystal grains oriented in the Cube orientation is less than 6%, the mechanical strength is satisfied, but the bending resistance is insufficient. Therefore, in the rolling surface of the rolled copper foil of the present embodiment, the area ratio of the crystal grains oriented in the Cube orientation is 6% or more, preferably 10% or more.
- the metal material is usually a polycrystal, but the rolled copper foil is manufactured by repeating rolling a plurality of times, so that the crystals in the foil accumulate in a specific orientation.
- a texture Such a state of a metal structure accumulated in a certain direction is called a texture.
- a coordinate system is required to define the crystal orientation. Therefore, in the present specification, according to a general texture notation method, the rolling direction (RD) in which the rolled copper foil is rolled and proceeding is the X axis, the width direction (TD) of the rolled copper foil is the Y axis, and the rolling is performed.
- the normal direction (ND) of the rolling surface perpendicular to the rolling surface of the copper foil is taken as a Z-axis orthogonal coordinate system (see FIG. 1).
- the orientation of one crystal grain present in the rolled copper foil 1 is expressed by the Miller index (hkl) of the crystal plane perpendicular to the Z axis (parallel to the rolled surface) and the index [uvw] of the crystal direction parallel to the X axis. ]
- (hkl) [uvw] In the form of (hkl) [uvw].
- (132) [6-43] and (231) [3-46] are shown.
- (132) plane of the crystal constituting the crystal grain is perpendicular to ND, and the [6-43] direction of the crystal constituting the crystal grain is parallel to RD.
- (132) [6-43] and (231) [3-46] are equivalent from the symmetry of the face-centered cubic lattice.
- An orientation group having such an equivalent orientation uses parentheses ( ⁇ or ⁇ >) to represent the family, and is represented as ⁇ 132 ⁇ ⁇ 643>.
- the crystal orientation (hkl) [uvw] itself uniquely determines the orientation of the crystal and does not depend on the observation direction. That is, the crystal orientation can be specified by measuring from the rolling direction (RD) or from the rolling surface normal direction (ND).
- RD rolling direction
- ND rolling surface normal direction
- crystal grains are observed on the RD surface 1C, and the area ratio on this observation surface is measured. More specifically, in the entire RD surface 1C, an azimuth whose deviation angle from the Cube azimuth is within 13 ° is measured, and the area is calculated by image analysis. It is obtained by dividing by the total area of the surface 1C.
- EBSD is an abbreviation for Electron BackScatter Diffraction (Electron Backscattering Diffraction).
- Reflected electron Kikuchi line diffraction (Kikuchi pattern) that occurs when a sample is irradiated with an electron beam in a scanning electron microscope (SEM).
- SEM scanning electron microscope
- This is the crystal orientation analysis technology used.
- the entire RD surface of the sample is scanned in steps of 0.5 ⁇ m in each of ND and TD, and using the analysis software (EDAX TSL, trade name “Orientation Imaging Microscopy v5”), the crystal orientation Is analyzed.
- EDAX TSL trade name “Orientation Imaging Microscopy v5”
- the cross section is polished by CP (cross section polisher).
- the rolled copper foil 1 of the present embodiment includes crystal grains oriented in a Cube orientation (an orientation in which the deviation angle from the Cube orientation is within 13 °) at both ends 1Ca and 1Cb of the RD surface 1C.
- the area ratio is measured in the same manner as described above and is 15% or more, preferably 20% or more, it is possible to suppress the occurrence of fatigue failure at the end in the width direction of the rolled copper foil 1. , Better bending resistance can be realized.
- the rolled copper foil 1 of the present embodiment preferably has a flex life of 500,000 times or more in a flex resistance test.
- the flex life is 500,000 times or more, the product durability of FFC is particularly excellent. Therefore, the flex life of the rolled copper foil 1 of this embodiment is 500,000 times or more. Preferably, it is 700,000 times or more.
- the rolled copper foil of this embodiment is hard copper, for example.
- hard copper is a so-called work-hardened material in which strain is accumulated in the material by plastic working, whereas hard copper is finished in an annealing process accompanied by recrystallization. Become a cold worked material.
- the rolled copper foil of the present embodiment is not limited to hard copper, and may be soft copper.
- the rolled copper foil of the present embodiment includes [1] a first wire drawing process, [2] a first heat treatment process, [3] a second wire drawing process, and [4] a first wire drawing process. It can be manufactured through each step of 1 rolling treatment step, [5] second heat treatment step, [6] second rolling treatment step, and [7] third heat treatment step. [6] If the characteristics of the present invention are satisfied after completion of the second rolling treatment step, [7] the third heat treatment step may be omitted. The steps [1] to [7] will be described below.
- First wire drawing treatment process A round wire 2 (or bar) made of copper or copper alloy cast with an outer diameter of ⁇ 8.0 mm or more is subjected to a first wire drawing treatment to obtain ⁇ 0.400- Process until it reaches 4.000 mm.
- the second wire drawing treatment is performed on the round wire 3 having a diameter of ⁇ 0.400 to 4.000 mm to process to ⁇ 0.100 to 0.400 mm. (High wire drawing processing).
- the outer diameter of the round wire after the second wire drawing treatment has a great influence on the sheet width control after the rolling treatment, which will be described later, and is determined according to the desired dimensions of the final product.
- the area reduction rate needs to be 75% or more.
- the area reduction rate in the second wire drawing process is preferably 85%, more preferably 90%.
- the reason for increasing the area reduction rate in this step is to increase the integration of the Cube orientation after the second heat treatment step (recrystallization treatment).
- the dimensions of the plate-like wire 5 formed by the first rolling process are unambiguous because they are determined by many factors such as wire type, lubrication, roll-to-wire diameter ratio, rolling reduction, number of passes, and tension. Rather, the dimensions are arbitrary within a controllable range, but the area reduction rate is preferably 4% or more.
- the thickness reduction rate Z in the second rolling process is 50% or less, preferably 15 to 50% (high rolling process).
- the thickness reduction rate is high, the number of Cube orientation crystal grains decreases.
- the foil material 6 is annealed to remove strain. This step may be omitted.
- the heat treatment conditions in this step are, for example, 150 to 300 ° C. and 10 seconds to 2 hours.
- the third heat treatment is intended to further increase the bending by rearrangement of dislocations by low-temperature heat treatment, and does not affect the size of crystal grains.
- the rolled copper foil 1 is manufactured by performing a series of processes from the first wire drawing process to the third heat treatment.
- the foil material 6 becomes the rolled copper foil 1 as it is.
- a rolled copper foil having excellent bending resistance and excellent buckling resistance when applied to FFC is obtained.
- a process is easy and it becomes possible to reduce manufacturing cost.
- the copper foil itself has mechanical strength, the copper does not soften even if it is heated during the subsequent laminating process, and it is not necessary to perform low-temperature heat treatment as a post-treatment. The degree of adhesion between the film and the copper foil does not decrease. Therefore, a highly reliable FFC can be provided, and thus a highly reliable SRC can be provided.
- a flexible flat cable As shown in FIG. 5, a flexible flat cable (FFC) according to an embodiment of the present invention includes a plurality of rolled copper foils 21-1 to 21-6 and an adhesive layer 22 in which the plurality of rolled copper foils are embedded. And insulating films 23 and 24 disposed on both sides of the adhesive layer.
- the rolled copper foils 21-1 to 21-6 are arranged side by side so that the in-plane directions of the rolled surfaces are substantially the same, and the insulating film 23 and the other rolled surface are provided on one rolled surface side of these rolled copper foils.
- An insulating film 24 is provided on the side.
- the adhesive layer 22 has a thickness sufficient to embed a plurality of rolled copper foils 21-1 to 21-6, and is sandwiched between insulating films 23 and 24.
- the adhesive layer 22 is made of a known adhesive that matches the insulating films 23 and 24.
- the insulating films 23 and 24 are made of a resin that can be laminated at a temperature lower than the recrystallization temperature of the rolled copper foil, and the resin that can be laminated is made of copper or copper alloy constituting the rolled copper foil. A resin that can exhibit good adhesion to an adhesive layer or a rolled copper foil at a temperature lower than the recrystallization temperature.
- the insulating films 23 and 24 are made of, for example, polyethylene terephthalate (PET) resin, preferably polyethylene terephthalate.
- an insulating film is disposed on both sides of the rolled copper foil, and laminating is performed at a temperature lower than the recrystallization temperature of the rolled copper foil, for example, 100 to 200 ° C. Under such temperature conditions, the rolled copper foil is formed inside the FFC while maintaining the above-described properties as hard copper. Therefore, compared with the case where it becomes soft copper, mechanical strength can be maintained higher, and it becomes difficult to buckle even if it is FFC of narrower width.
- the rolled copper foil used for the said manufacturing process is manufactured with the desired width
- Insulating films used in the manufacturing process each have a width of 10 mm to 20 mm and a thickness of 0.01 mm to 0.1 mm. Therefore, the FFC has a width of 10 mm to 20 mm and a thickness of 0.03 to 0.4 mm.
- the rolled copper foil of this embodiment it is possible to narrow the FFC.
- an insulating film that can be laminated at a temperature lower than the recrystallization temperature of the rolled copper foil can be selected, a low-cost film can be used, and the cost of FFC can be reduced.
- Patent Document 1 (Contrast with Patent Document 1 and Patent Document 2)
- the recrystallization heat treatment is usually performed when an insulating film is laminated on a copper foil. Becomes a copper foil corresponding to annealed copper having a recrystallized structure. For this reason, the mechanical strength of the copper foil in the final product is low.
- the FFC is buckled unless an auxiliary roller is attached, and does not play its role.
- the Cube orientation has a predetermined area ratio, so that the desired mechanical strength can be improved, and even when the FFC is narrowed, it is appropriate. By processing by laminating, FFC buckling can be prevented.
- the rolled copper foil of the said patent document 1 is described as a rolled copper foil suitable for FPC, and if the final rolling rate is considered, the strip rolling process and the slit process which cut
- the slitting process is more expensive than the round wire rolling process, and the processing difficulty increases when manufacturing narrow materials with a width of less than 0.8 mm. High cost is unavoidable.
- or FFC of this embodiment were manufactured from the round wire as above-mentioned, it can manufacture at low cost.
- Patent Document 2 is intended only for soft copper that has been recrystallized, and plastic processing before recrystallization corresponding to the wire drawing step before recrystallization defined in the scope of the present invention is optional. It can be determined that no assumption has been made about the crystal orientation control.
- the mechanical strength of the rolled copper foil is ensured by having a predetermined area ratio in the Cube orientation, so that the bending resistance can be improved, FFC buckling can be prevented by performing an appropriate laminating process.
- a round wire rod (TPC) with a diameter of 9.000 mm was drawn to form a round wire with a diameter of 0.600 to 4.000 mm, and then heat-treated at 200 to 600 ° C. for 10 seconds to 2 hours.
- TS tensile strength
- the round wire after the heat treatment was drawn at a surface reduction ratio of 75% or more to form a round wire having a diameter of 0.230 mm.
- a round wire having a diameter of 0.230 mm was subjected to a rolling process to form a plate-like wire having a thickness of 0.035 to 0.050 mm.
- the plate wire was again heat-treated at 200 to 600 ° C. for 10 seconds to 2 hours.
- the sheet wire after the heat treatment was further subjected to a rolling treatment to produce a foil material having a thickness of 0.035 mm.
- a final product was obtained by applying a strain relief annealing at 150 to 300 ° C. for 10 seconds to 2 hours.
- the final copper foil had a width of 0.800 mm and a thickness of 0.035 tmm.
- a round wire rod having a diameter of ⁇ 0.900 to 2.600 mm was formed by subjecting a round wire rod (TPC) having a diameter of 9.000 mm to heat treatment at 200 to 600 ° C. for 10 seconds to 2 hours.
- TS tensile strength
- the round wire after the heat treatment was subjected to a drawing process at a surface reduction ratio of 75% or more to form a round wire having a diameter of 0.170 mm.
- the round wire was subjected to a rolling process to form a plate wire having a thickness of 0.045 mm. Thereafter, the plate wire was again heat-treated at 200 to 600 ° C.
- Comparative Examples 5 to 8 Comparative methods 1 to 4, respectively, except that the wire diameter before the first rolling treatment was ⁇ 0.170 mm in order to obtain a foil material having a width of 0.500 to 1.400 mm and a thickness of 0.035 mm as a final product. A rolled copper foil was obtained.
- Comparative Examples 9-12 Comparative methods 1 to 4 except that the wire diameter before the first rolling treatment was ⁇ 0.260 mm in order to obtain a foil material having a width of 0.500 to 1.400 mm and a thickness of 0.035 mm as a final product. A rolled copper foil was obtained.
- Comparative Examples 13 to 16 Comparative methods 1 to 4 except that the wire diameter before the first rolling treatment was ⁇ 0.300 mm in order to obtain a foil material having a width of 0.500 to 1.400 mm and a thickness of 0.035 mm as a final product. A rolled copper foil was obtained.
- the area reduction rate in the second wire drawing process is divided into a cross-sectional area (substantially circular) of the round wire immediately before the second wire drawing process and a cross-sectional area (substantially circular) of the round wire immediately after the second wire drawing process. Based on the calculation. Further, the area reduction rate in the first rolling process is calculated based on the cross-sectional area of the round wire just before the first rolling process and the cross-sectional area (substantially rectangular) of the plate-like wire just after the first rolling process. Furthermore, the reduction ratio in the second rolling process was calculated based on the cross-sectional area of the plate wire immediately before the second rolling process and the cross-sectional area (substantially rectangular) of the foil material immediately after the second rolling process. .
- the area ratio (area ratio A) of crystal grains in which the deviation angle from the Cube orientation is within 13 ° on the RD surface 1C was measured.
- difference angle from Cube direction is within 13 degrees was measured in both ends 1Ca and 1Cb. The measurement was performed in a measurement area of about 500 ⁇ m square under a scan step of 0.5 ⁇ m. The measurement area was adjusted based on the inclusion of 200 or more crystal grains.
- the rotation angle was calculated centering on a common rotating shaft, and it was set as the shift
- the evaluation criteria are “Yes” for passing over 500,000 times when the life is judged to be sufficient as the product specifications, and “No” for over 400,000 times and less than 500,000 times where the life may not meet the product specifications. “A failure was evaluated as“ x ”when the product life was less than 400,000 times that did not meet the product specifications.
- the area ratio (area ratio A) of the crystal grains oriented in the orientation in which the deviation angle from the Cube orientation is within 13 ° on the rolled surface of the rolled copper foil is 6 %, The number of flexing lives was 500,000 times or more, and it was found that the flex resistance was good.
- the area ratio (area ratio B) of the crystal grains oriented in the orientation in which the deviation angle from the Cube orientation at both ends 1Ca and 1Cb is within 13 ° is 15% or more, and the bending resistance The properties were found to be good.
- the area ratio (area ratio A) of the crystal grains oriented in an orientation whose deviation angle from the Cube orientation is within 13 ° is outside the scope of the present invention.
- the area ratio (area ratio B) of the crystal grains oriented in the orientation in which the deviation angle from the Cube orientation at both ends 1Ca and 1Cb is within 13 ° is out of the range of the present invention, and the bending resistance is insufficient.
- the area ratio (area ratio A) of the crystal grains oriented in the orientation whose deviation angle from the Cube orientation is within 13 ° is 6% or more, and the number of flexing lives It became 500,000 times or more, and it turned out that bending resistance is favorable.
- the area ratio (area ratio B) of crystal grains oriented in an orientation in which the deviation angle from the Cube orientation at both ends 1Ca and 1Cb is within 13 ° is 15% or more, It was found that the bending resistance was good.
- the area ratio (area ratio A) of the crystal grains oriented in the orientation whose deviation angle from the Cube orientation is within 13 ° is outside the scope of the present invention.
- the area ratio (area ratio B) of the crystal grains oriented in the orientation in which the deviation angle from the Cube orientation at both ends 1Ca and 1Cb is within 13 ° is outside the scope of the present invention, and the bending resistance was insufficient.
- the desired crystal orientation area ratio was obtained, the lifespan varied greatly and did not necessarily reach 500,000 times. This is because the slit narrow width material has a reduced dimensional accuracy and has an adverse effect on the flexibility.
- the rolled copper foil 1 of the present embodiment is suitably used as a flexible flat cable (FFC) because it is excellent in flexibility and excellent in bending resistance.
- FFC flexible flat cable
- automobile parts such as a steering roll connector (SRC), a roof harness, a door harness, and a floor harness that are components of an airbag system in an automobile.
- SRC steering roll connector
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Abstract
Description
一方、特許文献2の技術では、丸線を圧延加工して銅箔を製造しており、耐屈曲性が高いことが開示されているが、集合組織制御を行っているわけではなく、近年、例えば上記SRCで求められている高い耐屈曲性の要求に対して特性のさらなる改善がもとめられていた。
(1)銅または銅合金からなり、圧延面と、該圧延面に隣接する両側面がせん断加工面ではない非せん断加工面を有する圧延銅箔であって、
Cube方位からのずれ角度が13°以内に配向する結晶粒が6%以上の面積率を有することを特徴とする、圧延銅箔。
(2)巾方向に関してそれぞれ10%幅に相当する両端領域において、Cube方位からのずれ角度が13°以内に配向する結晶粒が15%以上の面積率を有することを特徴とする、上記(1)記載の圧延銅箔。
(3)Mg、Zn、Sn、Ag、P、Cr、Si、Zr、Ti、Feの中から選ばれる1種または2種以上の元素を合計で0.005質量%以上1.0質量%以下含有し、残部が銅と不可避不純物からなる銅合金からなることを特徴とする、上記(1)または(2)記載の圧延銅箔。
(4)屈曲寿命回数が50万回以上であることを特徴とする、上記(1)~(3)のいずれかに記載の圧延銅箔。
(5)巾0.300mm~2.000mm、厚さ0.010mm~0.200mmで構成されていることを特徴とする、上記(1)~(4)のいずれかに記載の圧延銅箔。
(6)上記(1)~(5)のいずれかに記載の圧延銅箔と、
該圧延銅箔の両面に配置された絶縁フィルムとを有することを特徴とする、フレキシブルフラットケーブル。
(7)前記絶縁フィルムは、前記圧延銅箔の再結晶温度よりも低い温度でラミネート処理し得る樹脂で構成されていることを特徴とする、上記(5)または(6)記載のフレキシブルフラットケーブル。
(8)前記絶縁フィルムは、ポリエチレンテレフタレート系樹脂で構成されていることを特徴とする、上記(7)記載のフレキシブルフラットケーブル。
(9)上記(1)~(4)のいずれかに記載の圧延銅箔の製造方法であって、
銅または銅合金からなる丸線材に200~600℃、10秒~2時間の熱処理を施す第1熱処理工程と、
前記第1熱処理工程後の丸線材を減面率75%以上で伸線する伸線処理工程と、
前記伸線処理工程後の丸線材を圧延して板状線材を形成する第1圧延処理工程と、
前記板状線材に200~600℃、10秒~2時間の熱処理を施す第2熱処理工程と、 前記第1熱処理工程後の板状線材を減面率50%以下で圧延して箔材を形成する第2圧延処理工程と、を有することを特徴とする圧延銅箔の製造方法。
(10)前記第2圧延処理工程の後、前記箔材に歪取焼鈍を施す第3熱処理工程を更に有することを特徴とする、上記(9)記載の圧延銅箔の製造方法。
(11)上記(9)または(10)記載の製造方法により得られた圧延銅箔の両面に、絶縁フィルムを、前記圧延銅箔の再結晶温度よりも低い温度でラミネート処理して形成することを特徴とする、フレキシブルフラットケーブルの製造方法。
(12)前記圧延銅箔の圧延面に隣接する側面にスリット加工を行うことなく、絶縁フィルムを形成することを特徴とする、上記(11)記載のフレキシブルフラットケーブルの製造方法。
なお本発明における屈曲寿命回数とは、屈曲半径R=6.5mm、ストロークS=±13mm、環境温度85℃、回転速度900rpm、という試験条件のもとで行う屈曲試験において、圧延銅箔が破断したときの屈曲回数のことを言うものとする。
本発明の一実施形態となる圧延銅箔は、銅または銅合金からなる丸線材を圧延して得られる圧延銅箔である。
図1に示す通り、圧延銅箔1は、圧延面1Aと、それに隣接する、非せん断加工面からなる側面1Bを有する。なお図1中、X-Y-Z軸は直交座標系であり、X軸であるRDは圧延方向を示し、Z軸であるNDは、圧延面1Aに垂直な圧延法線方向を示し、Y軸であるTDは圧延巾方向であって、前記RDとTDの両方に垂直な方向を示す。また符号1Cで示すのは、圧延方向RDに垂直な断面であり、RD面とも称するものとする。またRD面1Cにおいて、符号1Ca、1Cbは、その両側それぞれ10%幅に相当する矩形の面積領域(両端領域)であり、以下、単に両端部1Ca,1Cbと称する。
本実施形態の圧延銅箔1は、Cube方位{001}<100>からのずれ角度が13°以内に配向する結晶粒の面積率が6%以上である。Cube方位とは材料中(圧延銅箔中)の銅または銅合金母相の結晶の方位である。この方位は、銅または銅合金母相の結晶(面心立方格子)の{001}面が圧延面に対して平行であり、かつ<100>方向が圧延方向(RD方向)と平行である結晶方位である。ただし、理想的な結晶方位からのずれ角度が13°以内(0°以上13°以内)であればその理想方位と同等として扱うことができ得るので、Cube方位からのずれ角度が13°以内の方位についてもCube方位と同等とすることができる。そこで、本実施形態の圧延銅箔は、厳密にCube方位に配向している結晶粒のみならず、Cube方位からプラスマイナス13°以内で3次元的に回転した方位に配向している結晶粒を含め、これらの結晶粒が、RD面で観察したときに、面積占有率(面積率)6%以上で存在する。以下、Cube方位からのずれ角度が13°以内の方位も含めて、単にCube方位と称することもある。
本実施形態の圧延銅箔1は、図1に示すように、RD面1Cの両端部1Ca、1Cbにおいて、Cube方位(Cube方位からのずれ角度が13°以内の方位)に配向する結晶粒の面積率を、上述したものと同様に測定し、それぞれ15%以上、好ましくはそれぞれ20%以上である場合、圧延銅箔1の巾方向端部で疲労破壊が発生することを抑制することができ、より優れた耐屈曲性を実現できる。
本実施形態の圧延銅箔1は、耐屈曲性試験において、屈曲寿命回数が50万回以上であるのが好ましい。屈曲寿命回数が50万回以上であると、FFCの製品耐久性が特に優れる。よって本実施形態の圧延銅箔1の屈曲寿命回数は50万回以上とする。好ましくは、70万回以上である。
本実施形態の圧延銅箔は、例えば硬銅である。ここで硬銅とは、塑性加工により歪が材料内に蓄積された、いわゆる加工硬化された材料であり、対比される軟銅が再結晶を伴う焼鈍工程で仕上げられることに対して、硬銅は、冷間加工仕上げされた材料になる。ただし、本実施形態の圧延銅箔は硬銅に限られず、軟銅であってもよい。
本実施形態の圧延銅箔は、例えば、図3に示すように、[1]第1伸線処理工程、[2]第1熱処理工程、[3]第2伸線処理工程、[4]第1圧延処理工程、[5]第2熱処理工程、[6]第2圧延処理工程、[7]第3熱処理工程、の各工程を経て製造することができる。なお、[6]第2圧延処理工程終了後に本発明の特性を満たしていれば、[7]第3熱処理工程は行わなくてもよい。以下、[1]~[7]の工程について説明する。
外径φ8.0mm以上で鋳造された銅または銅合金製の丸線材2(あるいは棒材)に対して、1回目の伸線処理を施し、φ0.400~4.000mmになるまで加工する。
上記[1]の伸線処理でφ0.400~4.000mmに加工された丸線材3を焼鈍する。本工程の熱処理条件は、200~600℃、10秒~2時間で行うのが好ましい。なお、軟化目安として、引張強度TSが250MPa程度となるようにするのが好ましい。
上記[2]の熱処理後、φ0.400~4.000mmの丸線材3に対して2回目の伸線処理を施し、φ0.100~0.400mmまで加工する(高伸線加工処理)。第2伸線処理後の丸線材の外径は、後述する圧延処理後の板巾制御に対して大きな影響を与えるため、最終製品の所望寸法に応じて決定されるが、本伸線処理における減面率は75%以上である必要がある。第2伸線処理工程における減面率は、好ましくは85%、より好ましくは90%である。またこの工程で減面率を高くするのは、第2熱処理工程(再結晶処理)後のCube方位の高集積化のためである。なお、減面率Xは、加工前の丸線材3の長手方向に垂直な断面積をA1、加工後の丸線材4の長手方向に垂直な断面積をA2としたとき、X=(A1-A2)*100/A1で現される。ただし、断面積は丸線材の外径で決まるため、加工前の丸線材3の外径をR1、加工後の丸線材4の外径をR2としたとき、X=(R12-R22)*100/R12としても同一の値として計算できるものである。
上記[3]の伸線処理後、丸線材4を圧延して板状線材5を形成する。最終製品で所望の巾、板厚を得るために、本圧延処理後の寸法には制限がある。例えば、最終製品の所望寸法が巾0.800mm、厚さ0.035mmである場合、本圧延処理で板巾0.770mmになるように圧延し、そのときの板厚は0.045mm程度が妥当である。その後、後述の仕上げ圧延処理(第2圧延処理)を施し、最終製品を形成する。本第1圧延処理にて形成される板状線材5の寸法は、線材種、潤滑状態、ロールと線の径比、圧下率、パス回数、張力など多くの因子によって決まるために一義的なものではなく、その寸法は制御可能な範囲で任意であるが、減面率が4%以上であるのが好ましい。ここでの減面率Yは、加工前の丸線材4の長手方向に垂直な断面積をA3、加工後の板状線材5の長手方向に垂直な断面積をA4としたとき、Y=(A3-A4)*100/A3で現される。また、後述する仕上げ圧延処理(第2圧延処理)にて減面率を指定しているため、該減面率に応じて本工程での減面率を設定する必要がある。
次に、上記[4]で圧延された板状線材5を焼鈍する。その際、平均結晶粒径の最小値は3μmであり、その最大値は板厚寸法と同じとする。本工程の熱処理条件は、200~600℃、10秒~2時間で行うのが好ましい。なお、軟化目安として、引張強度TSが250MPa程度となるようにするのが好ましい。
上記[5]の熱処理後、最終製品の寸法(厚さ)を得るために、板状線材5に仕上げ圧延処理を施して箔材6を形成する。本第2圧延処理における厚さ減少率Zは、50%以下であり、好ましくは、15~50%である(高圧延加工処理)。厚さ減少率Zは、加工前の板状線材5の厚さをt1、加工後の箔材6の厚さをt2としたとき、Z=(t1-t2)*100/t1で表される。厚さ減少率が高いと、Cube方位の結晶粒が少なくなる。このように、本実施形態では上記高伸線加工処理と本高圧延加工処理の双方を行うことにより、その後に再結晶化熱処理を行う必要がなく、箔材6の機械的強度を維持することができる。なお、この板状線材5から箔材6を得る圧延加工のみ、減面率ではなく、厚さ減少率で計算するものとする。
次に、箔材6を焼鈍して、歪取りを行う。この工程は省略しても良い。本工程の熱処理条件は、例えば、150~300℃、10秒~2時間である。本第3熱処理は、低温熱処理による転位の再配列による更なる高屈曲化を目的としており、結晶粒のサイズに影響を及ぼさないものである。このように第1伸線処理から第3熱処理までの一連の処理を施すことにより、圧延銅箔1が製造される。なお、第3熱処理工程を省略する場合は、箔材6がそのまま圧延銅箔1となる。
本発明の一例となる実施形態のフレキシブルフラットケーブル(FFC)は、図5に示すように、複数の圧延銅箔21-1~21-6と、これら複数の圧延銅箔を埋設する接着層22と、該接着層の両面に配置された絶縁フィルム23,24とを備えている。圧延銅箔21-1~21-6は、圧延面の面内方向がほぼ同一となるように並べて配置されており、これら圧延銅箔の一方の圧延面側に絶縁フィルム23、他方の圧延面側に絶縁フィルム24が設けられている。
接着層22は、複数の圧延銅箔21-1~21-6を埋設するのに十分な厚みを有しており、絶縁フィルム23,24によって挟持されている。接着剤層22は、絶縁フィルム23,24に適合する周知の接着剤で構成されている。
絶縁フィルム23,24は、上記圧延銅箔の再結晶温度よりも低い温度でラミネート処理し得る樹脂で構成されており、ラミネート処理し得る樹脂とは、圧延銅箔を構成する銅又は銅合金の再結晶温度よりも低い温度で、接着層あるいは圧延銅箔との良好な密着性を発現することができる樹脂をいう。絶縁フィルム23,24は、例えばポリエチレンテレフタレート(PET)系樹脂、好ましくはポリエチレンテレフタレートで構成されている。
本実施形態のFFCの製造方法では、上記圧延銅箔の両側に、例えば絶縁フィルムを配置し、前記圧延銅箔の再結晶温度よりも低い温度、例えば100~200℃でラミネート処理を行う。
このような温度条件により、圧延銅箔は、前述した硬銅としての性質を維持したままFFCの内部に形成される。したがって軟銅になった場合に比較して、より機械的強度を高く維持することができ、より狭巾のFFCであっても座屈しにくくなる。
また絶縁フィルムは、前記圧延銅箔の再結晶温度よりも低い温度でラミネート処理し得るものを選定できるので、低コストなものを使用することができ、FFCの低コスト化を図ることができる。
特許文献1の技術では、再結晶化熱処理することで立方体組織の発達を達成しているが、当該再結晶化熱処理は通常銅箔に絶縁フィルムをラミネートする際に行われており、ラミネート処理後は、再結晶組織を有する軟銅に相当する銅箔となる。そのため、最終製品における銅箔の機械的強度は低く、例えばUターン型のSRCでは、補助ローラをつけなければFFCは座屈してしまい、その役割を果たさない。また、近年進んでいるFFCの狭巾化に対しては、銅箔自体に機械的強度の向上が望まれており、軟銅あるいはそれに相当する導体よりも高い機械的強度を確保することが望まれている。
これに対し、本実施形態の圧延銅箔ないしFFCは上述してきた通り、丸線から製造されたものであるので、低コストで製造できる。
φ9.000mmの丸線材(TPC)に伸線処理を施してφ0.600~4.000mmの丸線材を形成し、その後、200~600℃、10秒~2時間で熱処理を行った。このときの軟化目安は引張強度(TS)=250MPaとした。さらにこの熱処理後の丸線材に減面率75%以上で伸線処理を施して、φ0.230mmの丸線材を形成した。次いで、φ0.230mmの丸線材に圧延処理を施して厚さ0.035~0.050mmの板状線材を形成した。その後、この板状線材に再び200~600℃、10秒~2時間で熱処理を行った。そして、熱処理後の板状線材にさらに圧延処理を施して厚さ0.035mmの箔材を作製した。最後に必要に応じて150~300℃、10秒~2時間で歪取焼鈍処理を施して最終製品を得た。最終製品の銅箔は巾0.800mm、厚さ0.035tmmであった。このような第1伸線処理→第1熱処理→第2伸線処理→第1圧延処理→第2熱処理→第2圧延処理→(第3熱処理)の一連のフローを製造工程(I)とした。
上記製造工程(I)に代えて、第1伸線処理(φ9.000mm→φ0.600mm)→第1熱処理(軟化目安:TS=250MPa)→第2伸線処理(φ0.600mm→φ0.230mm)→第1圧延処理(φ0.230mm→0.035mmt)→第2熱処理(再結晶化処理)の一連のフローからなる製造工程(I’)にて、最終製品を得た。
上記製造工程(I)に代えて、第1伸線処理(φ9.000mm→φ0.230mm)→第1圧延処理(φ0.230mm→0.050mmt)→第2熱処理(軟化目安:TS=250MPa)→第2圧延処理(0.050mmt→0.035mmt)の一連のフローからなる製造工程(II)にて、最終製品を得た。
上記製造工程(I)に代えて、第1伸線処理(φ9.000mm→φ0.400mm)→第1熱処理(軟化目安:TS=250MPa)→第2伸線処理(φ0.400mm→φ0.230mm)→第1圧延処理(φ0.230mm→0.0467mmt)→第2熱処理(軟化目安:TS=250MPa)→第2圧延処理(0.0467mmt→0.035mmt)の一連のフローからなる製造工程(III)にて、最終製品を得た。
上記製造工程(I)に代えて、第1伸線処理(φ9.000mm→φ4.000mm)→第1熱処理(軟化目安:TS=250MPa)→第2伸線処理(φ4.000mm→φ0.230mm)→第1圧延処理(φ0.230mm→0.035mmt)→第3熱処理(歪取熱処理)の一連のフローからなる製造工程(IV)にて、最終製品を得た。この工程では、第1圧延処理によって最終的な箔厚を得ているため、第2圧延処理工程および第2熱処理工程は実施していない。
上記製造工程(I)に代えて、第1伸線処理(φ9.000mm→φ0.600mm)→第1熱処理(軟化目安:TS=250MPa)→第2伸線処理(φ0.600mm→φ0.230mm)第1圧延処理(φ0.230mm→0.075mmt)→第2熱処理(軟化目安:TS=250MPa)→第2圧延処理(0.075mmt→0.035mmt)→第3熱処理(歪取熱処理)の一連のフローからなる製造工程(V)にて、最終製品を得た。
φ9.000mmの丸線材(TPC)に伸線処理を施してφ0.900~2.600mmの丸線材を形成し、その後、200~600℃、10秒~2時間で熱処理を行った。このときの軟化目安は引張強度(TS)=250MPaとした。さらにこの熱処理後の丸線材に減面率75%以上で伸線処理を施して、φ0.170mmの丸線材を形成した。次いで、その丸線材に圧延処理を施して厚さ0.045mmの板状線材を形成した。その後、この板状線材に再び200~600℃、10秒~2時間で熱処理を行った。そして熱処理後の板状線材にさらに圧延処理を施して、厚さ0.035mmの箔材を作成した。最後に必要に応じて歪取焼鈍処理を施して最終製品を得た。最終製品の銅箔は、巾0.500~1.400mm、厚さ0.035mmであった。このような第1伸線処理→第1熱処理→第2伸線処理→第1圧延処理→第2熱処理→第2圧延処理→(第3熱処理)の一連のフローを製造工程(I)とした。
最終製品として巾0.500~1.400mm、厚さ0.035mmの箔材を得るため第1圧延処理前の線径をφ0.170mmしたこと以外は、それぞれ比較例1~4と同様の方法にて圧延銅箔を得た。
最終製品として巾0.500~1.400mm、厚さ0.035mmの箔材を得るため第1圧延処理前の線径をφ0.260mmしたこと以外は、それぞれ比較例1~4と同様の方法にて圧延銅箔を得た。
最終製品として巾0.500~1.400mm、厚さ0.035mmの箔材を得るため第1圧延処理前の線径をφ0.300mmしたこと以外は、それぞれ比較例1~4と同様の方法にて圧延銅箔を得た。
スリット処理が用いられる例として、TPCからなる厚さ0.400mmの銅板に圧延処理を施して厚さ0.100mmの板材を作成し、次いで軟化目安を引張強度(TS)=250MPaとして再結晶化処理を行い、さらに、圧延処理を施して厚さ0.035mmの銅箔を形成し、最後に銅箔を細長く切断して、巾0.500及び0.800mm、厚さ0.035mmの銅箔を得た。このような第1圧延処理→熱処理→第2圧延処理→スリット処理の一連のフローを製造工程(VIII)とした。
上記第2伸線処理での減面率を、該第2伸線処理直前の丸線材の断面積(略円形)と、第2伸線処理直後の丸線材の断面積(略円形)とに基づいて算出した。また、上記第1圧延処理での減面率を、該第1圧延処理直前の丸線材の断面積と、第1圧延処理直後の板状線材の断面積(略矩形)とに基づいて算出し、さらに、上記第2圧延処理での圧下率を、該第2圧延処理直前の板状線材の断面積と、第2圧延処理直後の箔材の断面積(略矩形)とに基づいて算出した。
上述したEBSD法に用い、RD面1Cにおいて、Cube方位からのずれ角度が13°以内に配向する結晶粒の面積率(面積率A)を測定した。また、各圧延銅箔について、両端部1Ca、1Cbにおいて、Cube方位からのずれ角度が13°以内に配向する結晶粒の面積率(面積率B)を測定した。測定は、約500μm四方の測定領域で、スキャンステップが0.5μmの条件で測定を行った。測定面積は結晶粒を200個以上含むことを基準として調整した。なお、ずれ角度については、共通の回転軸を中心に回転角を計算し、ずれ角度とした。また、あらゆる回転軸に関してCube方位との回転角度を計算した。回転軸は最も小さいずれ角度で表現できるものを採用した。全ての測定点に対してこのずれ角度を計算して小数第一位までを有効数字とし、Cube方位から13°以内の方位を持つ結晶粒の面積を全測定面積で除し、面積率を算出した。
図6に示すようなFPC屈曲試験機(上島製作所社製、装置名「FT-2130」)を用い、試料固定板11及び可動板12に圧延銅箔1を固定し、モータ部13により可動板12を可動させて屈曲試験を行った。本耐屈曲試験は圧延銅箔単体で行った。試験条件は、屈曲半径R=6.5mm、ストロークS=±13mm、環境温度85℃、回転速度900rpm、屈曲寿命回数は圧延銅箔1が破断状態になったときの回数とし、圧延銅箔1が破断状態に至るまで屈曲試験を繰返し、そのときの屈曲寿命回数を測定した。評価基準は、寿命が製品仕様として十分であると判断される50万回以上を合格「○」、寿命が製品仕様を満たさない可能性のある40万回以上50万回未満を不合格「△」、寿命が製品仕様を満たさない40万回未満を不合格「×」とした。
2 丸線材
3 丸線材
4 丸線材
5 板状線材
6 箔材
7 圧延面
8 圧延面の巾方向両端領域
11 試料固定板
12 可動板
13 モータ部
20 フレキシブルフラットケーブル
21-1,21-2,21-3 圧延銅箔
21-4,21-5,21-6 圧延銅箔
22 接着層
23 絶縁フィルム
24 絶縁フィルム
RD 圧延方向
TD 巾方向
ND 圧延面法線方向
R 屈曲半径
Claims (12)
- 銅または銅合金からなり、圧延面と、該圧延面に隣接する両側面がせん断加工面ではない非せん断加工面を有する圧延銅箔であって、
Cube方位からのずれ角度が13°以内に配向する結晶粒が6%以上の面積率を有することを特徴とする、圧延銅箔。 - 巾方向に関してそれぞれ10%幅に相当する両端領域において、Cube方位からのずれ角度が13°以内に配向する結晶粒が15%以上の面積率を有することを特徴とする、請求項1記載の圧延銅箔。
- Mg、Zn、Sn、Ag、P、Cr、Si、Zr、Ti、Feの中から選ばれる1種または2種以上の元素を合計で0.005質量%以上1.0質量%以下含有し、残部が銅と不可避不純物からなる銅合金からなることを特徴とする、請求項1または2記載の圧延銅箔。
- 屈曲寿命回数が50万回以上であることを特徴とする、請求項1~3のいずれか1項に記載の圧延銅箔。
- 巾0.300mm~2.000mm、厚さ0.010mm~0.200mmで構成されていることを特徴とする、請求項1~4のいずれか1項に記載の圧延銅箔。
- 請求項1~5のいずれか1項に記載の圧延銅箔と、
該圧延銅箔の両面に配置された絶縁フィルムとを有することを特徴とする、フレキシブルフラットケーブル。 - 前記絶縁フィルムは、前記圧延銅箔の再結晶温度よりも低い温度でラミネート処理し得る樹脂で構成されていることを特徴とする、請求項5または6記載のフレキシブルフラットケーブル。
- 前記絶縁フィルムは、ポリエチレンテレフタレート系樹脂で構成されていることを特徴とする、請求項7記載のフレキシブルフラットケーブル。
- 請求項1~4のいずれか1項に記載の圧延銅箔の製造方法であって、
銅または銅合金からなる丸線材に200~600℃、10秒~2時間の熱処理を施す第1熱処理工程と、
前記第1熱処理工程後の丸線材を減面率75%以上で伸線する伸線処理工程と、
前記伸線処理工程後の丸線材を圧延して板状線材を形成する第1圧延処理工程と、
前記板状線材に200~600℃、10秒~2時間の熱処理を施す第2熱処理工程と、 前記第1熱処理工程後の板状線材を減面率50%以下で圧延して箔材を形成する第2圧延処理工程と、を有することを特徴とする圧延銅箔の製造方法。 - 前記第2圧延処理工程の後、前記箔材に歪取焼鈍を施す第3熱処理工程を更に有することを特徴とする、請求項9に記載の圧延銅箔の製造方法。
- 請求項9または10記載の製造方法により得られた圧延銅箔の両面に、絶縁フィルムを、前記圧延銅箔の再結晶温度よりも低い温度でラミネート処理して形成することを特徴とする、フレキシブルフラットケーブルの製造方法。
- 前記圧延銅箔の圧延面に隣接する側面にスリット加工を行うことなく、絶縁フィルムを形成することを特徴とする、請求項11記載のフレキシブルフラットケーブルの製造方法。
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CN114822985B (zh) * | 2022-03-30 | 2023-10-27 | 鹤山市合润电子科技有限公司 | 一种制造排线的方法以及排线 |
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EP3128036B1 (en) | 2020-07-01 |
US10522268B2 (en) | 2019-12-31 |
CN106029929B (zh) | 2019-03-22 |
JPWO2015152261A1 (ja) | 2017-04-13 |
EP3128036A1 (en) | 2017-02-08 |
KR20160137998A (ko) | 2016-12-02 |
EP3128036A4 (en) | 2018-05-09 |
CN106029929A (zh) | 2016-10-12 |
KR101893280B1 (ko) | 2018-08-29 |
US20170018329A1 (en) | 2017-01-19 |
JP6696895B2 (ja) | 2020-05-20 |
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