JPH0584607B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method of manufacturing a flat cable that can include a plurality of conductors within the insulation.

[Conventional technology]

Conventional flat cables are usually made by continuously extruding a conductor inside a synthetic resin through a so-called extrusion coating through an extrusion molding die, or by inserting two conductors into a synthetic resin. It was manufactured by placing two synthetic resin sheets together and melting and pressing them together to integrate them.

[Problem that the invention seeks to solve]

The conventional method uses thermoplastic resin, which limits the thickness of the coating resin, making it difficult to obtain a flat cable made of resin that is extremely thin and has excellent dimensional stability. .
In addition, the manufacturing process required a special extrusion device and a die, resulting in a large amount of equipment costs. Furthermore, the product had the disadvantage that adhesiveness at the interface between the metal conductor and the coating resin was weak, making it difficult to integrate them reliably.

However, the insulation of the flat cable manufactured in this way is mainly made of vinyl chloride resin,
Due to its nature, placing heavy objects on a flat cable carries the risk of electrical leakage, and the usage of the flat cable itself is also limited.

The present invention eliminates these drawbacks of conventional manufacturing methods and creates a flangier made of resin with excellent dimensional stability, which is thin and flexible, the coating resin does not peel off, and is safe even when heavy objects are placed on it. The present invention provides a method for easily manufacturing a power cable.

[Means for solving problems]

That is, the present invention includes (A) a step of applying a vinyl chloride plastisol composition containing an adhesion imparting agent to the entire surface or a portion of an insulating film having excellent dimensional stability; Step of stacking a sheet-shaped, band-shaped, or linear conductor on top; (C) Next, stacking another insulating film on top of it and heat bonding to integrate; (A)
This is a method for manufacturing a flat cable characterized by passing through the steps (B) and (C).

In the present invention, the insulating film with excellent dimensional stability includes, for example, a polyester resin film, a polyamide resin film, a polyimide resin film, a polysulfone resin film, etc. Thicknesses of 10 to 300 mm, preferably 30 to 200 mm, and usually 50 to 150 mm are often used.

The vinyl chloride-based plastisol composition applied thereto is composed of a vinyl chloride-based polymer, a plasticizer, and a stabilizer, and contains, for example, an adhesion agent that provides adhesion to an insulating film such as a polyester resin film. It is necessary that the To explain this in more detail below, the vinyl chloride polymer is produced by emulsion polymerization of vinyl chloride or a mixture of vinyl chloride and a comonomer copolymerizable with it in the presence of an emulsifier and a water-soluble polymerization initiator. The whole or a portion of vinyl chloride or a mixture of vinyl chloride and a comonomer copolymerizable therewith in the presence of a paste resin with a particle size of 5 mm or less, preferably about 0.05 to 3 mm, or a dispersant and an oil-soluble polymerization initiator. This is a paste resin or a resin for mixing paste resins manufactured by a fine suspension polymerization method in which the resin is mechanically finely dispersed and then polymerized. Furthermore, a vinyl chloride resin with a large particle size produced by ordinary suspension polymerization may be used in combination as long as it does not adversely affect the viscosity, fluidity, processability, etc. of the paste sol. Examples of comonomers that can be copolymerized with vinyl chloride include vinyl esters such as vinyl acetate, vinyl propionate, and vinyl laurate; acrylic esters such as methyl acrylate, ethyl acrylate, and butyl acrylate; and methyl methacrylate and ethyl methacrylate. Methacrylic acid esters, maleic esters such as dibutyl maleate and diethyl maleate, fumaric acid esters such as dibutyl fumarate and diethyl fumarate, vinyl ethers such as vinyl methyl ether, vinyl butyl ether and vinyl octyl ether, acrylonitrile, Examples include vinyl cyanides such as methacrylonitrile, olefins such as ethylene, propylene, and styrene, and vinylidene halides other than vinyl chloride or vinyl halides such as vinylidene chloride and vinyl bromide. The above amount is used in an amount of 30% by weight or less, preferably 20% by weight or less.

Vinyl chloride polymers are often polymerized using emulsifiers containing alkali metal salts, but due to the adhesive properties of plastisol compositions, the alkali metal content in vinyl chloride polymers is
It is desirable to select and use an emulsifier so that the amount is 1000 ppm or less. Emulsifiers that produce vinyl chloride polymers with low alkali metal content include:
Examples include ammonium salts or alkali metal salts of fatty acids whose alkyl group has 8 to 18 carbon atoms. Of course, the emulsifier is not limited to those mentioned above.

Plasticizers, which are one component of plastisol compositions, are
There are no particular restrictions on what can be used as a vinyl chloride polymer, but for example, phthalic acid di-
n-butyl (DBP), di-n-octyl phthalate, di-2-ethylhexyl phthalate (DOP),
Phthalic acid plasticizers such as diisooctyl phthalate, octyldecyl phthalate, diisodecyl phthalate, butylbenzyl phthalate (BBP), di-2-ethylhexyl isophthalate, di-2-adipate
Fatty acid ester plasticizers such as ethylhexyl (DOA), di-n-decyl adipate, diisodecyl adipate, di-2-ethylhexyl azelate, dibutyl sebacate, di-2-ethylhexyl sebacate, tributyl phosphate, phosphoric acid Tory
Phosphate ester plasticizers such as 2-ethylhexyl, 2-ethylhexyldiphenyl phosphate, totricresyl phosphate, epoxy plasticizers such as epoxidized soybean oil, epoxidized tall oil fatty acid-2-ethylhexyl, etc. One or a mixture of two or more of these may be used. The smaller the amount of plasticizer used, the better the adhesion, but it depends on the desired solid content concentration and fluidity of the paste sol, the performance of the flat cable to be obtained, the method of using the flat cable, etc. The amount is selected as appropriate and ranges from 30 to 400 parts by weight, preferably from 50 to 200 parts by weight, based on 100 parts by weight of the vinyl chloride polymer. Especially when considering the adhesion and fluidity of plastisol,
A range of 40 to 100 parts by weight is suitable.

In addition, a part of the plasticizer can be replaced with a diluent such as mineral spirits, texanol isobutyrate, dodecylbenzene, or an organic solvent that swells the vinyl chloride polymer such as toluene or xylene. It may also be made into an organosol.
The amount of the diluent and organic solvent to be added is appropriately determined depending on the performance of the flat cable to be obtained, but the amount of plasticizer used can be reduced by using the diluent and organic solvent.

The plastisol composition contains an adhesion-imparting agent so that a strong adhesive force can be obtained between the polyester film and the vinyl chloride resin obtained by gelling the plastisol composition. The adhesion imparting agent is preferably one that has reactivity to chemically bond with the polyester film in the composition, such as polyisocyanate compounds, polyisocyanate polymers, blocks of these compounds or polymers, polyaminoamide compounds,
Epoxy compounds, acrylic compounds, diallyl compounds, etc. are used, and among these, polyisocyanate compounds having isocyanate groups, polyisocyanate polymers, and blocks of these isocyanate groups are particularly preferred.

Examples of polyisocyanate compounds include fatty acid diisocyanates such as hexamethylene diisocyanate and lysine diisocyanate, alicyclic diisocyanates such as hydrogenated diphenylmethane diisocyanate, isophorone diisocyanate, and hydrogenated tolylene diisocyanate, tolylene diisocyanate, diphenylmethane diisocyanate, and naphthyl diisocyanate. Examples include aromatic diisocyanates such as diisocyanate and xylene diisocyanate.
Among these, aromatic diisocyanates, particularly tolylene diisocyanate and diphenylmethane diisocyanate are preferred. Polyisocyanate polymers can also be prepared by adding the above-mentioned polyisocyanate compounds, for example, in an inactivated solution such as ethyl acetate, methyl acetate, butyl acetate, methyl ethyl ketone, dioxane, chlorobenzene, or phthalate ester, phosphate ester, adipate ester. Alternatively, it can be obtained by polymerization by a known method in a plasticizer such as trimellitic acid ester using a known catalyst such as a tertiary amine, an alkali metal or alcoholate of Mannich's basic fatty acid.

As the polyisocyanate polymer used in the present invention, it is particularly preferable to use one containing an isyanurate ring obtained by polymerizing a polyisocyanate compound. Those containing isocyanurate rings are produced according to the method described above. Of course, as the polyisocyanate polymer, it is also possible to use so-called isocyanate group-terminated polyurethane, polyurea, etc., which are obtained by the reaction of polyisocyanate and an active hydrogen compound.

Sequestering agents, or blocking agents, used to prevent the low temperature reactivity of isocyanate groups are
Examples include long-chain alkylphenols, oxybenzoic acid esters, and lactams.
Of course, it is not limited to these. The appropriate amount of the blocking agent to be used is approximately equivalent to the amount of free isocyanate groups. Blocking of isocyanate groups can be easily carried out in the above-mentioned medium, and polyisocyanate blocks and polyisocyanate polymer blocks can be obtained. For example, it is preferable to use a diisocyanate polymer block having an average molecular weight in the range of 1,000 to 10,000. If the average molecular weight of the block body is less than 1000, the anchoring effect as an adhesive cannot be sufficiently exhibited and the adhesive strength is insufficient.On the other hand, if it is greater than 10000, the viscosity of the sol composition will increase significantly, so it is preferable. do not have.

The amount of adhesion promoter added is based on the vinyl chloride polymer.
It is preferably in the range of 1 to 25 parts by weight per 100 parts by weight that the effective NCO in the plastisol composition is
It is desirable to be present in the range 0.01 to 1% by weight, preferably 0.03 to 0.6% by weight, especially 0.05 to 0.5% by weight. For example, 33% by weight of oxybenzoic acid esterified diisocyanate polymer after polymerization and blocking in dibutyl phthalate.
- When dibutyl phthalate dilute solution is used, a plastisol composition is prepared by using 1 to 50 parts by weight per 100 parts by weight of vinyl chloride polymer, and if the amount of plasticizer is insufficient, the deficiency is supplemented. . Furthermore, since the content of effective NCO in the 33% by weight dibutyl phthalate dilute solution also varies, the dilute solution is adjusted and added as appropriate to obtain the desired NCO content of the plastisol composition. If the effective NCO is less than 0.03% by weight, the adhesion effect will be small, and if it is more than 1% by weight, undesirable phenomena such as increased sol viscosity and coloring will likely occur, and the adhesion will be impaired due to moisture absorption and rapid adhesive reaction. The phenomenon of bubble generation at the interface is observed, which tends to cause a decrease in adhesive strength.

Adhesive agents other than those mentioned above that can be contained in the plastisol composition include the following compounds.

As polyaminoamide compounds, commercially available products,
For example, product names Oiltech 505, Oiltech 506
(manufactured by Schering), as an epoxy compound,
Similarly, under the trade name Epicote 828 (manufactured by Ciel Chemical Co., Ltd.), trimethylolpropane trimethacrylate is used as the acrylic compound along with a slight amount of peroxide, and diallyl phthalate is used as the diallyl compound. These adhesion-imparting agents are used in an appropriate amount in consideration of their adhesion to the polyester film.

Plastisol compositions are typically mixed with stabilizers used in vinyl chloride resins. Many of these stabilizers generally act as dissociation promoters of isocyanate block bodies. As a stabilizer,
Inorganic metal compounds such as lead white, basic lead silicate, tribasic lead sulfate, tribasic lead phosphite, silica gel co-precipitated lead silicate, zinc white, lauric acid, stearic acid, ricinoleic acid, naphthenic acid, salicylic acid, 2
- Organic compounds such as metal salts of cadmium, barium, calcium, zinc, lead, tin or magnesium such as ethylhexoic acid fatty acids or resin acids, and zinc octylate, dibutyltin laurate, dioctyltin malate, dibutyltin Examples include mercaptide. Organic acid liquid composite stabilizers such as calcium-zinc, barium-zinc, magnesium-zinc, and cadmium-barium-zinc stabilizers, which are usually commercially available as stabilizers for vinyl chloride resins, can also be used.

However, the amount added is not particularly limited, but
Usually 0.5 to 100 parts by weight of vinyl chloride polymer
10 parts by weight, preferably 1 to 5 parts by weight can achieve that purpose. Furthermore, when an alkali metal compound and a metal compound such as lead, tin, cadmium, or zinc are used together, the adhesive strength is synergistically improved.

To produce a plastisol composition, a vinyl chloride polymer, a plasticizer, an adhesive agent, and if necessary, a stabilizer, a colorant, other additives, etc. are mixed uniformly. For example, by using a vinyl chloride polymer that has been completely sealed and stored immediately after production, a vacuum defoaming process is performed during plastisol production before adding an adhesion agent, and the adhesion agent is added. Afterwards, it is preferable to perform stirring and mixing after degassing the gas phase under vacuum or replacing the gas phase with an inert gas such as nitrogen.

When producing a composition, the introduction of moisture into the composition should be avoided as much as possible, and specifically, relative humidity should be avoided.
It is desirable to prepare in an atmosphere of 80% or less. Generally, if the sol is mixed in an atmosphere with a relative humidity of 80% or higher, at least 0.2% by weight or more of trace water will be absorbed into the sol, causing a decrease in adhesive properties.

The vinyl chloride-based plastisol composition described above can be easily applied to the above-mentioned plastic film with excellent dimensional stability by a known ordinary coating method, and after the coating heat treatment, it does not adhere to the film. It exhibits an H-type peel strength of 0.5 kg/inch or more. It is necessary for the plastisol composition used in the present invention to have such a peel strength, and if it is less than this, it is difficult to expect a sufficient effect to encapsulate and integrate the conductor and achieve the purpose of a flat cable. .

Further, other insulating films used in the method of the present invention include films coated with a plastisol composition.
If necessary, the plastisol composition may be heated and gelled to be integrated.

The conductor disposed and fixed in such a material is made of an ordinary conductive metal material, and is arbitrarily selected to have a linear shape, a thin strip shape, a sheet shape, or the like, depending on the intended use of the flat cable.

Usually, as shown in FIG. 1, a vinyl chloride plastisol composition layer 2 is coated on a film 1 using various conventionally known coating means such as a coater, and a strip-shaped conductor 3 or a linear conductor 3' is coated on the coated layer. When placed, the conductor is buried in the plastisol layer 2 under its own weight as shown in FIG. Then, if the film 1a is further layered on top of the film 1a and heated appropriately in an oven and then cooled, a flat cable with an integrated whole as shown in the cross section of FIG. 2 can be obtained.The blastisol composition 2 was once heated to gel and cooled. Thereafter, the conductors 3, 3' are placed thereon, and then the film 1a is placed on top of the film 1a and subjected to heat and pressure treatment, resulting in a structure as shown in FIG. 3, and any method can be used as desired.

Note that the films 1 and 1a are transparent, and the fourth
As shown in the figure, plastisols 2 and 2 have different colors from each other.
By applying a in sequence, a flat cable with different colors on both sides can be obtained.

〔Effect of the invention〕

According to the method of the present invention, a film with excellent insulating properties and a vinyl chloride resin are in strong contact with each other without using special equipment or machines as in the conventional method, and it is flexible, robust, and has excellent dimensional stability. Not only can flat cables be easily obtained, but relatively thin cables can also be manufactured easily, and the use of transparent film and plastisol color scheme allows for free coloring, which has extremely great effects. . Furthermore, even if this flat cable is wired under a carpet or carpet tiles, no unevenness will appear on the surface of the carpet tiles, and even if heavy objects are placed on the cables, there will be no risk of breakage or electrical leakage.

〔Example〕

On a polyethylene terephthalate film with a width of 6 cm, a length of 1 m, and a thickness of 38 mm, plastisol of the following composition is applied using a bar coater to a width of 5 cm and a thickness of 10 mm. Copper foil was placed, and then a polyethylene terephthalate film was placed on top of it, and then heated in an oven at 180°C, which is above the dissociation temperature of blocked polyisocyanurate, for 3 minutes to bond the plastisol and polyethylene terephthalate film. After that, it was cooled. The copper foil was buried in the plastisol due to its own weight, resulting in a highly flexible flat cable with a thickness of about 150 mm, as shown in the cross section of Figure 2.

The peel strength between film layer 1 and intermediate layer 2 is
0.6Kg/inch Peel strength of film 1a layer and intermediate layer 2 is 0.7Kg/inch
It was a thin and sturdy flat cable that did not peel off even when bent.

Plastisol formulation: Vinyl chloride paste resin (Vinica P-540,
(Manufactured by Mitsubishi Kasei Vinyl Co., Ltd.) 100 parts by weight Polyester plasticizer (Diasizer D-
409, manufactured by Mitsubishi Kasei Vinyl Corporation) 45 parts by weight DOP 10 parts by weight Liquid Sn-SH stabilizer (MARK465, manufactured by Adeka Argus) 4 parts by weight Blocked polyisocyanurate (oxybenzoic acid ester blocked TDI trimer) 33% DBP solution) 15 parts by weight

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing a state in which a plastisol composition is applied on a film and a conductor is layered, and FIGS. 2 to 4 are sectional views showing examples of flat cables obtained by the present invention. . 1... Film with excellent dimensional stability, 2... Plastisol composition layer, 3,3'... Electric conductor.

Claims (1)

[Scope of Claims] 1 (A) A step of applying a vinyl chloride plastisol composition containing an adhesion promoter to the entire surface or a portion of an insulating film having excellent dimensional stability; (B) the above plastisol composition; It is characterized by going through the following steps: (C) layering a sheet, band, or wire conductor on top of the object; (C) then layering another insulating film on top of it and heat-laminating it to integrate it; A manufacturing method for a flat cable. 2. The method for manufacturing a flat cable according to claim 1, which includes the step of once heating and gelling the plastisol composition applied on the insulating film before the step of overlapping the conductor. 3. The method according to claim 1 or 2, wherein the other insulating film is the same insulating film used in step (A) and coated with a plastisol composition containing an adhesion imparting agent. Manufacturing method of flat cable.