JP3959987B2 - Flat cable manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a flat cable used for manufacturing a shielded flat cable provided with a shield tape excellent in EMI countermeasures and impedance stabilization, and in particular, manufacturing of a flat cable with a conductor serving as a drain wire exposed. It is about the method.
[0002]
[Prior art]
Conventionally, as a shielded flat cable of this type, a shield layer is provided with a shield tape or the like in a state where one or both sides of the flat cable or the periphery is wrapped, and the drain layer of the flat cable is electrically connected. There is a thing of structure.
[0003]
Then, as a method of connecting the shield layer and the drain wire, as disclosed in Japanese Patent Laid-Open No. 64-14813, an ultrasonic vibration is directly applied to the drain wire directly from the top of the shield tape, thereby super Create a flat cable with the drain wire exposed in advance as disclosed in Japanese Unexamined Patent Publication No. 3-112014, or a method of electrical connection by sonic welding, and then wrapping the entire circumference with shielding tape There is a method of seam welding the shield tape and the drain wire.
[0004]
[Problems to be solved by the invention]
On the other hand, according to the method of connecting the shield layer and the drain wire by spot welding as disclosed in JP-A-64-14813, stress is concentrated on the spot welded part when used in a bent state. The continuity between the shield layer and the drain wire tends to be unstable.
[0005]
In addition, if a shield layer is provided on the insulating layer of the flat cable and the shield layer and the drain wire are to be directly seam welded, it is necessary to displace the insulating layer between the drain wire and the shield layer and weld it. There are disadvantages that the speed of seam welding is extremely reduced, the production efficiency is poor, and the product cost is increased.
[0006]
Therefore, as a method of connecting the shield layer and the drain wire, the method in which the drain wire of the flat cable is exposed over the entire length and the shield layer and the drain wire are connected by seam welding is more quality than the method by spot welding. Excellent.
[0007]
At this time, as disclosed in Japanese Patent Laid-Open No. 3-112014, each conductor is sandwiched between insulating tapes and crimped with a heat roll to produce a flat cable, and insulation of the portion located on the surface of the conductor that becomes the drain wire According to the method of peeling the tape and exposing the drain wire over the entire length, it is necessary to separate the insulating tape, and the insulating tape is firmly welded so that the insulating tape is difficult to peel off smoothly. There was a problem.
[0008]
Then, in view of the said problem, this invention aims at providing the manufacturing method of the flat cable which can manufacture easily the flat cable which the drain wire suitable for manufacture of the flat cable with a shield exposes continuously.
[0009]
[Means for Solving the Problems]
The technical means for achieving the above object is that the ultrasonic vibration of the ultrasonic welder is obtained by sandwiching a plurality of linear conductors arranged in parallel with a predetermined interval between two strip-like insulating films. In a flat cable manufacturing method comprising an ultrasonic welding process in which both insulating films facing each other on both sides of each linear conductor are ultrasonically welded by a horn that imparts the horn and an anvil disposed opposite to the horn, the horn and In a state of approaching the anvil, the linear conductors are formed on a facing surface of at least one of the horn and the anvil so as to form a plurality of conductor passage openings through which the linear conductors can pass individually with the predetermined interval. Conductor passage groove portions are formed, and the drain conductors constituting the drain wires among the respective linear conductors are in contact with both side surfaces of the conductor passage groove portions during the ultrasonic welding process. Therefore, the conductor which is thicker than the other linear conductors is used, and in the ultrasonic welding step, the insulating film is cut by contact between the conductor passage groove side surface and the drain conductor while facing each other on both sides of each linear conductor. It is in the point which welds both insulating films.
[0010]
Moreover, it is good also as a method of superposing | stacking several said other linear conductors and forming the said drain conductor.
[0011]
Furthermore, as a pre-process of the ultrasonic welding step, a temporary bonding step of temporarily bonding the linear conductors and the two insulating films to each other with a heated heat roll in a state where the linear conductors are sandwiched between the two insulating films. Furthermore, it is good also as a method provided.
[0012]
Moreover, it is good also as a method further equipped with the cutting film winding process which winds up the said insulating film cut | disconnected by both sides by the contact with the both sides | surfaces of the said conductor passage groove part as a post process of the said ultrasonic welding process.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIGS. 1 to 3 are diagrams showing a manufacturing apparatus used in a flat cable manufacturing method, which is the most in a predetermined supply path P (moving direction). A plurality of conductor supply rolls 2 serving as a conductor supply section in which the linear conductors 1 are accommodated are provided on the upstream side, and the respective linear conductors 1 are guided to the downstream side in a state of being arranged in parallel with a predetermined interval. A pitch guide 3 is provided.
[0014]
Each conductor supply roll 2 has a copper or copper alloy linear conductor 1 wound in advance, and a plurality of conductors are provided in accordance with the number of linear conductors 1 arranged in parallel in a manufactured flat cable. Yes. And in this embodiment, it is set as the structure which manufactures the flat cable in which the six linear conductors 1 are arrange | positioned in parallel, and especially one of them is comprised as the drain conductor 1a used as a drain wire, Two conductor supply rolls 2 are arranged. In this embodiment, as the drain conductor 1a, for example, a rectangular conductor having a rectangular cross section made of an annealed copper wire having a thickness of 0.25 mm and a width of 1.5 mm is used. As the other linear conductors 1, for example, A rectangular conductor having a rectangular cross section made of an annealed copper wire having a thickness of 0.15 mm and a width of 1.5 mm is used, and the conductors 1 and 1a are arranged in parallel at intervals of 2.5 mm.
[0015]
Further, on the downstream side of the pitch guide 3, the heat rolls 4 are respectively arranged on both the upper and lower sides with the supply path P interposed therebetween. Film rolls 6 for supplying 5 are provided.
[0016]
Each film roll 6 is preliminarily wound with a strip-shaped insulating film 5, and each insulating film 5 is made of a flexible and ultrasonically weldable resin film, for example, as shown in FIG. It has a structure having a polyester adhesive layer 5b having a thickness of 1 μm on one side surface of a polyethylene terephthalate (PET) film 5a having a thickness of 100 μm, and the surface provided with the adhesive layer faces the respective linear conductors 1 and 1a. Are arranged as shown.
[0017]
In addition, an ultrasonic welder 7 is disposed on the downstream side of the heat roll 4, and the ultrasonic welder 7 is provided at a position where the supply path P is sandwiched from above and below, as shown in FIGS. A horn 8 and an anvil 9 for applying ultrasonic vibrations are provided. The horn 8 and the anvil 9 are configured to be movable toward and away from each other along the vertical direction. The anvil 9 is an axis orthogonal to the supply path P. It is comprised in the substantially cylindrical columnar body supported rotatably around the center.
[0018]
As shown in FIGS. 2 and 3, a plurality of conductor passage openings 10 through which the respective linear conductors 1 and 1a can individually pass with a predetermined distance from each other with the horn 8 and the anvil 9 approaching each other. A plurality of circumferential conductor passage groove portions 11 are formed on the outer peripheral surface of the anvil 9 facing the lower surface of the horn 8 with the same pitch interval as each of the linear conductors 1 and 1a.
[0019]
Further, the groove width of each conductor passage groove portion 11 is formed to be substantially the same as the width of each linear conductor 1, 1a, and the open end side of each conductor passage groove portion 11 is formed in a taper shape that gradually becomes wider in the opening direction. Has been.
[0020]
As shown in FIGS. 3 and 4, when the horn 8 and the anvil 9 approach each other and perform ultrasonic welding, the drain conductor 1a configured to be thick is arranged on both sides of the corresponding conductor passage groove portions 11. The insulating film 5 of the part is comprised so that a surface may be melted | melted and contacted.
[0021]
On the downstream side of the ultrasonic welder 7, guide rollers 12 are respectively arranged above and below the supply path P, and further on the downstream side of the drain conductor 1 a that has been blown through the guide roller 13. A film take-up roll 14 for taking up the insulating film 5 is provided.
[0022]
A cable take-up roll 17 for taking up the flat cable 16 manufactured via the guide roller 15 is disposed downstream of the film take-up roll 14.
[0023]
And each linear conductor 1 and 1a supplied from each conductor supply roll 2 is made into the parallel arrangement | positioning state with the predetermined space | interval with the pitch guide 3, and is supplied between the both heat rolls 4 of a downstream. At this time, the insulating films 5 are supplied from the respective film rolls 6 to the upper and lower sides of the respective linear conductors 1, 1 a, for example, by passing between the thermal rolls 4 heated to a temperature of 170 ° C. 1a and both insulating films 5 are temporarily bonded (temporary bonding process).
[0024]
Thereafter, the linear conductors 1, 1 a and both insulating films 5 that are temporarily bonded are guided between the horn 8 and the anvil 9 in the ultrasonic welding machine 7 on the downstream side. Then, at the position of the ultrasonic welding machine 7, the linear conductors 1, 1 a and both insulating films 5 are sandwiched between the horn 8 and the anvil 9 and the ultrasonic welding machine 7 is operated.
[0025]
That is, ultrasonic vibration generated by an ultrasonic vibration generation mechanism (vibrator or the like) (not shown) is applied to the horn 8, and the horn 8 is vibrated in the width direction of the insulating film 5, and the ultrasonic vibration is generated. As shown in FIG. 3, the insulating films 5 brought into pressure contact with the circumferential protrusions 19 located on both sides of each conductor passage groove 11 are brought into contact with each linear conductor 1, 1 a by the ultrasonic vibration energy applied. Are ultrasonically welded on both sides (ultrasonic welding process).
[0026]
At this time, in the drain conductor 1a portion configured to be thick, both sides thereof come into contact with both side surfaces of the conductor passage groove portion 11, and the insulating film 5 in that portion is melted and cut.
[0027]
In this state, when the linear conductors 1, 1 a and both insulating films 5 are sequentially supplied along the supply path P by the winding action of the cable winding roll 17, the anvil 9 is driven to rotate around the horizontal axis. Alternatively, the anvil 9 rotates in synchronization with the supply of the insulating film 5 and the winding of the cable take-up roll 17 by driving a rotation driving unit (not shown), and the lower surface of the anvil 9 is in sliding contact with the upper surface of the upper insulating film 5. 9, the projecting ridges 19 on both sides of the conductor passage groove 11 are in contact with the lower surface of the lower insulating film 5 while rotating, and the two insulating films 5 are continuous along the length direction thereof. While being ultrasonically welded, the lower insulating film 5 is continuously cut at both side positions of the drain conductor 1a.
[0028]
And the insulating film 5 of the cut | disconnected part is peeled off from the surface of the drain conductor 1a with the film winding roll 14, and is wound up (cutting film winding process), and here one side surface (FIG. 4 corresponding to the lower surface) is sequentially manufactured.
[0029]
The flat cable 16 is sequentially wound around the cable winding roll 17.
[0030]
According to the manufacturing method of the flat cable 16 by the manufacturing apparatus configured as described above, the drain conductor 1a serving as the drain wire is configured to be thicker than each of the other linear conductors 1, and the ultrasonic welding by the ultrasonic welding machine 7 is performed. At the time of welding, it is a simple method in which the drain conductor 1a is brought into contact with both side surfaces of the conductor passage groove 11 and the insulating film 5 is cut by melting, and the flat cable 16 in which the drain conductor 1a is continuously exposed is easily manufactured. There are advantages you can do.
[0031]
Moreover, since the temporary bonding process by the hot roll 4 is provided as a pre-process of the ultrasonic welding process by the ultrasonic welder 7, the positional deviation between the linear conductors 1 and 1a can be effectively prevented and more stable. Ultrasonic welding can be performed.
[0032]
Further, since a cut film winding process for winding the cut insulating film 5 is provided as a subsequent process of the ultrasonic welding process, a flat in which the drain conductor 1a is continuously exposed easily by a series of continuous manufacturing processes. A cable 16 is obtained.
[0033]
Then, as shown in FIG. 5, the manufactured flat cable 16 is wrapped around the entire circumference with the shield tape 21 as in the prior art, and continuously at the exposed portion of the drain conductor 1a and the shield tape 21 in contact with each other. By seam welding, a shielded flat cable excellent in EMI countermeasures and impedance stabilization can be provided.
[0034]
Moreover, in the said embodiment, although the structure which uses the thick drain conductor 1a different from the other linear conductor 1 as a drain wire is shown, it is thick by supplying the linear conductor 1 in multiple sheets in a superposition | polymerization form. It is good also as a structure which comprises the drain conductor 1a of a meat structure. In this case, there is an advantage that it is not necessary to separately manufacture the thick drain conductor 1a.
[0035]
And in the ultrasonic welding process by the ultrasonic welding machine 7, when the cut insulating film 5 is peeled off, the side of the cut insulating film 5 among the plurality of linear conductors 1 in the drain conductor 1a is polymerized. The linear conductor 1 may be peeled off together with the insulating film 5, but the insulating film 5 can be removed with at least the linear conductor 1 positioned on the other insulating film 5 side remaining, as described above. Moreover, the flat cable 16 in which the linear conductor 1 serving as the drain wire is continuously exposed can be easily manufactured.
[0036]
1 and 4, a slitter 23 may be provided on the downstream side of the supply path P of the ultrasonic welder 7 so that the insulating film 5 can be cut more reliably.
[0037]
Moreover, in the said embodiment, although each conductor passage groove part 11 has shown the structure formed in the anvil 9, it is good also as a structure formed in the horn 8 side, and also in both the horn 8 and the anvil 9 It is good also as a structure in which each conductor passage groove part 11 is formed.
[0039]
Moreover, in each said embodiment, although the structure which used the drain conductor 1a as the end linear conductor 1 among the six linear conductors 1 is shown, it is the structure where the drain conductor 1a is located in the intermediate part. Also, the number of each linear conductor 1 is not limited to six, and may be appropriately determined as necessary.
[0040]
【The invention's effect】
As described above, according to the flat cable manufacturing method of the present invention, in the state where the horn and the anvil are close to each other, a plurality of conductor passage openings are formed in which each linear conductor can pass individually with a predetermined distance from each other. Therefore, a conductor passage groove portion is formed on at least one of the opposing surfaces of the horn and the anvil, and the drain conductor constituting the drain wire in each linear conductor is formed in the conductor passage groove portion during the ultrasonic welding process. Use a conductor that is thicker than the other linear conductors so that both side surfaces come into contact with each other, while cutting the insulating film by contact between the conductor passage groove side surface and the drain conductor in the ultrasonic welding process. This is a method in which both insulating films facing each other are welded, and there is an advantage that a flat cable in which a drain conductor is continuously exposed can be easily manufactured.
[0041]
Further, if a method of forming a drain conductor by polymerizing a plurality of other linear conductors, it is not necessary to separately manufacture a thick drain conductor.
[0042]
Further, as a pre-process of the ultrasonic welding step, a method further comprising a temporary bonding step of temporarily bonding each linear conductor and both insulating films to each other with a heated heat roll in a state where each linear conductor is sandwiched between both insulating films. If so, there is an advantage that more stable ultrasonic welding can be performed.
[0043]
In addition, as a subsequent process of the ultrasonic welding process, if the method further includes a cut film winding process for winding the insulating film cut on both sides by contact with both side surfaces of the conductor passage groove, a continuous series of manufacturing processes Thus, a flat cable in which the drain conductor is continuously exposed can be easily obtained.
[Brief description of the drawings]
FIG. 1 is a schematic explanatory diagram of a flat cable manufacturing apparatus used in an embodiment of the present invention.
FIG. 2 is an operation explanatory diagram of the horn and the anvil.
FIG. 3 is an explanatory diagram of the operation of the horn and the anvil.
FIG. 4 is an enlarged cross-sectional view of a main part.
FIG. 5 is a cross-sectional view of a shielded flat cable.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Linear conductor 1a Drain conductor 2 Conductor supply roll 3 Pitch guide 4 Heat roll 5 Insulating film 6 Film roll 7 Ultrasonic welding machine 8 Horn 9 Anvil 10 Conductor passage opening 11 Conductor passage groove part 14 Film winding roll 16 Flat cable 17 Cable Winding roll 19 ridge 21 shield tape 23 slitter

Claims (4)

A plurality of linear conductors arranged in parallel with a predetermined interval are sandwiched between two strip-shaped insulating films, and are arranged opposite to the horn for applying ultrasonic vibration of an ultrasonic welder. In the manufacturing method of a flat cable provided with an ultrasonic welding step of welding both insulating films facing each other on both sides of each linear conductor by an anvil,
In a state in which the horn and the anvil are close to each other, at least one of the horn and the anvil is formed so as to form a plurality of conductor passage openings in which the respective linear conductors can pass individually with the predetermined distance from each other. Conductor passage grooves are formed on the opposing surfaces,
The drain conductor constituting the drain wire among the respective linear conductors uses a conductor that is thicker than the other linear conductors so that both side surfaces of the conductor passage groove portion come into contact with each other during the ultrasonic welding process. A method of manufacturing a flat cable, characterized in that, in the ultrasonic welding step, the two insulating films facing each other on both sides of each linear conductor are welded while cutting the insulating film by contact between a conductor passage groove side surface and a drain conductor. . The flat cable manufacturing method according to claim 1, wherein the drain conductor is formed by superposing a plurality of the other linear conductors. As a pre-process of the ultrasonic welding step, the method further includes a temporary bonding step of temporarily bonding the linear conductors and the two insulating films to each other with a heated heat roll in a state where the linear conductors are sandwiched between the two insulating films. The method for producing a flat cable according to claim 1 or 2. 4. A cut film winding step of winding up the insulating film cut on both sides by contact with both side surfaces of the conductor passage groove as a subsequent step of the ultrasonic welding step. The manufacturing method of the flat cable in any one of.

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