Flat wire manufacturing apparatus and its manufacturing method

Abstract

The present invention relates to a flat wire manufacturing device, comprising an upper PET insulating tape, a lower PET insulating tape, a conductor layer, a first conveying device, a second conveying device, a rolling device and an ultrasonic transducer. The rolling device includes an upper rolling device and a lower rolling device. The upper rolling device includes an upper rolling roller and an upper fixed shaft. The upper rolling roller and the lower rolling roller are arranged one above the other, and a rolling area is formed between the upper rolling roller and the lower rolling roller. The ultrasonic transducer is installed at the upper fixed shaft, and the ultrasonic emission direction of the ultrasonic transducer faces the rolling area. It does not generate VOC substances, does not affect the health of workers, and the PET insulating tape does not need to be pre-coated with adhesive, with low cost, comfortable working environment for employees. Moreover, by using the ultrasonic welding method, the connection effect is good and the production efficiency is high.

Description

Technical Field

[0001] The present invention relates to the field of flat wires, and particularly to a flat wire manufacturing device and a manufacturing method thereof. Background Art

[0002] Flexible Flat Cable (FFC) can arbitrarily select the number of conductors and the spacing, making the connection more convenient, greatly reducing the volume of electronic products, reducing production costs, and improving production efficiency. It is most suitable for use as a data transmission cable between moving parts and the main board, between PCB boards, and in miniaturized electrical equipment. Common specifications include flexible cable wires with various spacings such as 0.5mm, 0.8mm, 1.0mm, 1.25mm, 1.27mm, 1.5mm, 2.0mm, 2.54mm, etc.

[0003] Currently, it is widely used in the connection between the print heads of various printers and the main board, and the signal transmission and board-to-board connection of products such as plotters, scanners, copiers, audio systems, liquid crystal appliances, fax machines, and various DVD players.

[0004] The existing flat wire manufacturing method is as follows: Use an upper PET insulating tape with pre-coated adhesive and a lower PET insulating tape with pre-coated adhesive. Place a conductor layer composed of conductors that are parallel and separated from each other on the lower PET insulating tape with pre-coated adhesive. Then, place the upper PET insulating tape with pre-coated adhesive on the surface of the conductor layer. Finally, use a heating roller to roll and press, and the upper PET insulating tape with pre-coated adhesive and the lower PET insulating tape with pre-coated adhesive are bonded together, and the upper PET insulating tape with pre-coated adhesive and the lower PET insulating tape with pre-coated adhesive wrap the conductor layer to form a flat wire with several conductors insulated from each other.

[0005] The above manufacturing method has the following disadvantages: (1) Since an upper PET insulating tape with pre-coated adhesive and a lower PET insulating tape with pre-coated adhesive are used, in order to avoid the melting of the adhesive, the upper PET insulating tape and the lower PET insulating tape must be stored in a low-temperature environment of -25°C. (2) When producing flat wires using an upper PET insulating tape with pre-coated adhesive and a lower PET insulating tape with pre-coated adhesive, in order to avoid the melting of the adhesive during the production process, the temperature of the production workshop needs to be limited to not higher than 18°C. Workers are prone to catching cold and getting sick in such a low-temperature environment. (3) Since the upper PET insulating tape with pre-coated adhesive and the lower PET insulating tape with pre-coated adhesive need to be rolled and pressed by a heating roller to melt the adhesive in order to bond the upper PET insulating tape and the lower PET insulating tape, VOC substances are generated when the adhesive melts, and VOC substances have an impact on human health. Summary of the Invention

[0006] The first object of the present invention is to provide a flat wire manufacturing device with energy conservation, low cost, and high production efficiency.

[0007] The second object of the present invention is to provide a method for manufacturing a flat wire with energy saving, low cost and high production efficiency.

[0008] The first object of the present invention is achieved as follows:

[0009] A flat wire manufacturing device includes an upper PET insulating tape, a lower PET insulating tape, a conductor layer, a first conveying device, a second conveying device, a rolling device and an ultrasonic transducer. The rolling device includes an upper rolling device and a lower rolling device. The upper rolling device includes an upper rolling roller and an upper fixed shaft, and the upper rolling roller is sleeved on the upper fixed shaft in a rotatable manner. The lower rolling device includes a lower rolling roller and a lower rotating shaft, and the lower rolling roller is sleeved on the lower rotating shaft. The upper rolling roller and the lower rolling roller are arranged one above the other, and a rolling area is formed between the upper rolling roller and the lower rolling roller. The ultrasonic transducer is installed at the upper fixed shaft, and the ultrasonic emission direction of the ultrasonic transducer faces the rolling area.

[0010] The first conveying device and the second conveying device are arranged one above the other. The outlet of the first conveying device faces above the inlet of the rolling area, and the outlet of the second conveying device faces the bottom of the inlet of the rolling area.

[0011] The first conveying device drives the upper PET insulating tape to extend into the upper part of the rolling area through the inlet of the rolling area. The conductor layer extends into the middle of the rolling area through the inlet of the rolling area. The second conveying device drives the lower PET insulating tape to extend into the bottom of the rolling area through the inlet of the rolling area, so that the upper PET insulating tape, the conductor layer and the lower PET insulating tape are arranged in an upper, middle and lower manner.

[0012] The ultrasonic transducer generates ultrasonic vibrations. The ultrasonic waves are transmitted through the upper fixed shaft to vibrate between the upper PET insulating tape, the conductor layer and the lower PET insulating tape located in the rolling area, causing energy to accumulate between the upper PET insulating tape, the conductor layer and the lower PET insulating tape. As a result, the upper PET insulating tape and the lower PET insulating tape located in the rolling area melt. The upper rolling roller and the lower rolling roller rotate, and the upper rolling roller and the lower rolling roller jointly roll the upper PET insulating tape, the conductor layer and the lower PET insulating tape in the rolling area, causing the upper PET insulating tape, the conductor layer and the lower PET insulating tape to be connected into one body to form a flat wire, and the flat wire is discharged along the outlet of the rolling area.

[0013] The ultrasonic transducer generates ultrasonic vibrations, which are transmitted to the rolling area through the upper fixed shaft. The upper PET insulating tape, the conductor layer, and the lower PET insulating tape are arranged in an upper, middle, and lower manner. When the upper PET insulating tape, the conductor layer, and the lower PET insulating tape pass through the rolling area, the ultrasonic vibrations generated by the ultrasonic transducer cause the upper PET insulating tape and the lower PET insulating tape to melt. At this time, the upper rolling roller and the lower rolling roller jointly roll the upper PET insulating tape, the conductor layer, and the lower PET insulating tape, so that the upper PET insulating tape and the lower PET insulating tape are connected and wrap the conductor layer to form a flat wire. The production method is simple. By using the ultrasonic transducer to melt the upper PET insulating tape and the lower PET insulating tape, there is no need to use the existing technology of heating adhesives for connection, no need to consider the storage temperature of the adhesives, no need to limit the workshop temperature, no need to heat the adhesives, and no VOC substances will be generated. Therefore, there is no need to consider the cooling temperature, the production workshop does not need a constant low temperature, the air-conditioning energy consumption is reduced to achieve energy conservation, and no VOC substances are generated, which does not affect the health of workers. Moreover, the PET insulating tape does not need to be pre-coated with adhesives, the cost is low, the working environment of employees is comfortable, and by using the ultrasonic welding method, the connection effect is good and the production efficiency is high.

[0014] The first object of the present invention can also be solved by the following technical measures:

[0015] Further, the conductor layer includes several conductors that are parallel to each other and separated from each other, and an insulating area is formed between the conductors. When the upper PET insulating tape and the lower PET insulating tape are connected to wrap the conductor layer, a flat wire with several mutually insulated conductors can be formed.

[0016] Further, both the first conveying device and the second conveying device are reduction gear sets, and the reduction gear sets are formed by meshing multiple gears. A corresponding roller is connected to the end face of each gear. By setting the reduction gear sets, the speed of the upper PET insulating tape and the lower PET insulating tape entering the rolling area is slowed down, so as to extend the time for the upper PET insulating tape and the lower PET insulating tape to be placed in the rolling area. The ultrasonic vibrations generated by the ultrasonic transducer can be continuously transmitted to the upper PET insulating tape and the lower PET insulating tape, improving the melting effect of the upper PET insulating tape and the lower PET insulating tape. When the upper rolling roller and the lower rolling roller jointly roll the upper PET insulating tape, the conductor layer, and the lower PET insulating tape, the upper PET insulating tape and the lower PET insulating tape are connected and wrap the conductor layer to form a flat wire with a better sealing effect.

[0017] Further, it further includes an upper-layer PET insulating tape extruder, which is provided with a feed inlet and a discharge outlet. The discharge outlet is communicated with the inlet of the first conveying device, and the upper-layer PET insulating tape produced by the upper-layer PET insulating tape extruder is wound around a roller. When the upper rolling roller and the lower rolling roller jointly drive the upper-layer PET insulating tape to move, the upper-layer PET insulating tape drives the roller to rotate, and at the same time drives the reduction gear set to rotate, thereby reducing the moving speed of the upper-layer PET insulating tape.

[0018] Further, it further includes a lower-layer PET insulating tape extruder, which is provided with a feed inlet and a discharge outlet. The discharge outlet is communicated with the inlet of the second conveying device, and the upper-layer PET insulating tape produced by the lower-layer PET insulating tape extruder is wound around a roller. When the upper rolling roller and the lower rolling roller jointly drive the lower-layer PET insulating tape to move, the lower-layer PET insulating tape drives the roller to rotate, and at the same time drives the reduction gear set to rotate, thereby reducing the moving speed of the lower-layer PET insulating tape.

[0019] Further, the specification of the ultrasonic transducer is 20KHz, 5KW.

[0020] Further, the lower rolling device further includes a lower motor, which is connected to the lower rotating shaft, and the lower motor drives the lower rolling roller to rotate through the lower rotating shaft.

[0021] Further, the lower motor drives the lower rolling roller to rotate clockwise through the lower rotating shaft. The rotation directions of the upper rolling roller and the lower rolling roller are opposite. The upper rolling roller rotates counterclockwise. The upper rolling roller and the lower rolling roller jointly drive the upper-layer PET insulating tape, the conductor layer and the lower-layer PET insulating tape to move.

[0022] Further, the upper-layer PET insulating tape corresponding to the insulating area and the lower-layer PET insulating tape corresponding to the insulating area are bonded together. The upper-layer PET insulating tape corresponding to the insulating area and the lower-layer PET insulating tape corresponding to the insulating area are bonded together, thereby separating the conductors, and several flat wires with insulated conductors can be formed.

[0023] The second object of the present invention is achieved as follows:

[0024] A method for manufacturing a flat wire, comprising the following steps,

[0025] Step 1: Put the PET insulating material into the upper-layer PET insulating tape extruder along the feed inlet, and adjust the temperature of the production workshop to 25°C.

[0026] Step 2: Wind the upper-layer PET insulating tape discharged from the outlet of the upper-layer PET insulating tape extruder around the roller of the first conveying device, and then extend the upper-layer PET insulating tape into the area above the rolling area through the inlet of the rolling area of the rolling device;

[0027] Step 3: Put the PET insulating material into the lower-layer PET insulating tape extruder along the feed inlet;

[0028] Step 6: Wind the lower-layer PET insulating tape discharged from the outlet of the lower-layer PET insulating tape extruder around the roller of the second conveying device, and then extend the lower-layer PET insulating tape into the area below the rolling area through the inlet of the rolling area of the rolling device;

[0029] Step 5: Extend the conductor layer into the middle of the rolling area through the inlet of the rolling area of the rolling device;

[0030] Step 6: Start the upper-layer PET insulating tape extruder, the lower-layer PET insulating tape extruder, the rolling device and the ultrasonic transducer;

[0031] Step 7: The upper-layer PET insulating tape produced by the upper-layer PET insulating tape extruder is discharged through the outlet. The lower-layer PET insulating tape produced by the lower-layer PET insulating tape extruder is discharged through the outlet. The ultrasonic transducer generates ultrasonic vibrations and transmits them between the upper-layer PET insulating tape, the conductor layer and the lower-layer PET insulating tape, causing the upper-layer PET insulating tape and the lower-layer PET insulating tape located in the rolling area to melt. The lower motor of the rolling device drives the lower rolling roller to rotate clockwise. The rotation directions of the upper rolling roller and the lower rolling roller are opposite, and the upper rolling roller rotates counterclockwise. The upper rolling roller and the lower rolling roller jointly roll the upper-layer PET insulating tape, the conductor layer and the lower-layer PET insulating tape together to form a flat wire. At the same time, the upper rolling roller and the lower rolling roller jointly drive the flat wire to be discharged from the rolling area to the outlet.

[0032] The ultrasonic transducer generates ultrasonic vibrations, which are transmitted to the rolling area through the upper fixed shaft. The upper PET insulating tape, the conductor layer, and the lower PET insulating tape are arranged in an upper, middle, and lower configuration. When the upper PET insulating tape, the conductor layer, and the lower PET insulating tape pass through the rolling area, the ultrasonic vibrations generated by the ultrasonic transducer cause the upper PET insulating tape and the lower PET insulating tape to melt. At this time, the upper rolling roller and the lower rolling roller jointly roll the upper PET insulating tape, the conductor layer, and the lower PET insulating tape, causing the upper PET insulating tape and the lower PET insulating tape to connect and wrap the conductor layer to form a flat wire. The production method is simple. By using the ultrasonic transducer to melt the upper PET insulating tape and the lower PET insulating tape, there is no need to use the existing technology of heating adhesives for connection. There is no need to consider the storage temperature of the adhesive, there is no need to limit the workshop temperature, there is no need to heat the adhesive, and no VOC substances will be generated. Therefore, there is no need to consider the cooling temperature. The production workshop does not require a constant low temperature, and the air-conditioning energy consumption is reduced to achieve energy conservation. Moreover, no VOC substances are generated, which does not affect the health of workers. In addition, the PET insulating tape does not require pre-coated adhesive, the cost is low, the working environment of employees is comfortable, and by using the ultrasonic welding method, the connection effect is good and the production efficiency is high.

[0033] The beneficial effects of the present invention are as follows:

[0034] In the present invention, the ultrasonic transducer generates ultrasonic vibrations, which are transmitted to the rolling area through the upper fixed shaft. The upper PET insulating tape, the conductor layer, and the lower PET insulating tape are arranged in an upper, middle, and lower configuration. When the upper PET insulating tape, the conductor layer, and the lower PET insulating tape pass through the rolling area, the ultrasonic vibrations generated by the ultrasonic transducer cause the upper PET insulating tape and the lower PET insulating tape to melt. At this time, the upper rolling roller and the lower rolling roller jointly roll the upper PET insulating tape, the conductor layer, and the lower PET insulating tape, causing the upper PET insulating tape and the lower PET insulating tape to connect and wrap the conductor layer to form a flat wire. The production method is simple. By using the ultrasonic transducer to melt the upper PET insulating tape and the lower PET insulating tape, there is no need to use the existing technology of heating adhesives for connection. There is no need to consider the storage temperature of the adhesive, there is no need to limit the workshop temperature, there is no need to heat the adhesive, and no VOC substances will be generated. Therefore, there is no need to consider the cooling temperature. The production workshop does not require a constant low temperature, and the air-conditioning energy consumption is reduced to achieve energy conservation. Moreover, no VOC substances are generated, which does not affect the health of workers. In addition, the PET insulating tape does not require pre-coated adhesive, the cost is low, the working environment of employees is comfortable, and by using the ultrasonic welding method, the connection effect is good and the production efficiency is high.

[0035] In the present invention, a reduction gear set is provided to slow down the speed at which the upper PET insulating tape and the lower PET insulating tape enter the rolling area, thereby prolonging the time that the upper PET insulating tape and the lower PET insulating tape are placed in the rolling area. The ultrasonic vibration generated by the ultrasonic transducer can be continuously transmitted to the upper PET insulating tape and the lower PET insulating tape, improving the melting effect of the upper PET insulating tape and the lower PET insulating tape. When the upper rolling roller and the lower rolling roller jointly roll the upper PET insulating tape, the conductor layer, and the lower PET insulating tape, the upper PET insulating tape and the lower PET insulating tape are connected and wrap the conductor layer to form a flat wire with a better sealing effect. Description of the Drawings

[0036] Figure 1 It is a schematic diagram of a flat wire manufacturing device.

[0037] Figure 2 It is a sectional view of a flat wire.

[0038] Figure 3 It is a schematic diagram of the conductor layer of a flat wire. Detailed Embodiment

[0039] The present invention will be further described below in conjunction with the drawings and embodiments:

[0040] Embodiment, in combination with Figures 1 to 3 As shown, a flat wire manufacturing device includes an upper PET insulating tape 1, a lower PET insulating tape 2, a conductor layer 3, a first conveying device 4, a second conveying device 5, a rolling device 6, an ultrasonic transducer 7, an upper PET insulating tape extruder 8, and a lower PET insulating tape extruder 9.

[0041] The rolling device 6 includes an upper rolling device (not shown in the figure) and a lower rolling device (not shown in the figure). The upper rolling device includes an upper rolling roller 61 and an upper fixed shaft (not shown in the figure). The upper rolling roller 61 is sleeved on the upper fixed shaft in a rotatable manner.

[0042] The lower rolling device includes a lower rolling roller 62, a lower motor, and a lower rotating shaft. The lower rolling roller 62 is sleeved on the lower rotating shaft. The lower motor is connected to the lower rotating shaft, and the lower motor drives the lower rolling roller to rotate clockwise through the lower rotating shaft. The rotating directions of the upper rolling roller and the lower rolling roller are opposite, and the upper rolling roller rotates counterclockwise.

[0043] The upper rolling roller 61 and the lower rolling roller 62 are arranged one above the other, and a rolling area 10 is formed between the upper rolling roller 61 and the lower rolling roller 62.

[0044] The ultrasonic transducer 7 has a specification of 20KHz, 5KW. The ultrasonic transducer 7 is installed at the upper fixed shaft, and the ultrasonic emission direction of the ultrasonic transducer 7 faces the rolling area 10.

[0045] The first conveying device 4 is a reduction gear set (not shown in the figure), and the reduction gear set is formed by meshing a plurality of gears. The end face of each gear is respectively connected with a corresponding roller 11.

[0046] The upper-layer PET insulating tape extruder 8 is provided with a feed inlet 81 and a discharge outlet 82. The discharge outlet 82 communicates with the inlet of the first conveying device 4. The upper-layer PET insulating tape 1 produced by the upper-layer PET insulating tape extruder 8 is wound around the roller 11 of the first conveying device 4.

[0047] The second conveying device 5 is a reduction gear set, and the reduction gear set is formed by meshing a plurality of gears. The end face of each gear is respectively connected with a corresponding roller 11.

[0048] The lower-layer PET insulating tape extruder 9 is provided with a feed inlet 81 and a discharge outlet 82. The discharge outlet 82 communicates with the inlet of the second conveying device 5. The upper-layer PET insulating tape 1 produced by the lower-layer PET insulating tape extruder 9 is wound around the roller 11 of the second conveying device 5.

[0049] The conductor layer 3 is composed of several conductors 31 that are parallel to each other and separated from each other. An insulating region 32 is formed between the conductors 31 and the conductors 31.

[0050] Assembly of the flat wire manufacturing device:

[0051] The first conveying device 4 and the second conveying device 5 are arranged one above the other. The outlet of the first conveying device 4 faces above the inlet of the rolling area 10, and the outlet of the second conveying device 5 faces the bottom of the inlet of the rolling area 10. The conductor 31 layer 3 extends into the middle of the rolling area 10 through the inlet of the rolling area 10 of the rolling device 6.

[0052] The upper-layer PET insulating tape 1 produced by the upper-layer PET insulating tape extruder 8 is discharged through the discharge outlet 82. The upper-layer PET insulating tape 1 discharged from the discharge outlet 82 of the upper-layer PET insulating tape extruder 8 is wound around the roller 11 of the first conveying device 4. Then, the upper-layer PET insulating tape 1 is extended into the upper part of the rolling area 10 through the inlet of the rolling area 10 of the rolling device 6.

[0053] The lower-layer PET insulating tape 2 discharged from the discharge outlet 82 of the lower-layer PET insulating tape extruder 9 is wound around the roller 11 of the second conveying device 5. Then, the lower-layer PET insulating tape 2 is extended into the lower part of the rolling area 10 through the inlet of the rolling area 10 of the rolling device 6.

[0054] The conductor 31 layer 3 extends into the middle of the rolling area 10 through the inlet of the rolling area 10 of the rolling device 6.

[0055] When the upper PET insulating tape extruder 8, the lower PET insulating tape extruder 9, the rolling device 6, and the ultrasonic transducer 7 are started: the upper PET insulating tape extruder 8 produces the upper PET insulating tape 1, the lower PET insulating tape extruder 9 produces the lower PET insulating tape 2, the lower motor drives the lower rolling roller 62 to rotate clockwise (the lower rolling roller 62 is the driving wheel), the rotation directions of the upper rolling roller 61 and the lower rolling roller 62 are opposite, the upper rolling roller 61 (the upper rolling roller 61 is the driven wheel) rotates counterclockwise, and the upper rolling roller 61 and the lower rolling roller 62 jointly drive the upper PET insulating tape 1, the conductor layer 3, and the lower PET insulating tape 2 to move.

[0056] The ultrasonic transducer 7 generates ultrasonic vibrations, and the ultrasonic vibrations are transmitted between the upper PET insulating tape 1, the conductor layer 3, and the lower PET insulating tape 2 located in the rolling area 10, causing energy to accumulate between the upper PET insulating tape 1, the conductor layer 3, and the lower PET insulating tape 2, resulting in the melting of the upper PET insulating tape 1 and the lower PET insulating tape 2 located in the rolling area 10. The upper rolling roller 61 and the lower rolling roller 62 rotate, and the upper rolling roller 61 and the lower rolling roller 62 jointly roll the upper PET insulating tape 1, the conductor layer 3, and the lower PET insulating tape 2 in the rolling area 10, causing the upper PET insulating tape 1 corresponding to the insulating area 32 of the conductor layer 3 and the lower PET insulating tape 2 corresponding to the insulating area 32 to be bonded together, and the upper PET insulating tape 1, the conductor layer 3, and the lower PET insulating tape 2 are connected into one body to form a flat wire 100, and the flat wire 100 is discharged along the outlet of the rolling area 10.

[0057] Manufacturing method of the flat wire 100:

[0058] Step 1: Put the PET insulating material into the upper PET insulating tape extruder 8 along the feed port 81, and adjust the temperature of the production workshop to 25 °C.

[0059] Step 2: Wind the upper PET insulating tape 1 discharged from the discharge port 82 of the upper PET insulating tape extruder 8 around the roller 11 of the first conveying device 4, and then extend the upper PET insulating tape 1 into the upper part of the rolling area 10 through the inlet of the rolling area 10 of the rolling device 6;

[0060] Step 3: Put the PET insulating material into the lower PET insulating tape extruder 9 along the feed port 81;

[0061] Step 4: Wind the lower PET insulating tape 2 discharged from the discharge port 82 of the lower PET insulating tape extruder 9 around the roller 11 of the second conveying device 5, and then extend the lower PET insulating tape 2 into the lower part of the rolling area 10 through the inlet of the rolling area 10 of the rolling device 6;

[0062] Step 5: Insert the conductor layer 3 into the middle of the rolling area 10 through the entrance of the rolling area 10 of the rolling device 6;

[0063] Step 6: Start the upper layer PET insulating tape extruder 8, the lower layer PET insulating tape extruder 9, the rolling device 6 and the ultrasonic transducer 7;

[0064] Step 7: The upper layer PET insulating tape extruder 8 produces the upper layer PET insulating tape 1 and discharges it through the discharge port 82. The lower layer PET insulating tape extruder 9 produces the lower layer PET insulating tape 2 and discharges it through the discharge port 82. The ultrasonic transducer 7 generates ultrasonic vibrations and transmits them to between the upper layer PET insulating tape 1, the conductor layer 3 and the lower layer PET insulating tape 2 through the upper fixed shaft, causing the upper layer PET insulating tape 1 and the lower layer PET insulating tape 2 located in the rolling area 10 to melt. The lower motor of the rolling device 6 drives the lower rolling roller 62 to rotate clockwise, and the upper rolling roller 61 rotates counterclockwise. The upper rolling roller 61 and the lower rolling roller 62 jointly roll the upper layer PET insulating tape 1, the conductor layer 3 and the lower layer PET insulating tape 2, and the upper layer PET insulating tape 1, the conductor layer 3 and the lower layer PET insulating tape 2 are bonded together to form a flat wire 100. At the same time, the upper rolling roller 61 and the lower rolling roller 62 jointly drive the flat wire 100 to be discharged from the rolling area 10 towards the outlet.

[0065] The ultrasonic transducer 7 generates ultrasonic vibrations and transmits them to the rolling area 10 through the upper fixed shaft. The upper layer PET insulating tape 1, the conductor layer 3 and the lower layer PET insulating tape 2 are arranged in an upper, middle and lower manner. When the upper layer PET insulating tape 1, the conductor layer 3 and the lower layer PET insulating tape 2 pass through the rolling area 10, the ultrasonic vibrations generated by the ultrasonic transducer 7 cause the upper layer PET insulating tape 1 and the lower layer PET insulating tape 2 to melt. At this time, the upper rolling roller 61 and the lower rolling roller 62 jointly roll the upper layer PET insulating tape 1, the conductor layer 3 and the lower layer PET insulating tape 2, so that the upper layer PET insulating tape 1 and the lower layer PET insulating tape 2 are connected and wrap the conductor layer 3 to form a flat wire 100. The production method is simple. By using the ultrasonic transducer 7 to melt the upper layer PET insulating tape 1 and the lower layer PET insulating tape 2, there is no need to use the existing technology of heating adhesives for connection, no need to consider the storage temperature of adhesives, no need to limit the workshop temperature, no need to heat adhesives, no VOC substances will be generated, so there is no need to consider the cooling temperature. The production workshop does not require a constant low temperature, the air-conditioning energy consumption is reduced to achieve energy saving, and no VOC substances are generated, which does not affect the health of workers. Moreover, the PET insulating tape does not need to be pre-coated with adhesives, the cost is low, the working environment of employees is comfortable, and by using the ultrasonic welding method, the connection effect is good and the production efficiency is high.

Claims

1. A flat wire manufacturing device, comprising an upper-layer PET insulating tape, a lower-layer PET insulating tape, a conductor layer, a first conveying device, a second conveying device, a rolling device, and an ultrasonic transducer, characterized in that: The rolling device includes an upper rolling device and a lower rolling device. The upper rolling device includes an upper rolling roller and an upper fixed shaft. The upper rolling roller is sleeved on the upper fixed shaft in a rotatable manner. The lower rolling device includes a lower rolling roller and a lower rotating shaft. The lower rolling roller is sleeved on the lower rotating shaft. The upper rolling roller and the lower rolling roller are arranged one above the other, and a rolling area is formed between the upper rolling roller and the lower rolling roller. The ultrasonic transducer is installed at the upper fixed shaft, and the ultrasonic emission direction of the ultrasonic transducer faces the rolling area. The first conveying device and the second conveying device are arranged one above the other. The outlet of the first conveying device faces above the inlet of the rolling area, and the outlet of the second conveying device faces the bottom of the inlet of the rolling area. The first conveying device drives the upper-layer PET insulating tape to extend into the upper part of the rolling area through the inlet of the rolling area. The conductor layer extends into the middle of the rolling area through the inlet of the rolling area. The second conveying device drives the lower-layer PET insulating tape to extend into the bottom of the rolling area through the inlet of the rolling area, so that the upper-layer PET insulating tape, the conductor layer, and the lower-layer PET insulating tape are arranged one above the other, one in the middle, and one below. The ultrasonic transducer generates ultrasonic vibrations. The ultrasonic waves are transmitted through the vibration of the upper fixed shaft to between the upper-layer PET insulating tape, the conductor layer, and the lower-layer PET insulating tape located in the rolling area, causing energy to accumulate between the upper-layer PET insulating tape, the conductor layer, and the lower-layer PET insulating tape, resulting in the melting of the upper-layer PET insulating tape and the lower-layer PET insulating tape located in the rolling area. The upper rolling roller and the lower rolling roller rotate, and the upper rolling roller and the lower rolling roller jointly roll the upper-layer PET insulating tape, the conductor layer, and the lower-layer PET insulating tape in the rolling area, causing the upper-layer PET insulating tape, the conductor layer, and the lower-layer PET insulating tape to be connected into one body to form a flat wire, and the flat wire is discharged along the outlet of the rolling area. The conductor layer is composed of several conductors that are parallel to each other and separated from each other, and an insulating area is formed between the conductors. Both the first conveying device and the second conveying device are reduction gear sets, and the reduction gear sets are formed by the meshing of multiple gears. The end face of each gear is respectively connected with a corresponding roller. The upper-layer PET insulating tape corresponding to the insulating area and the lower-layer PET insulating tape corresponding to the insulating area are bonded together. By providing a reduction gear set, the speed of the upper-layer PET insulating tape and the lower-layer PET insulating tape entering the rolling area is slowed down, so as to extend the time for the upper-layer PET insulating tape and the lower-layer PET insulating tape to be placed in the rolling area. The ultrasonic vibrations generated by the ultrasonic transducer can be continuously transmitted to the upper-layer PET insulating tape and the lower-layer PET insulating tape, improving the melting effect of the upper-layer PET insulating tape and the lower-layer PET insulating tape. The upper-layer PET insulating tape is wound around the roller. When the upper rolling roller and the lower rolling roller jointly drive the upper-layer PET insulating tape to move, the upper-layer PET insulating tape drives the roller to rotate, and at the same time drives the reduction gear set to rotate, thereby reducing the moving speed of the upper-layer PET insulating tape.

2. The flat wire manufacturing apparatus according to claim 1, wherein: It further includes an upper-layer PET insulating tape extruder, which is provided with a feed inlet and a discharge outlet. The discharge outlet is communicated with the inlet of the first conveying device, and the upper-layer PET insulating tape produced by the upper-layer PET insulating tape extruder is wound around a roller.

3. The flat wire manufacturing device according to claim 1, characterized in that: It further includes a lower-layer PET insulating tape extruder, which is provided with a feed inlet and a discharge outlet. The discharge outlet is communicated with the inlet of the second conveying device, and the upper-layer PET insulating tape produced by the lower-layer PET insulating tape extruder is wound around a roller.

4. The flat wire manufacturing apparatus according to claim 1, wherein: The specification of the ultrasonic transducer is 20KHz, 5KW.

5. The flat wire manufacturing apparatus according to claim 1, wherein: The lower rolling device further includes a lower motor, which is connected to a lower rotating shaft. The lower motor drives the lower rolling roller to rotate through the lower rotating shaft.

6. The flat wire manufacturing apparatus according to claim 5, characterized in that: The lower motor drives the lower rolling roller to rotate clockwise through the lower rotating shaft. The rotating directions of the upper rolling roller and the lower rolling roller are opposite. The upper rolling roller rotates counterclockwise. The upper rolling roller and the lower rolling roller jointly drive the upper-layer PET insulating tape, the conductor layer and the lower-layer PET insulating tape to move.

7. A method for manufacturing a flat wire using the flat wire manufacturing apparatus according to claim 1, characterized in that: It includes the following steps Step 1: Put the PET insulating material into the upper-layer PET insulating tape extruder along the feed inlet, and adjust the temperature of the production workshop to 25°C. Step 2: Wind the upper-layer PET insulating tape discharged from the discharge outlet of the upper-layer PET insulating tape extruder around the roller of the first conveying device, and then extend the upper-layer PET insulating tape into the upper part of the rolling area through the inlet of the rolling area of the rolling device. Step 3: Put the PET insulating material into the lower-layer PET insulating tape extruder along the feed inlet. Step 4: Wind the lower-layer PET insulating tape discharged from the discharge outlet of the lower-layer PET insulating tape extruder around the roller of the second conveying device, and then extend the lower-layer PET insulating tape into the lower part of the rolling area through the inlet of the rolling area of the rolling device. Step 5: Extend the conductor layer into the middle of the rolling area through the inlet of the rolling area of the rolling device. Step 6: Start the upper-layer PET insulating tape extruder, the lower-layer PET insulating tape extruder, the rolling device and the ultrasonic transducer. Step 7: The upper-layer PET insulating tape produced by the upper-layer PET insulating tape extruder is discharged through the discharge outlet. The lower-layer PET insulating tape produced by the lower-layer PET insulating tape extruder is discharged through the discharge outlet. The ultrasonic transducer generates ultrasonic vibration and transmits it between the upper-layer PET insulating tape, the conductor layer and the lower-layer PET insulating tape, causing the upper-layer PET insulating tape and the lower-layer PET insulating tape located in the rolling area to melt. The lower motor of the rolling device drives the lower rolling roller to rotate clockwise. The rotating directions of the upper rolling roller and the lower rolling roller are opposite. The upper rolling roller rotates counterclockwise. The upper rolling roller and the lower rolling roller jointly roll the upper-layer PET insulating tape, the conductor layer and the lower-layer PET insulating tape together to form a flat wire. At the same time, the upper rolling roller and the lower rolling roller jointly drive the flat wire to be discharged from the rolling area to the outlet.

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