Method for manufacturing flat conductor

Abstract

This invention relates to a method for manufacturing flat conductors. A method for manufacturing a flat conductor by removing the insulating film of the conductor by irradiating it with a laser includes a first step in which four planar portions of the outer side of the flat conductor are sequentially designated as a first facet, a second facet, a third facet, and a fourth facet. A second corner portion is defined between the second and third facets, and a fourth corner portion is defined between the fourth and first facets. In a first posture, a laser is irradiated onto a first region including the first facet, the first corner portion, and the second facet. The first posture is configured such that the first and second facets are facing the laser irradiation portion, and the angle formed at the intersection of a line parallel to the laser's optical axis and the first facet on the fourth corner side is an obtuse angle, and the angle formed at the intersection of a line parallel to the optical axis and the second facet on the second corner side is also an obtuse angle.

Description

Technical Field

[0001] This invention relates to a method for manufacturing flat wires by laser irradiation. Background Technology

[0002] Previously, flat conductors with an insulating film formed on their surface were widely used, for example, as conductors wound around the stator cores of electric motors used in vehicles such as electric cars. When using such flat conductors, the insulating film needs to be removed at the electrical connection points to expose the core wire. Therefore, the insulating film needs to be removed from the connection points of the flat conductors.

[0003] The method for removing the insulating film from a flat conductor, i.e., the manufacturing method of the flat conductor, involves irradiating each of the four faces of the flat conductor with a laser to remove the film, and irradiating two corners on the same face separately, relative to the insulating film remaining at the four corners. However, this removal method requires four steps to irradiate each of the four faces separately, and then two more steps to irradiate the two corners on the same face separately, totaling six steps. In contrast, to reduce the number of steps, a removal method has been developed that pre-coats the four corners of the flat conductor with a laser-absorbing coating (see Patent Document 1). According to this removal method, since the corners absorb laser light and thus easily generate heat, the insulating film at the corners can be easily removed by simply irradiating each of the four faces separately with a laser.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2012-70483

[0005] However, in the manufacturing method of the flat wire described in Patent Document 1, an absorbent coating must be applied before irradiating the flat wire with a laser, in order to reduce the cost of the coating operation and the coating. Summary of the Invention

[0006] Therefore, the objective is to provide a method for manufacturing flat wires that can reduce the number of processes and eliminate the need for additional processes such as coating.

[0007] The method for manufacturing this flat conductor is a method for removing the insulating film of the flat conductor by irradiating it with a laser. It includes: a first step in which, in a first position, four planar portions of the outer side of the flat conductor are arranged in an adjacent order as a first facet, a second facet, a third facet, and a fourth facet; the corner between the first facet and the second facet is designated as a first corner; the corner between the second facet and the third facet is designated as a second corner; the corner between the third facet and the fourth facet is designated as a third corner; and the corner between the fourth facet and the first facet is designated as a fourth corner. In this first position, a first area including the first facet, the first corner, and the second facet is irradiated with the laser. The first position is configured such that the first facet and the second facet are facing the irradiated portion of the laser, and the angle formed at the intersection of a line parallel to the optical axis of the laser and the first facet on the side of the fourth corner is an obtuse angle, and the angle formed at the intersection of a line parallel to the optical axis and the second facet on the side of the second corner is also an obtuse angle.

[0008] According to this method for manufacturing flat conductors, the number of processes can be reduced and additional processes such as coating are not required. Attached Figure Description

[0009] Figure 1 This is a cross-sectional view showing the flat wire of the first embodiment.

[0010] Figure 2 This is a flowchart illustrating a method for manufacturing a flat conductor according to the first embodiment.

[0011] Figure 3A This is a simplified cross-sectional view of a flat conductor in a first orientation state during the manufacturing method of the flat conductor according to the first embodiment.

[0012] Figure 3B This is a simplified cross-sectional view of a flat conductor in the first step of the manufacturing method of the flat conductor according to the first embodiment, in which a laser is irradiated on a first range.

[0013] Figure 3C This is a simplified cross-sectional view of the flat conductor in a second orientation state during the manufacturing method of the flat conductor according to the first embodiment.

[0014] Figure 3D This is a simplified cross-sectional view of the flat conductor in the state of being irradiated with laser in a second step during the second process of the manufacturing method of the flat conductor according to the first embodiment.

[0015] Figure 4AThis is a simplified cross-sectional view of the flat conductor in the third orientation state during the manufacturing method of the flat conductor according to the first embodiment.

[0016] Figure 4B This is a simplified cross-sectional view of a flat conductor in the state of being irradiated with laser in a third area during the third step of the manufacturing method of the flat conductor according to the first embodiment.

[0017] Figure 4C This is a simplified cross-sectional view of the flat conductor in the fourth orientation state during the manufacturing method of the flat conductor according to the first embodiment.

[0018] Figure 4D This is a simplified cross-sectional view of a flat conductor in the fourth step of the manufacturing method of the flat conductor according to the first embodiment, in which a laser is irradiated in a fourth region.

[0019] Figure 5 This is a flowchart illustrating a method for manufacturing a flat wire according to the second embodiment.

[0020] Figure 6A This is a simplified cross-sectional view of the flat conductor in a first orientation state during the manufacturing method of the flat conductor in the second embodiment.

[0021] Figure 6B This is a simplified cross-sectional view of a flat conductor in the state of being irradiated with laser light in the first step of the manufacturing method of the flat conductor according to the second embodiment.

[0022] Figure 6C This is a simplified cross-sectional view of a flat conductor in the fifth step of the manufacturing method of the flat conductor according to the second embodiment, in which the conductor is held in a first posture and irradiated with laser light in the fifth and sixth ranges.

[0023] Figure 7A This is a simplified cross-sectional view of the flat conductor in a second orientation state during the manufacturing method of the flat conductor according to the second embodiment.

[0024] Figure 7B This is a simplified cross-sectional view of the flat conductor in the state of being irradiated with laser in the second range during the second process of the manufacturing method of the flat conductor according to the second embodiment.

[0025] Figure 7C This is a simplified cross-sectional view of a flat conductor in the sixth step of the manufacturing method of the flat conductor according to the second embodiment, in which the conductor is held in a second posture and irradiated with laser light in the seventh and eighth ranges.

[0026] Figure 8 This is a flowchart illustrating a method for manufacturing a flat conductor according to the third embodiment.

[0027] Figure 9A This is a simplified cross-sectional view of a flat conductor in a first orientation state during the manufacturing method of the flat conductor according to the third embodiment.

[0028] Figure 9B This is a simplified cross-sectional view of a flat conductor in the state where a laser is irradiated in the first, fifth, and sixth ranges during the first step of the manufacturing method of the flat conductor according to the third embodiment.

[0029] Figure 9C This is a simplified cross-sectional view of a flat conductor in a second orientation state during the manufacturing method of the flat conductor according to the third embodiment.

[0030] Figure 9D This is a simplified cross-sectional view of the flat conductor in the state where the second, seventh, and eighth ranges are irradiated with laser in the second step of the manufacturing method of the flat conductor according to the third embodiment.

[0031] Figure 10 This is a flowchart illustrating the manufacturing method of the flat wire according to the fourth embodiment.

[0032] Figure 11A This is a simplified cross-sectional view of a flat conductor in a first orientation state during the manufacturing method of the flat conductor according to the fourth embodiment.

[0033] Figure 11B This is a simplified cross-sectional view of a flat conductor in the state of being irradiated with a first laser in the first step of the manufacturing method of the flat conductor according to the fourth embodiment.

[0034] Figure 11C This is a simplified cross-sectional view of a flat conductor in the state of being irradiated with a second laser in a second area during the second step of the manufacturing method of the flat conductor according to the fourth embodiment.

[0035] Figure 12A This is a simplified cross-sectional view of a flat conductor in a third orientation state during the manufacturing method of the flat conductor according to the fourth embodiment.

[0036] Figure 12B This is a simplified cross-sectional view of a flat conductor in the state where a first laser is irradiated in a third area during the third step of the manufacturing method of the flat conductor according to the fourth embodiment.

[0037] Figure 12C This is a simplified cross-sectional view of a flat conductor in the fourth step of the manufacturing method of the flat conductor according to the fourth embodiment, in which a second laser is irradiated in a fourth region.

[0038] Figure 13This is a flowchart illustrating the manufacturing method of the flat wire according to the fifth embodiment.

[0039] Figure 14A This is a simplified cross-sectional view of a flat conductor in a first orientation state during the manufacturing method of the flat conductor according to the fifth embodiment.

[0040] Figure 14B This is a simplified cross-sectional view of a flat conductor in the state of being irradiated with a first laser in a first area during the first step of the manufacturing method of the flat conductor according to the fifth embodiment.

[0041] Figure 14C This is a simplified cross-sectional view of a flat conductor in the fifth step of the manufacturing method of the flat conductor according to the fifth embodiment, in which a first laser is irradiated on a fifth range and a sixth range.

[0042] Figure 15A This is a simplified cross-sectional view of a flat conductor in the state of being irradiated with a second laser in a second area during the second step of the manufacturing method of the flat conductor according to the fifth embodiment.

[0043] Figure 15B This is a simplified cross-sectional view of the flat conductor in the state where a second laser is irradiated in the seventh and eighth regions during the sixth step of the manufacturing method of the flat conductor according to the fifth embodiment.

[0044] Figure 16 This is a flowchart illustrating the manufacturing method of the flat wire according to the sixth embodiment.

[0045] Figure 17A This is a simplified cross-sectional view of a flat conductor in a first orientation state during the manufacturing method of the flat conductor according to the sixth embodiment.

[0046] Figure 17B This is a simplified cross-sectional view of a flat conductor in the state where a laser is irradiated in the first, fifth, and sixth regions during the first step of the manufacturing method of the flat conductor according to the sixth embodiment.

[0047] Figure 17C This is a simplified cross-sectional view of a flat conductor in the state where a laser is irradiated in the second step of the manufacturing method of the flat conductor according to the sixth embodiment, specifically in the second step, to the state where the second, seventh, and eighth ranges are irradiated. Detailed Implementation

[0048] <First Implementation>

[0049] The following is based on Figures 1 to 4D A first embodiment of the method for manufacturing the flat conductor of the present invention will be described. In this embodiment, the flat conductor is used as a coil wound around the stator core of an electric motor.

[0050] [Structure of flat conductors]

[0051] First, refer to Figure 1 The structure of the flat conductor 1 will be described. The flat conductor 1 is a rectangular conductor with an insulating film 3, for example, made of enamel coating, formed on the surface of the core wire 2. The flat conductor 1 has four planar portions on its outer side. The planar portions are arranged in adjacent order as a first facet 11, a second facet 12, a third facet 13, and a fourth facet 14. The corner between the first facet 11 and the second facet 12 is designated as the first corner 21, the corner between the second facet 12 and the third facet 13 is designated as the second corner 22, the corner between the third facet 13 and the fourth facet 14 is designated as the third corner 23, and the corner between the fourth facet 14 and the first facet 11 is designated as the fourth corner 24. In this embodiment, these corner portions 21 to 24 are all in the shape of a rounded cross-section. In addition, in this embodiment, the corner portions 21 to 24 are all in the shape of a rounded cross-section after beveling, but it is not limited to this, for example, they can also be in the shape of a straight cross-section after beveling.

[0052] To wind the flat conductor 1 onto the stator core, for example, the insulating film 3 is removed at the end of the equipotential connection portion, exposing the core wire 2. Therefore, a laser is irradiated onto the connection portion of the flat conductor 1, thereby forming a removal portion where the insulating film 3 has been removed. While the laser used to form the removal portion is not particularly limited, for example, a green laser, a CO2 laser, or a YAG laser can be used. In this embodiment, a laser irradiation device capable of irradiating the irradiation portion is used to irradiate the portion of the flat conductor 1 that is the irradiation target, forming the removal portion. Furthermore, the specifications of an example laser used in this embodiment are as follows: Laser diameter: 0.06 mm, pulse energy: 1 mJ, frequency: 300 kHz, pulse width: 240 nsec, pitch width: 0.03 mm in the feed direction, line offset: 0.06 mm. Furthermore, while the focal length of the laser is not particularly limited, it is, for example, set to a position offset from the uppermost point (shortest distance) of the inclined flat conductor 1 towards the core wire 2. Additionally, in the following description... Figures 3A to 4D In the diagram, the irradiation parts 5 and 6, which are laser irradiation devices, are shown as Fθ lenses for convenience, but in reality, the entire irradiation part is represented.

[0053] [Manufacturing method of flat conductors]

[0054] The following is based on Figure 2 The flowchart shown and Figures 3A to 4D The process diagram shown illustrates the manufacturing method of the flat conductor 1 in this embodiment. Furthermore, in Figures 3A to 4D In the diagram, the insulating film is represented by a thick solid line, and the laser is represented by an arrow.

[0055] First, such as Figure 3A As shown, the flat conductor 1 is placed in the laser irradiation device in a first posture (step S1). In this embodiment, the first posture is a posture in which the first facet 11 and the second facet 12 are positioned opposite the laser irradiation section 5, and the first facet 11 and the second facet 12 are tilted relative to the optical axis OA1 of the laser. Here, the optical axis OA1 refers to the optical axis OA1 related to the irradiated laser. That is, the first posture is a posture in which the angle θ11 formed at the intersection point P11 of the straight line L11 parallel to the optical axis OA1 and the first facet 11 on the side of the fourth corner 24 is an obtuse angle, and the angle θ12 formed at the intersection point P12 of the straight line L12 parallel to the optical axis OA1 and the second facet 12 on the side of the second corner 22 is an obtuse angle. In this embodiment, in the first posture, the angle θ1 formed at the intersection point P1 of the straight line L1 parallel to the optical axis OA1 on the side of the first corner 21 is 45°. That is, θ11 = θ12 = 135°.

[0056] like Figure 3B As shown, the first area Ar1 is irradiated with laser (step S2, first process). In this embodiment, the first area Ar1 is the area formed by the first face 11, the first corner 21, and the second face 12. The laser is set to irradiate alternately in both directions with a line offset of 0.06 mm. As a result, the first face 11, the first corner 21, and the second face 12 can be irradiated in one process, so the number of processes can be reduced, for example, compared to the case where the first face 11 and the second face 12 are irradiated in two different processes.

[0057] like Figure 3C As shown, the flat conductor 1 is rotated 180° from the first posture and positioned in the laser irradiation device in a second posture (step S3). In this embodiment, the second posture is a posture in which the third facet 13 and the fourth facet 14 are opposite the laser irradiation part 5 and are tilted relative to the optical axis OA1 of the laser. That is, the second posture is a posture in which the angle θ13 formed at the intersection point P13 of the line L13 parallel to the optical axis OA1 and the third facet 13 on the side of the second corner 22 is an obtuse angle, and the angle θ14 formed at the intersection point P14 of the line L14 parallel to the optical axis OA1 and the fourth facet 14 on the side of the fourth corner 24 is an obtuse angle. In this embodiment, in the second posture, the angle θ2 formed at the intersection point P2 of the line L1 parallel to the optical axis OA1 and the third corner 23 on the side of the second facet 13 is 45°. That is, θ13 = θ14 = 135°.

[0058] like Figure 3DAs shown, the second area Ar2 is irradiated with laser (step S4, second process). In this embodiment, the second area Ar2 is the area formed by the third face 13, the third corner 23, and the fourth face 14. Therefore, the third face 13, the third corner 23, and the fourth face 14 can be irradiated in one process, so the number of processes can be reduced compared to the case where the third face 13 and the fourth face 14 are irradiated in two different processes.

[0059] Through the first and second processes described above, laser light can be applied to the first facet 11, second facet 12, third facet 13, and fourth facet 14 throughout the entire circumference of the flat conductor 1, thus removing the insulating film 3 (refer to...) roughly throughout the entire circumference. Figure 1 However, since each corner is formed with a cross-sectional arc shape, and laser light is irradiated from the side relative to the front ends of the second corner 22 and the fourth corner 24, it is possible that a small amount of insulating film may remain at the front ends of each of the second corner 22 and the fourth corner 24. Therefore, in this embodiment, regarding the second corner 22 and the fourth corner 24, after performing the first and second processes, laser light is further irradiated from the front end side of the corner.

[0060] Furthermore, since the insulating film that may remain at the front ends of the second corner 22 and the fourth corner 24 is removed at this time, removal can be achieved even if the laser output is set to a low level lower than that of the first and second processes. Therefore, in this embodiment, after the second process is completed, the flat wire 1 is removed from the laser irradiation device and placed in another low-output laser irradiation device to perform the following processes.

[0061] After the second process is completed, as Figure 4A As shown, the flat conductor 1 is rotated 90° from the second posture and then positioned in the low-output laser irradiation device in a third posture (step S5). In this embodiment, the third posture is a posture in which the second corner portion 22 is positioned opposite the laser irradiation portion 6 and tilted relative to the optical axis OA2 of the laser. That is, the third posture is a posture in which the angle θ15 formed at the intersection point P15 of the straight line L15 parallel to the optical axis OA2 and the second face portion 12 is an obtuse angle on the side of the first corner portion 21, and the angle θ16 formed at the intersection point P16 of the straight line L16 parallel to the optical axis OA2 and the third face portion 13 is an obtuse angle on the side of the third corner portion 23. In this embodiment, in the third posture, the second face portion 12 and the third face portion 13 are set such that the angle θ3 formed at the intersection point P3 of the straight line L1 in the direction parallel to the optical axis OA2 and the side of the second corner portion 22 is 45°. That is, θ15 = θ16 = 135°.

[0062] like Figure 4BAs shown, laser light is irradiated into the third range Ar3 (step S6, third process). In this embodiment, the third range Ar3 is the range including the second corner 22. A portion Ar3a of the third range Ar3 overlaps with the end portion that is part of the first range Ar1, and another portion Ar3b of the third range Ar3 overlaps with the end portion that is part of the second range Ar2. The laser light irradiated into the third range Ar3 in the third process is a low-output laser light with a lower output than the laser light irradiated into the first range Ar1 in the first process.

[0063] like Figure 4C As shown, the flat conductor 1 is rotated 180° from the third posture and positioned in the laser irradiation device in a fourth posture (step S7). In this embodiment, the fourth posture is a posture in which the fourth corner portion 24 is positioned opposite the laser irradiation portion 6 and tilted relative to the optical axis OA2 of the laser. That is, the fourth posture is a posture in which the angle θ17 formed on the side of the third corner portion 23 at the intersection point P17 of the straight line L17 parallel to the optical axis OA2 and the fourth face portion 14 is an obtuse angle, and the angle θ18 formed on the side of the first corner portion 21 at the intersection point P18 of the straight line L18 parallel to the optical axis OA2 and the first face portion 11 is an obtuse angle. In this embodiment, in the fourth posture, the angle θ4 formed on the side of the fourth corner portion 24 at the intersection point P4 of the straight line L1 in the direction parallel to the optical axis OA2 is 45°. That is, θ17 = θ18 = 135°.

[0064] like Figure 4D As shown, laser light is irradiated into the fourth range Ar4 (step S8, fourth process). In this embodiment, the fourth range Ar4 is the range including the fourth corner 24. A portion Ar4a of the fourth range Ar4 overlaps with the end portion that is part of the second range Ar2, and another portion Ar4b of the fourth range Ar4 overlaps with the end portion that is part of the first range Ar1. The laser light irradiated into the fourth range Ar4 in the fourth process is a low-output laser light with a lower output than the laser light irradiated into the first range Ar1 in the first process.

[0065] By performing the first to fourth steps described above, an insulating film 3 (refer to) is formed on the surface. Figure 1 A flat conductor 1 is irradiated with a laser, which can remove the insulating film 3.

[0066] As explained above, according to the manufacturing method of the flat conductor 1 of this embodiment, laser light is irradiated in a first position. Therefore, in one laser irradiation step performed while the flat conductor 1 is fixed, two adjacent planar portions and one corner between them can be irradiated. As a result, in order to reduce the number of steps, it is not necessary to apply an absorbent coating to the corner of the flat conductor 1 before irradiating the laser. Therefore, the number of steps is small, and additional steps such as coating are not required.

[0067] Furthermore, according to the manufacturing method of the flat conductor 1 in this embodiment, after irradiating with laser in a first posture, laser is irradiated in a second posture. Based on the laser irradiation in the second posture, it is also possible to irradiate two adjacent planar portions and a corner portion between them in a single laser irradiation process while fixing the flat conductor 1, so the operation of irradiating the entire circumference of the flat conductor 1 with laser can be achieved in a minimum of two steps.

[0068] Furthermore, according to the manufacturing method of the flat conductor 1 in this embodiment, after performing the first and second processes, the third and fourth processes are performed to irradiate the second corner 22 and the fourth corner 24 with laser. Therefore, by forming each corner into a cross-sectional arc shape, even if a small amount of insulating film remains at the leading edge of each of the second corner 22 and the fourth corner 24, the generation of insulating film residue can be suppressed. Moreover, compared to the laser used in the first and second processes, the laser output at this time is low. Therefore, by setting the first and second processes and the third and fourth processes on different production lines, a high-output laser irradiation device can be used in the production line of the first and second processes, and a low-output laser irradiation device can be used in the production line of the third and fourth processes. This reduces production time and, compared to using a high-output laser irradiation device in the production line of the third and fourth processes, suppresses the increase in cost.

[0069] Furthermore, according to the manufacturing method of the flat conductor 1 in this embodiment, in the third step, a portion Ar3a of the third range Ar3 irradiated with laser overlaps with the end portion that is part of the first range Ar1, and another portion Ar3b overlaps with the end portion that is part of the second range Ar2. Similarly, in the fourth step, a portion Ar4a of the fourth range Ar4 irradiated with laser overlaps with the end portion that is part of the second range Ar2, and another portion Ar4b overlaps with the end portion that is part of the first range Ar1. Therefore, laser irradiation can be performed without gaps at each of the boundary portions between the first range Ar1 and the third range Ar3, the third range Ar3 and the second range Ar2, the second range Ar2 and the fourth range Ar4, and the fourth range Ar4 and the first range Ar1. Thus, the removal of the insulating film 3 can be achieved with high precision.

[0070] Furthermore, while the above embodiment describes the case where the first and second processes, and the third and fourth processes, are set up on different production lines, it is not limited to this. For example, the first and second processes, and the third and fourth processes, can be set up on a continuous production line, in which case the generation of insulating film residue can also be suppressed. In this case, it is not necessary to reposition the flat wire 1 to a different laser irradiation device, thus improving workability. In addition, in this case, the laser output in the third and fourth processes can be lower than the laser output in the first and second processes.

[0071] Furthermore, in this embodiment, the third and fourth steps are described after the execution of the first and second steps, but this is not a limitation; the first and second steps may also be executed after the execution of the third and fourth steps. Additionally, for example, if the corners are right-angled in cross-section, and the insulating film residue can be generated using only the first and second steps, the third and fourth steps may be omitted.

[0072] Furthermore, although the first range Ar1 in this embodiment is described as being composed of the first face portion 11, the first corner portion 21, and the second face portion 12, it is not limited to this. For example, it could also be composed of the fourth corner portion 24, the first face portion 11, the first corner portion 21, the second face portion 12, and the second corner portion 22. Similarly, although the second range Ar2 in this embodiment is described as being composed of the third face portion 13, the third corner portion 23, and the fourth face portion 14, it is not limited to this. For example, it could also be composed of the second corner portion 22, the third face portion 13, the third corner portion 23, the fourth face portion 14, and the fourth corner portion 24. Therefore, for example, when the fourth corner portion 24 and the second corner portion 22 are shaped like right angles in cross-section, after the execution of the first and second steps, if it is difficult to leave insulating film residue at each of the leading ends of the fourth corner portion 24 and the second corner portion 22, by performing only the first and second steps, it is possible to remove the insulating film 3 of the flat wire 1 throughout the entire circumference, including the fourth corner portion 24 and the second corner portion 22.

[0073] Furthermore, although this embodiment describes a situation where a portion of the third range Ar3, Ar3a, overlaps with the end portion of the first range Ar1, and another portion of Ar3b overlaps with the end portion of the second range Ar2, it is not limited to this. For example, the third range Ar3 can be defined as a range Ar30 whose two ends do not overlap with the first range Ar1 and the second range Ar2, respectively (see reference). Figure 4BSimilarly, in this embodiment, although it has been described that a portion Ar4a of the fourth range Ar4 overlaps with the end that is part of the second range Ar2, and another portion Ar4b overlaps with the end that is part of the first range Ar1, it is not limited thereto. For example, the fourth range Ar4 may also be a range Ar40 whose two ends do not overlap with the first range Ar1 and the second range Ar2 respectively (see...). Figure 4D In the above cases, the range of laser irradiation can be narrowed in the third or fourth process, thus shortening the operation time.

[0074] Furthermore, in this embodiment, although the angle θ1 formed at the intersection of the first face 11 and the second face 12 with the straight line L1 parallel to the optical axis in the first posture at the first corner 21 side, the angle θ2 formed at the intersection of the third face 13 and the fourth face 14 with the straight line L1 parallel to the optical axis in the second posture at the third corner 23 side, the angle θ3 formed at the intersection of the second face 12 and the third face 13 with the straight line L1 parallel to the optical axis in the third posture at the second corner 22 side, and the angle θ4 formed at the intersection of the fourth face 14 and the first face 11 with the straight line L1 parallel to the optical axis in the fourth posture at the fourth corner 24 side are all 45°, it is not limited to this.

[0075] As long as the aforementioned angles θ1 to θ4 are greater than 0° and less than 90°, two planar portions can be irradiated in a single laser irradiation process performed with the flat conductor 1 fixed. The side with the optical axis nearly perpendicular applies high energy efficiency to the planar portion, but if one of the two planar portions irradiated in a single irradiation process becomes larger, the other becomes smaller. Therefore, as long as the aforementioned angles θ1 to θ4 are greater than 0° and less than 90°, considering the angles of the two planar portions irradiated in a single irradiation process relative to each optical axis, it is preferably 30° or more and 60° or less, and most preferably 45°.

[0076] Similarly, in this embodiment, the angle θ11 formed at the intersection point P11 of line L11 and the first face 11 on the side of the fourth corner 24, the angle θ12 formed at the intersection point P12 of line L12 and the second face 12 on the side of the second corner 22, the angle θ13 formed at the intersection point P13 of line L13 and the third face 13 on the side of the second corner 22, and the angle θ14 formed at the intersection point P14 of line L14 and the fourth face 14 on the side of the fourth corner 24 are all specified. The angle θ15 formed at the intersection point P15 of line L15 and the second face 12 on the side of the first corner 21, the angle θ16 formed at the intersection point P16 of line L16 and the third face 13 on the side of the third corner 23, the angle θ17 formed at the intersection point P17 of line L17 and the fourth face 14 on the side of the third corner 23, and the angle θ18 formed at the intersection point P18 of line L18 and the first face 11 on the side of the first corner 21 are all 135°, but are not limited to this.

[0077] If the aforementioned angles θ11 to θ18 are obtuse angles, then in a single laser irradiation process performed with the flat conductor 1 fixed, two planar portions can be irradiated. Considering the angles of the two planar portions irradiated in a single irradiation process relative to their respective optical axes, it is preferable that the aforementioned angles θ11 to θ18 are 120° or more and 150° or less, and most preferably 135°.

[0078] Furthermore, although this embodiment describes the case where θ1 = θ2 = θ3 = θ4 = 45° (θ11 to θ18 = 135°), as mentioned above, it is not limited to this. Therefore, for example, the angle θ1 of the first posture in the first process could be 30°, and the angle θ2 of the second posture in the second process could be 60°, making the angles different. Therefore, although this embodiment performs a 180° rotation when moving from the first posture to the second posture, a 90° rotation when moving from the second posture to the third posture, and a 180° rotation when moving from the third posture to the fourth posture, it is not limited to this, and the rotation angle can be adjusted according to θ1, θ2, θ3, and θ4.

[0079] <Second Implementation>

[0080] Next, refer to Figure 5Figure 7 will be used to describe the second embodiment of the present invention in detail. In this embodiment, the structure differs from the first embodiment in the following aspects: after the execution of the first step, the first posture is maintained while the fifth region Ar5, including the fourth corner 24, and the sixth region Ar6, including the second corner 22, are further irradiated with laser; after the execution of the second step, the second posture is maintained while the seventh region Ar7, including the second corner 22, and the eighth region Ar8, including the fourth corner 24, are further irradiated with laser. Apart from this, the structure is the same as the first embodiment, so the reference numerals are the same and detailed descriptions are omitted.

[0081] according to Figure 5 The flowchart shown, and Figures 6A to 7C The process diagram shown illustrates the manufacturing method of the flat conductor 1 in this embodiment. Furthermore, in Figures 6A to 7C In the diagram, the insulating film is represented by a thick solid line, and the laser is represented by an arrow.

[0082] First, the first step is the same as in the first implementation method. That is, as follows: Figure 6A As shown, the flat wire 1 is positioned in the laser irradiation device in a first posture (step S1). Next, as... Figure 6B As shown, a laser is irradiated into the first area Ar1 (step S2, first process). Here, the first area Ar1 is the area formed by the fourth corner 24, the first face 11, the first corner 21, the second face 12, and the second corner 22.

[0083] Moreover, such as Figure 6C As shown, with the flat conductor 1 in a first posture, laser light is irradiated onto a fifth region Ar5 containing the fourth corner 24 and a sixth region Ar6 containing the second corner 22 (step S11, fifth process). The fifth region Ar5 only needs to contain at least the fourth corner 24; in this embodiment, it is defined as the region containing the fourth corner 24 and the end of the first face 11 continuous therewith. The sixth region Ar6 only needs to contain at least the second corner 22; in this embodiment, it is defined as the region containing the second corner 22 and the end of the second face 12 continuous therewith. That is, at least a portion of the fifth region Ar5 and the sixth region Ar6 overlaps with the end of the first region Ar1.

[0084] Next, the second step is the same as in the first embodiment. That is, as follows: Figure 7A As shown, the flat wire 1 is rotated 180° and positioned in a second posture (step S3). Next, as... Figure 7B As shown, a laser is irradiated into the second region Ar2 (step S4, second process). The second region Ar2 here is the region formed by the second corner 22, the third face 13, the third corner 23, the fourth face 14, and the fourth corner 24.

[0085] Moreover, such as Figure 7C As shown, with the flat conductor 1 in the second posture, laser light is irradiated onto the seventh range Ar7, which includes the second corner 22, and the eighth range Ar8, which includes the fourth corner 24 (step S12, sixth process). The seventh range Ar7 only needs to include at least the second corner 22; in this embodiment, it is defined as the range including the second corner 22 and the end of the third face 13 that is continuous therewith. The eighth range Ar8 only needs to include at least the fourth corner 24; in this embodiment, it is defined as the range including the fourth corner 24 and the end of the fourth face 14 that is continuous therewith. That is, at least a portion of the seventh range Ar7 and the eighth range Ar8 overlaps with the end of the second range Ar2.

[0086] Thus, in the fifth and sixth processes, the second corner 22 and the fourth corner 24, which are prone to insulation film residue, are concentratedly irradiated with laser, thereby locally increasing the input heat. Therefore, even if the flat wire 1 is set to the first or second posture, the generation of insulation film residue at the second corner 22 and the fourth corner 24 can be suppressed.

[0087] As explained above, the manufacturing method of the flat conductor 1 according to this embodiment involves irradiating the laser in a first posture and then in a second posture. Therefore, in a single laser irradiation step performed while the flat conductor 1 is fixed, two adjacent planar portions, two corners at their ends, and one corner between them can be irradiated, enabling the laser irradiation of the entire circumference of the flat conductor 1 to be completed in a minimum of two steps. Consequently, to reduce the number of steps, it is unnecessary to apply an absorbent coating to the corners of the flat conductor 1 before laser irradiation. Therefore, the number of steps is small, and additional steps such as coating are not required.

[0088] Furthermore, according to the manufacturing method of the flat conductor 1 in this embodiment, after performing the first step, while the flat conductor 1 is in a first posture, laser is irradiated onto the fifth range Ar5 and the sixth range Ar6. Additionally, after performing the second step, while the flat conductor 1 is in a second posture, laser is irradiated onto the seventh range Ar7 and the eighth range Ar8. Therefore, in the fifth and sixth steps, laser is concentrated on the second corner 22 and the fourth corner 24, where insulating film residue is prone to occur, thereby locally increasing the input heat. As a result, the generation of insulating film residue at the second corner 22 and the fourth corner 24 is suppressed, and the flat conductor 1 does not need to be set to a posture other than the first or second posture. Therefore, the flat conductor 1 only needs to be rotated once, the number of steps is reduced, and additional steps such as coating are not required.

[0089] Furthermore, although the second embodiment described above describes the case where the fifth step is performed after the first step and the sixth step is performed after the second step, it is not limited to this. The first step may be performed after the fifth step, or the second step may be performed after the sixth step.

[0090] <Third Implementation Method>

[0091] Next, refer to Figures 8-9D The third embodiment of the present invention will be described in detail. In this embodiment, the structure differs from the first embodiment in that, in the first step, a high-output laser is irradiated onto the fifth range Ar5 containing the fourth corner portion 24 and the sixth range Ar6 containing the second corner portion 22, and in the second step, a high-output laser is irradiated onto the seventh range Ar7 containing the second corner portion 22 and the eighth range Ar8 containing the fourth corner portion 24. Apart from this, the structure is the same as the first embodiment, so the reference numerals are the same and detailed descriptions are omitted.

[0092] according to Figure 8 The flowchart shown, and Figures 9A to 9D The process diagram shown illustrates the manufacturing method of the flat conductor 1 in this embodiment. Furthermore, in Figures 9A to 9D In the diagram, the insulating film is represented by a thick solid line, and the laser is represented by an arrow.

[0093] First, such as Figure 9A As shown, the flat wire 1 is positioned in the laser irradiation device in a first posture (step S1). Then, as... Figure 9B As shown, laser light is irradiated into the first range Ar1 (step S21, first process). The first range Ar1 is the range formed by the fourth corner 24, the first face 11, the first corner 21, the second face 12, and the second corner 22. Here, within the first range Ar1, compared to the range Ar1a other than the fifth range Ar5 and the sixth range Ar6 within the first range Ar1, a high-output laser is irradiated into the fifth range Ar5 (containing the fourth corner 24) and the sixth range Ar6 (containing the second corner 22).

[0094] Next, as Figure 9C As shown, the flat wire 1 is rotated 180° and positioned in the laser irradiation device in a second posture (step S3). Then, as... Figure 9DAs shown, laser light is irradiated into the second range Ar2 (step S22, second process). Here, the second range Ar2 is the range formed by the second corner 22, the third face 13, the third corner 23, the fourth face 14, and the fourth corner 24. Here, within the second range Ar2, a high-output laser, with an output higher than that of the range Ar2a other than the seventh range Ar7 and the eighth range Ar8 within the second range Ar2, is irradiated into the seventh range Ar7 (containing the second corner 22) and the eighth range Ar8 (containing the fourth corner 24).

[0095] Thus, in the first and second processes, high-output lasers are irradiated on the second corner 22 and the fourth corner 24, which are prone to insulation film residue. Therefore, even if the flat wire 1 is set to the first or second posture, the generation of insulation film residue in the second corner 22 and the fourth corner 24 can be suppressed.

[0096] As explained above, the manufacturing method of the flat conductor 1 according to this embodiment involves irradiating the laser in a first posture and then in a second posture. Therefore, in a single laser irradiation step performed while the flat conductor 1 is fixed, two adjacent planar portions, two corners at their ends, and one corner between them can be irradiated, enabling the laser irradiation of the entire circumference of the flat conductor 1 to be completed in a minimum of two steps. Consequently, to reduce the number of steps, it is unnecessary to apply an absorbent coating to the corners of the flat conductor 1 before laser irradiation. Therefore, the number of steps is small, and additional steps such as coating are not required.

[0097] Furthermore, according to the manufacturing method of the flat conductor 1 in this embodiment, in the first step, a high-output laser is irradiated into the fifth range Ar5 and the sixth range Ar6. In the second step, a high-output laser is irradiated into the seventh range Ar7 and the eighth range Ar8. Therefore, in the first and second steps, the second corner 22 and the fourth corner 24, which are prone to insulation film residue, are irradiated with a high-output laser, locally increasing the input heat. As a result, the generation of insulation film residue at the second corner 22 and the fourth corner 24 is suppressed, and the flat conductor 1 does not need to be set to a position other than the first or second position. Therefore, the flat conductor 1 only needs to be rotated once, the number of steps is reduced, and additional steps such as coating are not required.

[0098] <Fourth Implementation>

[0099] Next, refer to Figures 10-12C The fourth embodiment of the present invention will be described in detail. In this embodiment, the structure differs from the first embodiment in that two laser irradiation devices are provided sandwiching the flat wire 1. Apart from this, the structure is the same as the first embodiment, so the reference numerals are the same and detailed descriptions are omitted.

[0100] like Figures 11A to 11C As shown, the first irradiation section 51 of the first laser irradiation device irradiating the first laser and the second irradiation section 52 of the second laser irradiation device irradiating the second laser are configured to irradiate lasers in opposing directions. That is, the optical axis OA1 of the first laser and the optical axis OA2 of the second laser are arranged parallel to each other. A flat conductor 1 is disposed between the first irradiation section 51 and the second irradiation section 52. The first laser irradiation device and the second laser irradiation device have the same structure as the laser irradiation device of the first embodiment described above, so detailed description is omitted.

[0101] The following is based on Figure 10 The flowchart and Figures 11A to 12C The process diagram shown illustrates the manufacturing method of the flat conductor 1 in this embodiment. Furthermore, in Figures 11A to 12C In the diagram, the insulating film is represented by a thick solid line, and the laser is represented by an arrow.

[0102] First, such as Figure 11A As shown, the flat wire 1 is positioned between the first irradiation section 51 and the second irradiation section 52 in a first posture (step S31). In this embodiment, the first posture is a posture in which the first facet 11 and the second facet 12 are opposite to the first irradiation section 51 and are inclined relative to the optical axis OA1 of the first laser. That is, the first posture is a posture in which the angle θ11 formed at the intersection point P11 of the straight line L11 parallel to the optical axis OA1 and the first facet 11 on the side of the fourth corner 24 is an obtuse angle, and the angle θ12 formed at the intersection point P12 of the straight line L12 parallel to the optical axis OA1 and the second facet 12 on the side of the second corner 22 is an obtuse angle. In this embodiment, in the first posture, the angle θ1 formed at the intersection point P1 of the straight line L1 parallel to the optical axis OA1 of the first laser and the side of the first corner 21 is 45°. That is, θ11 = θ12 = 135°.

[0103] Furthermore, in the first posture, the third facet 13 and the fourth facet 14 are positioned opposite the second irradiation unit 52, and the third facet 13 and the fourth facet 14 are inclined relative to the optical axis OA2 of the second laser. That is, in the first posture, the angle θ23 formed at the intersection point P23 of the straight line L23 parallel to the optical axis OA2 and the third facet 13 on the side of the second corner 22 is an obtuse angle, and the angle θ24 formed at the intersection point P24 of the straight line L24 parallel to the optical axis OA2 and the fourth facet 14 on the side of the fourth corner 24 is an obtuse angle. In this embodiment, in the first posture, the angle θ2 formed at the intersection point P2 of the straight line L2 parallel to the optical axis OA2 of the second laser on the side of the third corner 23 is 45°. That is, θ23 = θ24 = 135°.

[0104] like Figure 11B As shown, a first laser is irradiated from the first irradiation unit 51 into the first range Ar1 (step S32, first process). In this embodiment, the first range Ar1 is the range formed by the first face portion 11, the first corner portion 21, and the second face portion 12. Then, without rotating the flat conductor 1, as... Figure 11C As shown, a second laser is irradiated from the second irradiation unit 52 into the second range Ar2 (step S33, second process). In this embodiment, the second range Ar2 is the range formed by the third face portion 13, the third corner portion 23, and the fourth face portion 14.

[0105] Through the first and second processes described above, laser light can be applied to the first facet 11, second facet 12, third facet 13, and fourth facet 14 throughout the entire circumference of the flat conductor 1, thus removing the insulating film 3 (refer to...) roughly throughout the entire circumference. Figure 1 However, since each corner is formed with a cross-sectional arc shape, and laser light is irradiated from the side relative to the front ends of the second corner 22 and the fourth corner 24, it is possible that a small amount of insulating film may remain at the front ends of each of the second corner 22 and the fourth corner 24. Therefore, in this embodiment, regarding the second corner 22 and the fourth corner 24, after performing the first and second processes, laser light is further irradiated from the front end side of the corner.

[0106] Furthermore, since the insulating film that may remain on the front ends of the second corner 22 and the fourth corner 24 is removed at this time, removal can be achieved even with the laser output set to low, compared to the first and second processes. Therefore, in this embodiment, after the second process is completed, the flat wire 1 is removed from the laser irradiation device, placed in another low-output laser irradiation device, and the following process is performed.

[0107] like Figures 12A-12C As shown, the first irradiation section 61 of the first laser irradiation device irradiating a low-output first laser and the second irradiation section 62 of the second laser irradiation device irradiating a low-output second laser are configured to irradiate lasers in opposite directions. That is, the optical axes OA1 of the first laser and OA2 of the second laser are arranged parallel to each other. A flat conductor 1 is disposed between the first irradiation section 61 and the second irradiation section 62. Each low-output laser irradiation device has the same structure as the low-output laser irradiation device of the first embodiment described above, so detailed description is omitted.

[0108] After the second process is completed, as Figure 12AAs shown, with the flat conductor 1 rotated 90° from the first posture, it is placed in the low-output laser irradiation device in the third posture (step S34). In this embodiment, the third posture is a posture in which the second corner portion 22 is opposed to the irradiation portion 61 of the first laser, and the second corner portion 22 is tilted relative to the optical axis of the first laser. That is, the third posture is a posture in which the angle θ15 formed on the side of the first corner portion 21 at the intersection point P15 of the straight line L15 parallel to the optical axis OA1 and the second face portion 12 is an obtuse angle, and the angle θ16 formed on the side of the third corner portion 23 at the intersection point P16 of the straight line L16 parallel to the optical axis OA1 and the third face portion 13 is an obtuse angle. In this embodiment, in the third posture, the second face portion 12 and the third face portion 13 are set such that the angle θ3 formed on the side of the second corner portion 22 at the intersection point P3 of the straight line L1 in the direction parallel to the optical axis OA1 is 45°. That is, θ15 = θ16 = 135°.

[0109] Furthermore, in the third posture, the fourth corner portion 24 is positioned opposite the second irradiation portion 62, and the fourth corner portion 24 is inclined relative to the optical axis OA2 of the second laser. That is, in the third posture, the angle θ27 formed on the side of the third corner portion 23 at the intersection point P27 of the straight line L27 parallel to the optical axis OA2 and the fourth face portion 14 is an obtuse angle, and the angle θ28 formed on the side of the first corner portion 21 at the intersection point P28 of the straight line L28 parallel to the optical axis OA2 and the first face portion 11 is an obtuse angle. In this embodiment, in the third posture, the angle θ4 formed on the side of the fourth corner portion 24 at the intersection point P4 of the straight line L2 parallel to the optical axis OA2 is 45°. That is, θ27 = θ28 = 135°.

[0110] like Figure 12B As shown, a first laser is irradiated from the first irradiation unit 61 into the third range Ar3 (step S35, third process). In this embodiment, the third range Ar3 is the range including the second corner 22. A portion Ar3a of the third range Ar3 overlaps with the end portion that is part of the first range Ar1, and another portion Ar3b of the third range Ar3 overlaps with the end portion that is part of the second range Ar2. The first laser irradiating the third range Ar3 in the third process is a low-output laser with a lower output than the first laser irradiating the first range Ar1 in the first process.

[0111] Then, without rotating the flat wire 1, as follows: Figure 12CAs shown, a second laser is irradiated from the second irradiation unit 62 into the fourth range Ar4 (step S36, fourth process). In this embodiment, the fourth range Ar4 is the range including the fourth corner portion 24. A portion Ar4a of the fourth range Ar4 overlaps with the end portion that is part of the second range Ar2, and another portion Ar4b of the fourth range Ar4 overlaps with the end portion that is part of the first range Ar1. The second laser irradiating the fourth range Ar4 in the fourth process is a low-output laser with a lower output than the second laser irradiating the first range Ar1 in the first process.

[0112] By performing the first to fourth steps described above, it is possible to form an insulating film 3 (refer to) on the surface. Figure 1 The flat wire 1 is irradiated with a laser to remove the insulating film 3.

[0113] As explained above, according to the manufacturing method of the flat conductor 1 in this embodiment, the first laser and the second laser are irradiated in a first posture. Therefore, in a single irradiation step performed while the flat conductor 1 is fixed, two adjacent planar portions and a corner between them can be irradiated, and the operation of irradiating the entire circumference of the flat conductor 1 with laser can be achieved in a minimum of two steps. As a result, in order to reduce the number of steps, it is not necessary to apply an absorbent coating to the corner of the flat conductor 1 before irradiating the laser. Therefore, the number of steps is small, and additional steps such as coating are not required.

[0114] Furthermore, according to the manufacturing method of the flat wire 1 in this embodiment, the first irradiation unit 51 and the second irradiation unit 52 are arranged with the flat wire 1 sandwiched between them. Therefore, laser light can be continuously irradiated into the first range Ar1 and the second range Ar2 without rotating the flat wire 1 between the first and second processes. Thus, compared with the case where the flat wire 1 is rotated between the first and second processes, the operation time can be shortened.

[0115] Furthermore, according to the manufacturing method of the flat conductor 1 in this embodiment, after performing the first and second processes, the third and fourth processes are performed to irradiate the second corner 22 and the fourth corner 24 with laser. Therefore, by forming each corner into a cross-sectional arc shape, even if a small amount of insulating film remains at the front end of each of the second corner 22 and the fourth corner 24, the generation of insulating film residue can be suppressed. Additionally, although the fourth embodiment described above illustrates the case of providing two laser irradiation devices, it is not limited to this, and three or more laser irradiation devices may also be provided.

[0116] Furthermore, in the fourth embodiment described above, although the second process is performed after the first process is completed, it is not limited to this; the first and second processes can also be performed simultaneously and in parallel. In this case, the operation time can be shortened.

[0117] <Fifth Implementation>

[0118] Next, refer to Figures 13-15B The fifth embodiment of the present invention will be described in detail. In this embodiment, the structure differs from the second embodiment in that it has two laser irradiation devices sandwiching the flat wire 1. Furthermore, in this embodiment, the structure differs from the fourth embodiment in that, after performing the first step, it maintains a first posture and further irradiates the fifth region Ar5 (containing the fourth corner 24) and the sixth region Ar6 (containing the second corner 22) with a first laser; and after performing the second step, it further irradiates the seventh region Ar7 (containing the second corner 22) and the eighth region Ar8 (containing the fourth corner 24) with a second laser. Apart from this, the structure is the same as in the second and fourth embodiments, so the reference numerals are the same and detailed descriptions are omitted.

[0119] according to Figure 13 The flowchart and Figures 14A to 15B The process diagram shown illustrates the manufacturing method of the flat conductor 1 in this embodiment. Furthermore, in Figures 14A to 15B In the diagram, the insulating film is represented by a thick solid line, and the laser is represented by an arrow.

[0120] First, the first step is the same as in the fourth implementation method. That is, as follows: Figure 14A As shown, the flat wire 1 is positioned in the laser irradiation device in a first posture (step S31). Next, as... Figure 14B As shown, the first laser is irradiated from the first irradiation unit 51 into the first range Ar1 (step S32, first process). Here, the first range Ar1 is the range formed by the fourth corner 24, the first face 11, the first corner 21, the second face 12, and the second corner 22.

[0121] Moreover, such as Figure 14C As shown, with the flat conductor 1 in a first posture, a first laser is irradiated from the first irradiation unit 51 onto a fifth range Ar5 containing the fourth corner portion 24 and a sixth range Ar6 containing the second corner portion 22 (step S41, fifth process). The fifth range Ar5 only needs to contain at least the fourth corner portion 24; in this embodiment, it is defined as the range containing the fourth corner portion 24 and the end of the first face portion 11 continuous therewith. The sixth range Ar6 only needs to contain at least the second corner portion 22; in this embodiment, it is defined as the range containing the second corner portion 22 and the end of the second face portion 12 continuous therewith. That is, at least a portion of the fifth range Ar5 and the sixth range Ar6 overlaps with the end of the first range Ar1.

[0122] Then, as Figure 15AAs shown, the second laser is irradiated from the second irradiation section 52 to the second range Ar2 without rotating the flat wire 1 (step S34, second process). Here, the second range Ar2 is the range formed by the second corner 22, the third face 13, the third corner 23, the fourth face 14, and the fourth corner 24.

[0123] Then, as Figure 15B As shown, a second laser is irradiated from the second irradiation unit 52 onto a seventh range Ar7 containing the second corner portion 22 and an eighth range Ar8 containing the fourth corner portion 24 (step S42, sixth process). The seventh range Ar7 only needs to contain at least the second corner portion 22; in this embodiment, it is defined as the range containing the second corner portion 22 and the end portion of the third face portion 13 that is continuous therewith. The eighth range Ar8 only needs to contain at least the fourth corner portion 24; in this embodiment, it is the range containing the fourth corner portion 24 and the end portion of the fourth face portion 14 that is continuous therewith. That is, at least a portion of the seventh range Ar7 and the eighth range Ar8 overlaps with the end portion of the second range Ar2.

[0124] Thus, in the fifth and sixth processes, the second corner 22 and the fourth corner 24, which are prone to insulation film residue, are concentratedly irradiated with laser, thereby locally increasing the input heat. Therefore, even if the flat wire 1 is set to the first or second posture, the generation of insulation film residue at the second corner 22 and the fourth corner 24 can be suppressed.

[0125] As explained above, according to the manufacturing method of the flat conductor 1 in this embodiment, the first laser and the second laser are irradiated in a first posture. Therefore, in a single irradiation step performed while the flat conductor 1 is fixed, two adjacent planar portions, two corner portions at their ends, and one corner portion between them can be irradiated, enabling the irradiation of the entire circumference of the flat conductor 1 with laser in a minimum of two steps. Thus, to reduce the number of steps, it is not necessary to apply an absorbent coating to the corners of the flat conductor 1 before irradiation. Therefore, the number of steps is small, and additional steps such as coating are not required.

[0126] Furthermore, according to the manufacturing method of the flat conductor 1 in this embodiment, the first irradiation unit 51 and the second irradiation unit 52 are arranged with the flat conductor 1 clamped in place. Therefore, lasers can be continuously irradiated onto the sixth range Ar6 and the second range Ar2 without rotating the flat conductor 1 between the first and second processes. Thus, compared with the case where the flat conductor 1 is rotated between the first and second processes, the operation time can be shortened.

[0127] <Sixth Implementation Method>

[0128] Next, refer to Figures 16-17CThe sixth embodiment of the present invention will be described in detail. In this embodiment, the structure differs from the third embodiment in that it has two laser irradiation devices sandwiching the flat wire 1. Furthermore, in this embodiment, the structure differs from the fourth embodiment in that, in the first step, a high-output first laser is irradiated onto the fifth range Ar5 containing the fourth corner 24 and the sixth range Ar6 containing the second corner 22, and in the second step, a high-output second laser is irradiated onto the seventh range Ar7 containing the second corner 22 and the eighth range Ar8 containing the fourth corner 24. Apart from this, the structure is the same as in the third and fourth embodiments, so the reference numerals are the same and detailed descriptions are omitted.

[0129] according to Figure 16 The flowchart and Figure 16 The process diagram shown illustrates the manufacturing method of the flat conductor 1 in this embodiment. Furthermore, in Figures 17A-17C In the diagram, the insulating film is represented by a thick solid line, and the laser is represented by an arrow.

[0130] First, such as Figure 17A As shown, the flat wire 1 is positioned in the laser irradiation device in a first posture (step S31). Then, as... Figure 17B As shown, a first laser is irradiated from the first irradiation unit 51 into a first range Ar1 (step S51, first process). Here, the first range Ar1 is the range formed by the fourth corner portion 24, the first face portion 11, the first corner portion 21, the second face portion 12, and the second corner portion 22. Here, within the first range Ar1, a high-output first laser is irradiated into the fifth range Ar5 (including the fourth corner portion 24) and the sixth range Ar6 (including the second corner portion 22), which is an area Ar1a other than the fifth range Ar5 and the sixth range Ar6 within the first range Ar1.

[0131] Then, without rotating the flat wire 1, as follows: Figure 17C As shown, a second laser is irradiated from the second irradiation unit 52 into the second range Ar2 (step S52, second process). Here, the second range Ar2 is the range formed by the second corner portion 22, the third face portion 13, the third corner portion 23, the fourth face portion 14, and the fourth corner portion 24. Here, within the second range Ar2, a high-output second laser is irradiated into the seventh range Ar7 (containing the second corner portion 22) and the eighth range Ar8 (containing the fourth corner portion 24), which is an area Ar2a other than the seventh range Ar7 and the eighth range Ar8 within the second range Ar2.

[0132] Thus, in the first and second processes, high-output lasers are irradiated on the second corner 22 and the fourth corner 24, which are prone to insulation film residue. Therefore, even if the flat wire 1 is set to the first or second posture, the generation of insulation film residue in the second corner 22 and the fourth corner 24 can be suppressed.

[0133] As explained above, according to the manufacturing method of the flat conductor 1 in this embodiment, the first laser and the second laser are irradiated in a first posture. Therefore, in a single irradiation step performed while the flat conductor 1 is fixed, two adjacent planar portions, two corner portions at their ends, and one corner portion between them can be irradiated, enabling the irradiation of the entire circumference of the flat conductor 1 with laser in a minimum of two steps. Thus, to reduce the number of steps, it is not necessary to apply an absorbent coating to the corners of the flat conductor 1 before irradiation. Therefore, the number of steps is small, and additional steps such as coating are not required.

[0134] Furthermore, according to the manufacturing method of the flat conductor 1 in this embodiment, the first irradiation unit 51 and the second irradiation unit 52 are arranged with the flat conductor 1 in between, so the first range Ar1 and the second range Ar2 can be continuously irradiated with laser without rotating the flat conductor 1 between the first and second processes. Therefore, compared with the case where the flat conductor 1 is rotated between the first and second processes, the operation time can be shortened.

[0135] <Summary of various implementation methods>

[0136] Furthermore, the first to sixth embodiments described above at least have the following structure. The manufacturing method of the flat conductor (1) in the first to sixth embodiments is a manufacturing method of the flat conductor (1) by irradiating the insulating film (3) of the flat conductor (1) with a laser to remove the insulating film (3). The method includes a first step in which four planar portions on the outer side of the flat conductor (1) are arranged in an adjacent order as a first facet (11), a second facet (12), a third facet (13), and a fourth facet (14). The corner between the first facet (11) and the second facet (12) is designated as a first corner (21), the corner between the second facet (12) and the third facet (13) is designated as a second corner (22), the corner between the third facet (13) and the fourth facet (14) is designated as a third corner (23), and the corner between the fourth facet (14) and the first facet (14) is designated as a third corner (23). When the corner between the parts (11) is set as the fourth corner (24), in a first posture in which the first face (11) and the second face (12) are opposite to the irradiation part (5, 6, 51, 61) of the laser, and the angle (θ11) formed on the side of the fourth corner (24) at the intersection (P11) of the straight line (L11) parallel to the optical axis (OA1) of the laser and the first face (11) is an obtuse angle, and the angle (θ12) formed on the side of the second corner (22) at the intersection (P12) of the straight line (L12) parallel to the optical axis (OA1) and the second face (12) is an obtuse angle, the laser is irradiated on a first area (Ar1) including the first face (11), the first corner (21) and the second face (12).

[0137] According to this structure, the laser is irradiated in a first posture and in a second posture. Therefore, in a single irradiation process of the laser while fixing the flat conductor (1), it is possible to irradiate two adjacent planar portions and a corner between them. As a result, in order to reduce the number of processes, it is not necessary to apply an absorbent coating to the corner of the flat conductor (1) before irradiating the laser. Therefore, the number of processes is small, and additional processes such as coating are not required.

[0138] Furthermore, the manufacturing method of the flat conductor (1) in the first to third embodiments includes a second step of irradiating a second area (Ar2) including the third face (13), the third corner (23) and the fourth face (14) with the laser in a second posture state. The second posture is configured such that the third face (13) and the fourth face (14) are facing the irradiation part (5, 6) of the laser, and the angle (θ13) formed at the intersection (P13) of the line (L13) parallel to the optical axis (OA1) and the third face (13) on the side of the second corner (22) is an obtuse angle, and the angle (θ14) formed at the intersection (P14) of the line (L14) parallel to the optical axis (OA1) and the fourth face (14) on the side of the fourth corner (24) is an obtuse angle.

[0139] According to this structure, after irradiating the laser in the first posture, the laser is irradiated in the second posture. By irradiating the laser in the second posture, in one laser irradiation process performed while fixing the flat conductor (1), it is also possible to irradiate two adjacent flat parts and one corner between them, so the operation of irradiating the entire circumference of the flat conductor (1) with laser can be achieved in a minimum of two steps.

[0140] Furthermore, the manufacturing method of the flat conductor (1) in the first embodiment includes a third step of irradiating a third region (Ar3) including the second corner (22) with the laser while in a third posture state. The third posture is configured such that the second corner (22) is facing the irradiation part (6) of the laser, and the angle (θ15) formed on the side of the first corner (21) at the intersection (P15) of the straight line (L15) parallel to the optical axis (OA2) and the second surface part (12) is an obtuse angle, and the third corner (23) is formed at the intersection (P16) of the straight line (L16) parallel to the optical axis (OA2) and the third surface part (13). The angle (θ16) on the side is an obtuse angle; and in the state of the fourth posture, the fourth process of irradiating the fourth range including the fourth corner (24) with the laser, the fourth posture is set such that the fourth corner (24) is opposite to the irradiation part (6) of the laser, and the angle (θ17) formed on the side of the third corner (23) at the intersection (P17) of the straight line (L17) parallel to the optical axis (OA2) and the fourth face (14) is an obtuse angle, and the angle (θ18) formed on the side of the first corner (21) at the intersection (P18) of the straight line (L18) parallel to the optical axis (OA2) and the first face (11) is an obtuse angle.

[0141] According to this structure, even if a small amount of insulating film (3) remains at the front end of the second corner (22) and the fourth corner (24), the generation of insulating film residue can be suppressed.

[0142] In addition, the manufacturing method of the flat conductor (1) in the fourth to sixth embodiments, wherein the laser is a first laser irradiated from the first irradiation unit (51, 61), includes a second step. In the second step, the second laser is irradiated on a second irradiation unit (52, 62) in which the third face (13) and the fourth face (14) are positioned opposite to the second irradiation unit (52, 62) that irradiates a second laser different from the first laser. The angle (θ23) formed at the intersection (P23) of the straight line (L23) parallel to the optical axis (OA2) of the second laser and the third face (13) on the side of the second corner (22) is an obtuse angle. The angle (θ24) formed at the intersection (P24) of the straight line (L24) parallel to the optical axis (OA2) and the fourth face (14) on the side of the fourth corner (24) is an obtuse angle. The second laser is irradiated on a second area (Ar2) including the third face (13), the third corner (23) and the fourth face (14).

[0143] According to this structure, the first laser and the second laser are irradiated in a first posture. Therefore, in a single irradiation process of the laser while the flat conductor (1) is fixed, two adjacent planar portions and a corner between them can be irradiated, and the operation of irradiating the entire circumference of the flat conductor (1) with laser can be achieved in a minimum of two processes. As a result, in order to reduce the number of processes, it is not necessary to apply an absorbent coating to the corner of the flat conductor (1) before irradiating the laser. Therefore, the number of processes is small, and additional processes such as coating are not required. In addition, the irradiation units (51, 61) for irradiating the first laser in the first range (Ar1) and the irradiation units (52, 62) for irradiating the second laser in the second range (Ar2) are respectively arranged, so the first range (Ar1) and the second range (Ar2) can be irradiated continuously or simultaneously without rotating the flat conductor (1) between the first and second processes. Therefore, compared with the case where the flat conductor (1) is rotated between the first and second processes, the operation time can be shortened.

[0144] Furthermore, the manufacturing method of the flat conductor (1) in the fourth embodiment includes a third step, in which, in a state in which the second corner (22) is positioned opposite the first irradiation portion (51, 61), and the angle (θ15) formed on the side of the first corner (21) at the intersection (P15) of the straight line (L15) parallel to the optical axis (OA1) of the first laser and the second face portion (12) is an obtuse angle, and the angle (θ16) formed on the side of the third corner (23) at the intersection (P16) of the straight line (L16) parallel to the optical axis (OA1) of the first laser and the third face portion (13) is an obtuse angle, the third range including the second corner (22) is... (Ar3) Irradiate the first laser; and a fourth step, in which the fourth area including the fourth corner (24) is irradiated with the second irradiation part (52, 62) with the fourth corner (23) facing each other, and the angle (θ27) formed at the intersection (P27) of the line (L27) parallel to the optical axis (OA2) of the second laser and the fourth face (14) is an obtuse angle, and the angle (θ28) formed at the intersection (P28) of the line (L28) parallel to the optical axis (OA2) of the second laser and the first face (11) is an obtuse angle.

[0145] According to this structure, even if a small amount of insulating film (3) remains at the front ends of the second corner (22) and the fourth corner (24), the generation of insulating film residue can be suppressed.

[0146] In addition, in the manufacturing method of the flat conductor (1) of the first and fourth embodiments, a portion (Ar3a) of the third range (Ar3) overlaps with a portion of the first range (Ar1), and another portion (Ar3b) overlaps with a portion of the second range (Ar2), a portion (Ar4a) of the fourth range (Ar4) overlaps with a portion of the second range (Ar2), and another portion (Ar4b) overlaps with a portion of the first range (Ar1).

[0147] According to this structure, laser irradiation can be performed without gaps at each of the boundary portions between the first range (Ar1) and the third range (Ar3), the boundary portion between the third range (Ar3) and the second range (Ar2), the boundary portion between the second range (Ar2) and the fourth range (Ar4), and the boundary portion between the fourth range (Ar4) and the first range (Ar1). Therefore, the removal of the insulating film (3) can be achieved with high precision.

[0148] In addition, in the manufacturing method of the flat conductor (1) of the first to sixth embodiments, the first range (Ar1) includes the fourth corner portion (24) and the second corner portion (22).

[0149] According to this structure, the generation of insulating film residues in the second corner (22) and the fourth corner (24) can be suppressed.

[0150] In addition, in the manufacturing method of the flat conductor (1) of the first to sixth embodiments, the obtuse angle (θ11 to θ18, θ23, θ24, θ27, θ28) is 120° or more and 150° or less.

[0151] Based on this structure, considering the angles of the two planar portions irradiated in a single irradiation process relative to each optical axis, it is possible to achieve equalization of the energy efficiency received by each planar portion from the laser.

[0152] Industrial applications

[0153] The method for manufacturing flat conductors of the present invention can be applied, for example, to a method for manufacturing flat conductors in which the insulating film of the flat conductor is removed by irradiating it with a laser.

[0154] Explanation of reference numerals in the attached figures

[0155] 1…flat wire, 3…insulating film, 5, 6…irradiation section, 11…first face, 12…second face, 13…third face, 14…fourth face, 21…first corner, 22…second corner, 23…third corner, 24…fourth corner, 51, 61…first irradiation section (irradiation part), 52, 62…second irradiation section (irradiation part), Ar1…first range, Ar2…second range, Ar3…third range, Ar3a…part of the third range, Ar 3b…another part of the third range, Ar4…the fourth range, Ar4a…a part of the fourth range, Ar4b…another part of the fourth range, L1, L11~L14…straight lines parallel to the optical axis of the laser (first laser), L2, L15~L18, L23, L24, L27, L28…straight lines parallel to the optical axis of the second laser, OA1, OA2…optical axes, P11~P18, P23, P24, P27, P28…intersection points.

Claims

1. A method for manufacturing a flat conductor, comprising a method for removing the insulating film of a flat conductor by irradiating it with a laser, the method comprising a first step, a second step, a third step, and a fourth step. In the first process described above, When the four planar portions on the outer side of the aforementioned flat conductor are arranged in an adjacent order as a first facet, a second facet, a third facet, and a fourth facet, and the corner between the first facet and the second facet is designated as the first corner, the corner between the second facet and the third facet is designated as the second corner, the corner between the third facet and the fourth facet is designated as the third corner, and the corner between the fourth facet and the first facet is designated as the fourth corner, In a first posture, the laser irradiates a first area including the first face, the first corner, and the second face. This first posture is configured such that the first face and the second face are facing the irradiated portion of the laser, and the angle formed at the intersection of a line parallel to the laser's optical axis and the first face on the fourth corner side is an obtuse angle, and the angle formed at the intersection of a line parallel to the laser's optical axis and the second face on the second corner side is also an obtuse angle. In the second process, while in a second posture, the laser is irradiated onto a second area including the third face, the third corner, and the fourth face. This second posture is configured such that the third and fourth face are facing the irradiated portion of the laser, and the angle formed at the intersection of a line parallel to the optical axis and the third face on the side of the second corner is an obtuse angle, and the angle formed at the intersection of a line parallel to the optical axis and the fourth face on the side of the fourth corner is also an obtuse angle. In the third process, while in a third posture, the laser is irradiated onto a third area including the second corner. The third posture is configured such that the second corner is opposite to the irradiated portion of the laser, and the angle formed at the intersection of a line parallel to the optical axis and the second face is obtuse, and the angle formed at the intersection of a line parallel to the optical axis and the third face is obtuse. In the fourth process, in a fourth posture, the laser is irradiated on a fourth range including the fourth corner. The fourth posture is configured such that the fourth corner is opposite to the irradiation part of the laser, and the angle formed at the intersection of the line parallel to the optical axis and the fourth face is obtuse on the side of the third corner, and the angle formed at the intersection of the line parallel to the optical axis and the first face is obtuse on the side of the first corner.

2. The method for manufacturing a flat conductor according to claim 1, wherein, The aforementioned laser is the first laser emitted from the first irradiation unit. In the second process described above, the second laser is used to irradiate a second area containing the third face and the fourth face, with the second irradiation unit facing the second irradiation unit that irradiates a second laser different from the first laser, and the angle formed at the intersection of the line parallel to the optical axis of the second laser and the third face on the side of the second corner is an obtuse angle, and the angle formed at the intersection of the line parallel to the optical axis and the fourth face on the side of the fourth corner is an obtuse angle.

3. The method for manufacturing a flat conductor according to claim 2, wherein, In the third process described above, the first laser is used to irradiate a third area including the second corner, with the second corner facing the first irradiation portion, and the angle formed at the intersection of the line parallel to the optical axis of the first laser and the second face portion being an obtuse angle, and the angle formed at the intersection of the line parallel to the optical axis of the first laser and the third face portion being an obtuse angle. In the fourth process described above, the fourth area including the fourth corner is irradiated with the second irradiation unit, and the angle formed at the intersection of the line parallel to the optical axis of the second laser and the fourth face is an obtuse angle on the side of the third corner, and the angle formed at the intersection of the line parallel to the optical axis of the second laser and the first face is an obtuse angle on the side of the first corner, in a state where the second laser is positioned so that the fourth corner is opposite to the second irradiation unit, and the second laser is irradiated with the second laser.

4. The method for manufacturing a flat conductor according to claim 1 or 3, wherein, A portion of the aforementioned third range overlaps with a portion of the aforementioned first range, and another portion overlaps with a portion of the aforementioned second range. A portion of the aforementioned fourth range overlaps with a portion of the aforementioned second range, and another portion overlaps with a portion of the aforementioned first range.

5. The method for manufacturing a flat conductor according to any one of claims 1 to 3, wherein, The aforementioned first range includes the aforementioned fourth corner portion and the aforementioned second corner portion.

6. The method for manufacturing a flat conductor according to any one of claims 1 to 3, wherein, The obtuse angles mentioned above are 120° or higher and 150° or lower.

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