JP2845113B2 - Manufacturing method of flexible wiring - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is used to supply power to a linear motor, and is based on two copper foils forming two separate wiring paths of a positive pole and a negative pole. The present invention relates to a method for manufacturing a flexible wiring bonded on a film.

[0002]

2. Description of the Related Art Conventionally, a linear motor has been used for a device for automatically opening and closing a curtain of a one-box car, a curtain for a house window, and the like. This linear motor is a system in which a small movable coil runs by itself in a rail composed of a flexible wiring and a magnet, and is convenient and widely used because of its simple structure and easy mounting. FIG. 10 is a cross-sectional view showing the configuration of the linear motor. A flexible wiring 11 for supplying power to the left inner surface of the rail cover 12 having a U-shaped cross section is fixedly provided. Also,
Ferrite magnet 1 magnetized on the right inner surface of rail cover 12
4 are fixedly arranged. And flexible wiring 1
A movable coil 13 composed of two coils is slidably mounted between the coil 1 and the ferrite magnet 14.

According to the magnetization pitch of the ferrite magnet,
An electric current is supplied from the flexible wiring 11 patterned so as to generate a thrust in the same direction to the movable coil 13 via the current collecting brush 10. Here, the movable coil 13
Can be switched by changing the polarity of the current. The flexible wiring 11 used in such a linear motor is characterized in that two separate copper foils of a positive pole and a negative pole are adhered to the base film 15. Here, in order to operate the movable coil 13 smoothly, the flexible wiring 11 and the ferrite magnet 1
4 needs to be attached with high accuracy.

Next, a conventional method for manufacturing the flexible wiring 11 will be described. Conventional methods include a fred method and an etching method. FIG. 12 shows a flexible wiring 11 manufactured by the Fred method, and FIG. 11 shows a manufacturing process of the flexible wiring 11. First, the stainless steel belt is washed and polished to remove the previously attached resist. Next, a resist is printed by circuit pattern silk printing, and the resist is cured. At this time, the resist is printed on portions of the circuit pattern where copper foil is not required. Next, a copper foil pattern is formed on the stainless steel belt by ultra-high speed plating. Here, copper plating is not applied to the portion where the resist is applied since the portion has no conductivity. Next, the stainless steel belt and the base film are brought into close contact with each other, and the copper foil pattern formed on the stainless steel belt is transferred onto the base film. In the base film,
Since the adhesive is applied in advance, the copper foil pattern is adhered on the base film.

Next, the adhesive is cured to securely fix the copper foil pattern on the base film. Next, as shown in FIG. 12, a plurality of flexible wirings 11 printed on one sheet are subjected to surface treatment for rust prevention. Next, the guide holes 17 used for alignment with the magnets are punched out by a linear motor and slit processing is performed for each one. At this time, the position of the guide hole 17 is already
1 is printed on, and an operator visually performs the drilling with a magnifying glass. Finally, a final inspection is performed. Although the Fred method among the conventional methods has been described above, the etching method is a method in which a copper foil is adhered to the entire base film, a circuit pattern is printed by circuit pattern silk printing, and the copper foil other than the circuit pattern is removed by etching. The other method is the same as the Fred method, and the description is omitted.

[0006]

However, the Fred method and the etching method have the following problems. (1) In both cases, it was difficult to accurately manufacture the long flexible wiring 11. The reason is that, when manufacturing a long flexible wiring 11, the circuit pattern formed by a photographic film is enlarged and the printing is performed by dividing the circuit pattern into two or more times when manufacturing the long flexible wiring 11 due to a limitation of a device for printing on the base film. This is because the error occurs at the joint. Therefore, there is a particular problem in the method of manufacturing the flexible wiring 11 used for a linear motor requiring a long rail. (2) In the Fred method, it is necessary to provide a polishing step every time in order to maintain the surface roughness of the stainless steel belt, which causes an increase in cost. (3) In addition, the etching method requires treatment of waste liquid, and has a problem in that the entire equipment becomes large and cost increases.

As a means for solving these problems, the applicant of the present invention disclosed in Japanese Patent Application No. 5-142621, a copper foil having a connecting portion was punched out by a press working and affixed to a base film. Are proposed at the same time. However, the invention proposed in Japanese Patent Application No. 5-142621 has the following problems. (1) The flexible wiring was processed into a long shape and wound into a roll, and the cutting and the terminal processing of the flexible wiring were performed in the next step. However, there were many restrictions on the terminal processing and the degree of freedom in design was low. . FIG. 7 shows the terminal shape of the flexible wiring 11. The step portion 42 at the distal end is for positioning the flexible wiring 11 on the rail cover 12, and the mounting hole 41 is formed in the flexible wiring 11 by a screw.
Is a hole for fixing to the rail cover 12. However, it has been difficult to perform processing such as the mounting hole 41 by terminal processing in the next step.

That is, as shown in FIG.
There is a half-cut method for punching only the copper foil 16 while leaving the base film 15 around the periphery. However, punching out only the copper foil 16 as a metal part and leaving the base film 15 has a problem that the structure of the cutting blade is complicated and that it is difficult to obtain the precision of the cutting blade. In addition, since the copper foil 16 is adhered to the base film 16, it was difficult to peel off the hard-cut copper foil 16 from the base film 15.
As shown in FIG. 8, there is also a method in which the copper foil 16 and the base film 15 are punched out with a hole larger than the mounting hole 41, and a tape 43 having the mounting hole 41 is later attached to the base film 15. . However, this method has a problem that the number of steps is increased and a tape is required, which increases the cost.

(2) In the manufacturing method proposed in Japanese Patent Application No. 5-142621, the base film 15 supplied in the form of a roll has a seam in the middle. The flexible wiring 11 to which is adhered was extracted and discarded as a defective product. However, since the seam occurs only at a probability of about one in several hundreds, it is a time-consuming and inefficient operation.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problems, and a method of manufacturing a flexible wiring of a predetermined length used for a linear motor with high accuracy and at low cost. The purpose is to provide.

[0011]

SUMMARY OF THE INVENTION In order to solve the first problem, a method for manufacturing a flexible wiring according to the present invention comprises a base film and a base film which is closely attached to the base film and has no connection.
A method of manufacturing a flexible wiring having a predetermined length, comprising a copper foil forming a separate wiring path as described above, wherein (1) when forming a wiring path by punching a copper foil, the wiring path is separated into two or more wiring paths And punching out the wiring path so as to be integral with leaving a connecting part, and when terminal information is given,
A first punching step of transporting the copper foil without punching to form a copper foil terminal forming portion, and (2) a second punching step of punching the copper foil terminal forming portion to form a copper foil terminal portion (3) a bonding step of bonding the copper foil punched in the second punching step to the base film; and (4) a connecting portion of the copper foil punched so that the wiring path is integrated with the copper foil. A third punching step of punching together with the base film, and (5) a fourth punching step of punching a mounting hole in the base film near the end portion of the copper foil and cutting the base film.

According to another aspect of the present invention, there is provided an apparatus for manufacturing a flexible wiring, comprising: a transparent or semi-finished roll having a joint portion whose end faces are joined by an adhesive tape; From a transparent base film and a copper foil that is in close contact with the base film to form a wiring path,
A flexible wiring manufacturing apparatus for manufacturing a flexible wiring having a predetermined length, comprising: a joint detecting means for detecting a bonding part of a base film; a conveying means for conveying the flexible wiring in a longitudinal direction; And a product storage means for storing the cut flexible wiring. The joint detecting means detects the joint of the base film, and (1) the punching means detects the front of the joint. If cut, the punching machine discards the next cut flexible wiring without storing it in the product storage means. (2) If the punching means cuts after the joint, the punching machine cuts immediately before. The flexible wiring is discarded without being stored in the product storage means, and (3) when the punching means cuts off the joint, the punching machine cuts the flexible wiring just before. Both Kishiburu wiring and a flexible wiring cut in the following has a control means for discarding without housed in product storage means.

[0013]

The method for manufacturing a flexible wiring according to the present invention having the above configuration will be described in order. (1) In a first punching step, a copper foil supplied in a long shape is punched by a press machine to form a wiring path. At this time, punching is performed so that the wiring path is integrated except for the connection part in the wiring path divided into two, the positive pole pattern and the negative pole pattern. Further, when the terminal information of the flexible wiring is given, the copper foil is conveyed to form the copper foil terminal forming portion without punching. (2) In the second punching step, a copper foil terminal forming part is punched to form a copper foil terminal part. (3) In the bonding step, the copper foil punched in the second punching step is overlapped with a base film coated with a heat-sensitive adhesive and heated by a bonding machine to bond the copper foil to the base film. I do.

(4) In the third punching step, the connecting portion of the copper foil punched so that the wiring path is integrated is punched together with the base film to which the copper foil is adhered, so that the positive pole pattern and the negative pole pattern are formed. And separate. (5) In the fourth punching step, the base film near the end portion of the copper foil is perforated with an attachment hole formed of a base film having no copper foil attached thereto, and the base film is cut.

On the other hand, the joint detecting means detects the joint of the base film. The product storage means stores the flexible wiring cut to a predetermined length. here,
The control means detects the joint of the base film by the joint detecting means. (1) When the punching means cuts the front of the joint, the punching machine stores the next cut flexible wiring in the product storing means. (2) If the punching means cuts after the joint, the punching machine discards the flexible wiring cut immediately before without storing it in the product storage means, and (3) the punching means When the joint is cut, the punching machine discards both the flexible wiring cut immediately before and the flexible wiring cut next without storing them in the product storage means.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a flexible wiring 11 according to an embodiment of the present invention will be described below in detail with reference to the drawings. FIG. 6 shows the shape of the flexible wiring 11. A plus pole copper foil pattern 21 and a minus pole copper foil pattern 22 are bonded on a base film 15 having a predetermined length. The positive electrode copper foil pattern 21 and the negative electrode copper foil pattern 22 do not have a connection part. Further, pilot holes 18 are formed in the flexible wiring 11 at predetermined intervals. A copper foil terminal portion 49 is formed on the left end of the flexible wiring 11. The copper foil terminal portion 49 is formed with a step portion 42 at the tip end for positioning the flexible wiring 11 on the rail cover 12 and a mounting hole 41 for fixing the flexible wiring 11 to the rail cover 12 with screws. ing.

FIG. 1 is a conceptual diagram showing a manufacturing process of the flexible wiring 11. The copper foil 16 is supplied to the process as a copper foil drum 24 in a wound state. The copper foil 16 is drawn out to the transport line, and the first female mold 25a in the first punching process is used.
The first male die 25b is used to punch out the shape shown in FIG. That is, the U-shaped punches 19 are alternately and continuously formed, and at the same time, the pilot holes 18 are punched on both sides of the copper foil 16 at predetermined intervals. Next, the copper foil 16 is regulated by the punched pilot holes 18.
Is transported. Thereby, the copper foil 16 can be conveyed at an accurate interval with respect to the first punching dies 25a and 25b, and the U-shaped punching 19 can be formed at an accurate interval. Here, since the plus copper foil pattern 21 and the minus copper foil pattern 22 are integrated by the connecting portion, the copper foil 16 is transported while maintaining the mutual positional relationship of the U-shaped punching 19. Can be. In the first punching step, when the terminal information is given to the control device of the first punching machine (not shown), the first punching machine feeds the copper foil 16 one time without performing the punching operation. Thereby, a copper foil terminal forming portion is formed on the copper foil 16.

Next, the copper foil 16 is transported to a second punching step. The position information of the terminal forming portion formed on the copper foil 16 is transmitted to the control device of the second punching machine. Then, the second punching machine does not perform the punching operation when the information of the terminal forming section is not given, and feeds the copper foil 16 one time, and only when the information of the copper foil terminal forming section is given. Operate. That is, the second male mold 44 of the second punching process
b and the second female mold 44a, the terminal forming portion is punched into the shape shown in FIG. 3 to form the copper foil terminal portion 49. Here, the side part 49a of the copper foil terminal part 49 is slightly longer than the end part 49b shown in FIG. Also at this time, the copper foil 16 is conveyed while being regulated by the punched pilot holes 18. Thereby, the copper foil 16 can be conveyed to the first punching dies 25a and 25b at accurate intervals.

Next, the base film 15 is supplied from a base film drum 26. Here, a heat-sensitive adhesive is applied to a surface of the base film film 15 that contacts the copper foil 16. Then, by being heated by the bonding machine 27 including a pair of rollers, the adhesive is melted and the copper foil 16 is bonded to the base film 15.
This state is shown in FIG. FIG. 4B shows a BB cross-sectional view thereof. Next, by the third female mold 28a and the third male mold 28b in the third punching step, FIG.
As shown in the figure, the connection punching 20 is punched. Here, as shown in FIG. 4B, the connection portion punching 20 punches out both the copper foil 16 and the base film 15 at the same time. Thereby, the plus copper foil pattern 21 and the minus copper foil pattern 22 are separated. The positioning of the base film 15 and the copper foil 16 in the third punching step is performed in the lateral direction at the end of the base film 15, and the flow direction is performed by a CCD camera or the like (not shown).

Next, in a fourth punching step, the mounting hole 41 is pierced and the flexible wiring 11 is cut to a required length. That is, the fourth male mold 45b and the fourth female mold 4
5a, the final portion of the previous flexible wiring 11 is cut linearly to form the final end 50, and at the same time, the mounting hole 41 and the step portion 42 shown in FIG. 6 are formed in the base film 15 at the left end of the flexible wiring 11. I do. Next, the predetermined length of the flexible wiring 11 is fed without operating the fourth punching machine. This length is determined by counting the pilot holes 18 and positioning the length shorter than the pitch of the pilot holes 18 is controlled by a feed motor.
After feeding the flexible wiring 11 by a predetermined length, the fourth male mold 45b and the fourth female mold 45a cut the final part of the flexible wiring 11 linearly to form the final end 50, and at the same time, form the next flexible wiring. The mounting hole 41 and the step portion 42 shown in FIG.
To form Thus, the flexible wiring 11 having a predetermined length is completed. Completed flexible wiring 11
Are stored in the product storage pallet 47.

Next, seam detection of the base film 15 will be described. The seam of the base film 15 of this embodiment exists every 400 m. The seam detector is installed immediately before the fourth punching step in FIG. In this embodiment,
Flexible wiring 11 without an independent seam detector
Is also used for seam detection. FIG.
The configuration of the position detector 48 is shown in FIG. Flexible wiring 11
In order to detect the position of the flexible wiring 11 at the transfer position, the slit sensor 53 as the second transmission type photodetector is used.
And a spot sensor 52 as a first transmission type photodetector. Here, a slit having a width of 1.0 mm in the transport direction is attached to the light emitting surface of the light emitting device 53a and the light receiving surface of the light receiving device 53b that constitute the slit sensor 53. The slit detects the vertical slit 51 in FIG. The spot sensor 52 detects the upper slit 52 in FIG. An amplifier 54 is connected to each of the slit sensor 53 and the spot sensor 52. The amplifier 54 is connected to a relay 55.

Next, the position detecting method will be described. The output of the slit sensor 53 is shown in FIG. 13B, and the output of the spot sensor 52 is shown in FIG. Since the base film 15 is transparent or translucent, both sensors are at the Hi level where there is no copper foil 16. Normally, the outputs of the spot sensor 52 and the slit sensor 53 change periodically. However, since the joining tape for joining the base film 15 is stuck to the base film 15 in the section indicated by H in FIG. 13, the output of the spot sensor 52 is as shown in FIG. Then, the time T from the start of the previous output to the start of the next output becomes longer than the predetermined time. If the output of the spot sensor 52 is not longer than a predetermined time during the operation of the process, the seam detector determines that the base film 15 has a seam.

On the other hand, the main flowchart of the control device executes the flowchart shown in FIG. 15 at predetermined intervals. That is, when a joint is detected (S0, YES),
When the joint is at the cutting position in the fourth punching machine 45 (S1, YES), the two flexible wirings 11 before and after the cutting portion are not sent to the product storage pallet 47 but are discarded in a discard case (not shown) (S2). When the seam is not at the cutting position (S1, NO), and when the seam is before the cutting position (S3, YES), the flexible wiring 11 before the cutting portion is set.
Is not sent to the product storage pallet 47 and is discarded in a discard case (not shown) (S4). When the seam is after the cutting position (S3, NO), the flexible wiring 11 after the cutting portion
Is not sent to the product storage pallet 47 and is discarded in a discard case (not shown) (S5). When the joint is not detected and when the flexible wiring 11 is discarded, the process returns to the main flowchart once, and after a predetermined time, the present flowchart is executed again.

As described in detail above, the method of manufacturing the flexible wiring 11 according to the present embodiment is as follows. First, the flexible wiring 11 is punched in a state where the connecting portion is left in two separate wiring paths of the positive electrode pattern and the negative electrode pattern. Since the connecting portion of the copper foil is punched after the copper foil is adhered to the base film, the copper foil pattern can be punched with high precision even if the flexible wiring 11 becomes long, and a linear motor with high precision can be obtained. Can be manufactured. Further, since the terminal processing is performed on the same line, terminal processing such as leaving the base film 15 around the mounting hole 41 can be performed freely. In addition, since the flexible wiring 11 to which the bonding tape is attached is automatically discarded by detecting the bonding portion of the base film 15, no defective product is shipped, and no visual confirmation is required. So,
Production efficiency can be increased.

The embodiments of the present invention are not limited to the above-described embodiments, and various applications are possible. For example, in the present embodiment, the joining detector was installed immediately before the fourth punching machine,
It may be installed anywhere between the third and fourth punching machines. Further, in the present embodiment, the second punching machine obtains the position information of the copper foil terminal forming portion and performs the punching of the copper foil terminal portion, but detects the copper foil terminal forming portion before the second punching machine. May be installed, and the second punching machine may be operated based on the signal.

[0026]

As is apparent from the above description, according to the flexible wiring manufacturing method of the present invention, when a copper foil is punched to form a wiring path, (1) two or more wiring paths A first punching step of forming the copper foil terminal forming portion by carrying out the punching without performing the punching when the terminal information is given, while punching out the wiring path so as to be integral with leaving the connecting portion. And (2) a second punching step of punching a copper foil terminal forming portion to form a copper foil terminal portion;
(3) a bonding step of bonding the copper foil punched in the second punching step to the base film; and (4) a copper foil bonded to a connection portion of the copper foil punched so that the wiring path is integrated. Since the method includes a third punching step of punching the base film together with the base film and (5) a fourth punching step of punching the mounting hole in the base film near the end portion of the copper foil and cutting the base film, the flexible wiring 11 becomes longer. However, the copper foil pattern can be accurately punched out, and a highly accurate linear motor can be manufactured.
Further, since the terminal processing is performed on the same line, the terminal processing such as leaving the base film around the mounting hole can be performed freely, so that the degree of freedom in design can be increased.

Further, the apparatus for manufacturing a flexible wiring according to the present invention comprises a joint detecting means for detecting a joint of the base film, a conveying means for conveying the flexible wiring in a longitudinal direction, and a cutting of the flexible wiring to a predetermined length. And a product storage means for storing the cut flexible wiring, wherein the joint detecting means detects the joint of the base film, and (1) the punching means cuts the front of the joint. Is discarded without storing the flexible wiring cut next by the punching machine in the product storage means,
(2) When the punching means cuts after the joint, the punching machine discards the flexible wiring cut immediately before without storing it in the product storage means, and (3) the punching means cuts the joint. In the case, since the punching machine has a control means for discarding both the previously cut flexible wiring and the next cut flexible wiring without storing them in the product storing means, the bonding portion of the base film is detected. Since the flexible wiring to which the joining tape is stuck is automatically discarded, defective products are not shipped, and visual confirmation is unnecessary, so that production efficiency can be improved.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram showing steps of a method for manufacturing a flexible wiring according to one embodiment of the present invention.

FIG. 2 is a plan view showing a copper foil punched in a first punching step.

FIG. 3 is a plan view showing a copper foil punched in a second punching step.

FIG. 4 is a view showing a flexible wiring bonded in a bonding process.

FIG. 5 is a view showing a flexible wiring punched in a third punching step.

FIG. 6 is a plan view showing a configuration of a flexible wiring.

FIG. 7 is a plan view showing a terminal portion shape of a flexible wiring.

FIG. 8 is a plan view showing a terminal portion shape of a conventional flexible wiring.

FIG. 9 is a plan view showing a terminal portion shape of another conventional flexible wiring.

FIG. 10 is a sectional view showing a configuration of a linear motor.

FIG. 11 is a conceptual diagram showing steps of a conventional method for manufacturing a flexible wiring by the Fred method.

FIG. 12 is a plan view showing a configuration of a flexible wiring in an intermediate step of a conventional manufacturing method by the Fred method.

FIG. 13 is a signal diagram showing an output of the seam detector.

FIG. 14 is a block diagram illustrating a configuration of a seam detector.

FIG. 15 is a flowchart illustrating a control method of the seam detector.

[Explanation of symbols]

 Reference Signs List 15 base film 16 copper foil 25 first punching machine 27 bonding machine 28 third punching machine 30 slit sensor 31 spot sensor 44 second punching machine 45 fourth punching machine 47 product storage pallet

Continuation of the front page (72) Inventor Shigehiko Ozawa 100 Kanayama, Ichiriyama-cho, Kariya-shi, Aichi Toyota Auto Body Co., Ltd. (56) References JP-A-4-367293 (JP, A) JP-A-58-1006891 ( JP, A) JP 4634543 (JP, B1) (58) Fields investigated (Int. Cl. ⁶ , DB name) H05K 3/00, 3/04, 3/20

Claims (2)

(57) [Claims] 1. A method for manufacturing a flexible wiring having a predetermined length, comprising: a base film; and a copper foil which is in close contact with the base film and has no connecting portion and forms two or more separate wiring paths. When forming the wiring route by
The wiring path is punched out so that the wiring path is integrated while leaving a connection part in the two or more separated wiring paths, and when terminal information is given, the copper foil is conveyed without punching to perform the copper foil terminal. A first punching step of forming a forming part, a second punching step of punching the copper foil terminal forming part to form a copper foil terminal part, and forming the copper foil punched in the second punching step on the base film. A bonding step of bonding, a third punching step of punching a connection portion of the copper foil punched so that the wiring path is integrated with a base film to which the copper foil is bonded, and the base near the copper foil terminal portion. A method for manufacturing a flexible wiring, comprising: a fourth punching step of punching an attachment hole in a film and cutting the base film. 2. A transparent or translucent base film having a joint portion whose end faces are joined by an adhesive tape and supplied in a roll shape, and a copper foil which is in close contact with the base film to form a wiring path. Thus, in a flexible wiring manufacturing apparatus that manufactures a flexible wiring having a predetermined length, a bonding part detecting unit that detects the bonding part of the base film; a conveying unit that conveys the flexible wiring in a longitudinal direction; A punching machine that cuts the wiring at a predetermined length, and a product storage unit that stores the cut flexible wiring, wherein the bonding unit detection unit detects a bonding portion of the base film, and the punching unit is If you cut before the joint,
When the punching machine discards the flexible wiring that has been cut next without storing it in the product storage unit, and the punching unit cuts after the joint,
The punching machine discards the flexible wiring cut immediately before without storing the flexible wiring in the product storage means. An apparatus for manufacturing a flexible wiring, comprising a control means for discarding both of the cut flexible wirings without storing them in the product storage means.