Ultra-soft flat cable structure and preparation method thereof

Abstract

The invention relates to a structure of an ultra-soft flat cable and a preparation method of the ultra-soft flat cable. The structure of the ultra-flexible flat cable comprises a copper wire layer extending along the X direction, a first insulating layer and a second insulating layer covering the upper part and the lower part of the copper wire layer, and opening areas which are arranged at two ends of the flat cable and are exposed out of the end parts of the copper wire to form golden fingers. And a reinforcing plate is adhered outside the insulating layer in the golden finger area so as to enhance the structural stability and durability. Production is carried out in a whole-course roll-shaped operation mode, the conductor and the thin film material are attached through a hot pressing process, then punching is carried out at a designated position to form the golden finger area, and meanwhile, the reinforcing plate is attached. And finally, cutting into a specified length to form a finished product. According to the method, the technological process is simplified, the machining time is effectively shortened, the production precision and efficiency are improved, and errors are reduced, so that the ultra-soft flat cable is suitable for high-frequency bending application scenes and has stable electrical performance and mechanical strength.

Description

Technical Field

[0001] The present invention relates to the technical field of flexible flat cables (FFC), and in particular to the structure of an ultra-flexible flat cable and a preparation method thereof. Background Art

[0002] At present, ultra soft flexible cable (USFC) is mainly produced by injection molding machine using extrusion process. PVC rubber is added into the injection molding machine and produced by extrusion process. Figure 1 The coiled original wire 101 is as shown in FIG. Figure 2 After being flattened and cut to a specified length, the Figure 3 Cross-sectional structure (the outer part of the spaced copper wires 11 is completely covered with an insulating layer 12 made of PVC rubber) and Figure 4 The flat-shaped semi-finished cable 102 is then processed to remove the PVC insulation material at both ends of the cut-to-piece semi-finished cable 102, so that the two ends of the semi-finished cable 102 along the X direction of the copper wire 11 are respectively opened on the same surface, so that the exposed ends of the copper wire 11 are formed as shown in the figure. Figure 5 , Figure 6 The golden finger 111 shown, finally Figure 6 As shown, a reinforcing plate 13 is attached to the outer surface of the insulating layer 12 corresponding to the position of the gold finger 111 to form the ultra-soft flat cable (USFC) 10 .

[0003] As can be seen from the above, the current production process of the ultra-soft flat cable 10 includes two forms: a roll-shaped operation (production of the original cable 101) in which the coil is stretched and flattened, and a linear operation (production of the flat cable semi-finished product 102 to the ultra-soft flat cable 10) in which the coil is cut into small sections. The finished product in the roll-shaped operation is a long strip that can be wound and has no length limit; while the finished product in the linear operation is a line of a specific length, which has a smaller scope of application, lower processing accuracy, requires multiple processing and takes a long time. In addition, in the existing process, the gold fingers 111 at both ends of the finished line need to be processed separately, and the reinforcing plates 13 also need to be attached separately, which increases the error of the finished product and reduces the production efficiency. Summary of the invention

[0004] In view of the above situation, the purpose of the present invention is to provide a structure of an ultra-soft flat cable and a preparation method thereof, by using a full-process roll-to-roll operation method to bond the original ultra-soft flat cable, and allow simultaneous processing in the gold finger area, and simultaneously affix a reinforcement plate to the back of the finished product, to achieve roll-to-roll bonding under roll-to-roll operation, and then cut into finished products of specified length, thereby reducing processing time, improving accuracy, effectively reducing errors and improving production efficiency.

[0005] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is to provide a structure of an ultra-soft flat cable, including:

[0006] A copper wire layer extending along an X direction, wherein the copper wire layer has a first surface and a second surface opposite to each other;

[0007] a first insulating layer, attached to the first surface of the copper wire layer along the X direction;

[0008] a second insulating layer, attached to the second surface of the copper wire layer along the X direction;

[0009] a first opening, located at one end of the ultra-soft flat cable along the X direction and formed at an end of the first insulating layer or the second insulating layer; the first opening exposes one end of the copper wire layer and forms a first gold finger;

[0010] a second opening, located at the other end of the ultra-soft flat cable along the X direction and formed at the end of the first insulating layer or the second insulating layer; the second opening exposes the other end of the copper wire layer and forms a second gold finger;

[0011] A first reinforcing plate, attached to the first insulating layer or the second insulating layer corresponding to the position where the first opening is opened;

[0012] A second reinforcing plate, attached to the first insulating layer or the second insulating layer corresponding to the position where the second opening is opened;

[0013] It is characterized in that

[0014] The ultra-soft flat cable has two opposite ends extending along the X direction.

[0015] The end face of one end is formed by a flush cut surface formed by stacking and cutting the first insulating layer and the copper wire layer; the end face of the other end is formed by a flush cut surface formed by stacking and cutting the second insulating layer and the copper wire layer; or,

[0016] The end faces at both ends are formed by cutting and stacking the first insulating layer and the copper wire layer to form a flush cut surface; or

[0017] The end faces at both ends are formed by the flush cut surfaces formed by overlapping and cutting the second insulating layer and the copper wire layer.

[0018] A further improvement in the structure of the ultra-soft flat cable of the present invention is that the ultra-soft flat cable also includes a first reinforcement plate and a second reinforcement plate; wherein the first reinforcement plate is attached to the first insulating layer or the second insulating layer corresponding to the opening position of the first opening, and the first reinforcement plate and the first opening are located on the opposite side surfaces of the copper wire layer; the second reinforcement plate is attached to the first insulating layer or the second insulating layer corresponding to the opening position of the second opening, and the second reinforcement plate and the second opening are located on the opposite side surfaces of the copper wire layer.

[0019] A further improvement in the structure of the ultra-soft flat cable of the present invention is that the ultra-soft flat cable has two opposite ends extending along the X direction, wherein the end face of one end is composed of a flush surface formed by overlapping and cutting the first insulating layer, the copper wire layer and the first reinforcing plate; the end face of the other end is composed of a flush surface formed by overlapping and cutting the second insulating layer, the copper wire layer and the second reinforcing plate; or, the end faces of both ends are composed of flush surfaces formed by overlapping and cutting the first insulating layer, the copper wire layer and the first reinforcing plate; or, the end faces of both ends are composed of flush surfaces formed by overlapping and cutting the second insulating layer, the copper wire layer and the second reinforcing plate.

[0020] The present invention further provides a method for preparing a structure of an ultra-soft flat cable, the method comprising the following steps:

[0021] Conductor preparation step: providing a conductor as a wire core, and arranging the conductor on a production process line through a traction roller of a coiling operation device;

[0022] The film material providing step includes providing a film material as an insulating layer, wherein the film material includes a first film layer and a second film layer, and arranging the first film layer and the second film layer on a production process line through a plurality of hot pressing wheel groups of a roll-type operation device;

[0023] Punching processing step: removing the film material at a designated punching position on the film material to form a punching hole;

[0024] The step of hot pressing the film material: laminating the first film layer and the second film layer on the upper and lower sides of the conductor respectively, and hot pressing the first film layer and the second film layer by a hot pressing wheel group of a roll-type operation equipment, so that the first film layer and the second film layer are tightly combined on the upper and lower sides of the conductor to form a composite layer structure; the local conductor area of ​​the composite layer structure is exposed from the punching hole to form a gold finger area;

[0025] A reinforcing plate laminating step: laminating the reinforcing plate relative to the gold finger area onto the film material on the other side of the composite layer structure;

[0026] Cutting step: cutting the composite layer structure after punching and hot pressing from the middle part of the gold finger area and the overlapping area of ​​the reinforcement plate to form an independent piece of ultra-soft flat cable finished product.

[0027] A further improvement of the method for preparing the structure of the ultra-soft flat cable of the present invention is that the conductor is a conductive material selected from tinned flat copper wire, oxygen-free copper wire, aluminum wire or aluminum foil Mylar tape.

[0028] A further improvement of the method for preparing the structure of the ultra-soft flat cable of the present invention is that the film material is selected from one of PVC, TPE or TPU.

[0029] A further improvement in the method for preparing the structure of the ultra-soft flat cable of the present invention is that the roll-up operating equipment includes a first hot pressing wheel group, a second hot pressing wheel group and a third hot pressing wheel group; wherein the first hot pressing wheel group is arranged after the punching position, and is used to hot press the first film layer and the second film layer to the outside of the conductor; the second hot pressing wheel group is arranged after the first hot pressing wheel group and before the reinforcement plate bonding position, and is used to strengthen the hot pressing bonding of the composite layer structure; the third hot pressing wheel group is arranged between the reinforcement plate bonding position and the cutting position, and is used to hot press the reinforcement plate to the composite layer structure.

[0030] A further improvement in the method for preparing the structure of the ultra-soft flat cable of the present invention is that the ultra-soft flat cable has two opposite ends extending along the X direction, wherein the end face of one end is composed of a flush cut surface formed by stacking and cutting the conductor, the first film layer and the reinforcing plate; and the end face of the other end is composed of a flush cut surface formed by stacking and cutting the conductor, the second film layer and the reinforcing plate.

[0031] A further improvement of the method for preparing the structure of the ultra-soft flat cable of the present invention is that the ultra-soft flat cable has two opposite ends extending along the X direction, and the end faces of the two ends are formed by the conductor, the first film layer and the reinforcing plate being stacked and cut to form a flush cut surface.

[0032] A further improvement of the method for preparing the structure of the ultra-soft flat cable of the present invention is that the ultra-soft flat cable has two opposite ends extending along the X direction, and the end faces of the two ends are formed by the conductor, the second film layer and the reinforcing plate being stacked and cut to form a flush cut surface.

[0033] The present invention achieves remarkable technical effects in the production of ultra-soft flat cables by adopting a full-process roll-up operation method and precise lamination and cutting processes:

[0034] (1) Reduce processing steps and improve production efficiency

[0035] The traditional production method of ultra-soft flat cable requires cutting the original cable into a specific length, processing the gold finger areas at both ends, and attaching the reinforcement plate separately. The present invention adopts the full roll-up operation, which can continuously attach the original ultra-soft flat cable during the production process, and complete the processing of the gold finger area and the attachment of the reinforcement plate in one go in the roll state. This integrated operation significantly reduces the processing steps and processing time, thereby improving production efficiency.

[0036] (2) Reduce processing errors and improve product accuracy

[0037] In the prior art, linear operations are prone to cumulative errors due to multiple cutting and bonding processes, resulting in low precision of the finished product. Through the roll operation method of the present invention, the product can be bonded and cut in an uninterrupted state, making the process more stable and consistent, greatly reducing processing errors, ensuring the accuracy and consistency of the product, and suitable for high-precision application scenarios.

[0038] (3) Synchronous processing of the gold finger area to improve the consistency of the finished product

[0039] The present invention allows the gold finger area to be processed synchronously in a roll-like operation, without the need to process the gold fingers at both ends separately. This synchronous processing method not only simplifies the process, but also ensures the consistency of the gold finger areas at both ends, and reduces the quality deviation caused by position and angle errors during the production process.

[0040] (4) One-time bonding of reinforcement plates to improve structural stability

[0041] The reinforcing plate is laminated to the gold finger area at the same time, making the lamination position of the reinforcing plate more accurate, effectively improving the mechanical strength and durability of the ultra-soft cable. The lamination of the reinforcing layer enhances the bending resistance of the gold finger area and extends the service life of the cable in a high-frequency bending environment.

[0042] (5) Reduce material waste and save production costs

[0043] Through the continuous production method of roll operation, materials can be used efficiently, avoiding the waste of materials caused by multiple cutting in traditional methods. At the same time, the process of independent processing of reinforcement plates and gold finger areas is reduced, making the entire production process more economical and reducing manufacturing costs.

[0044] In summary, the present invention has significant technical effects in improving production efficiency, enhancing product precision, improving structural stability and reducing production costs. It solves the problems of complicated processes, large errors, low production efficiency, etc. in the existing ultra-soft flat cable production, and provides an innovative technical solution for the large-scale and efficient production of ultra-soft flat cables. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 This is a schematic diagram of the appearance of the existing coiled original line.

[0046] Figure 2 It is a schematic diagram of the appearance of the existing unfolded and flattened original line.

[0047] Figure 3 yes Figure 2 Schematic diagram of the cross-sectional structure at the position of section line 3-3.

[0048] Figure 4 It is a schematic diagram of the planar appearance of an existing semi-finished cable arrangement.

[0049] Figure 5 It is a planar appearance schematic diagram of a gold finger made from an existing semi-finished flat cable product.

[0050] Figure 6 It is a schematic diagram of the side appearance of an existing ultra-soft flat cable.

[0051] Figure 7 It is a schematic diagram of a device for preparing the structure of the ultra-soft flat cable of the present invention.

[0052] Figure 8 It is a schematic diagram of the processing flow of the structure of the ultra-soft flat cable of the present invention.

[0053] Fig. 9 It is a cross-sectional schematic diagram of a first structural embodiment of the ultra-soft flat cable of the present invention.

[0054] Fig.10 It is a cross-sectional schematic diagram of a second structural embodiment of the ultra-soft flat cable of the present invention.

[0055] Fig.11 It is a schematic diagram of the first processing flow of the PVC film used for the super-soft flat cable of the present invention.

[0056] Fig.12 It is a schematic diagram of the cross-sectional structure of the PVC film produced by the first processing flow of the present invention.

[0057] Fig.13 It is a schematic diagram of the second processing flow of the PVC film used for the super-soft flat cable of the present invention.

[0058] Fig.14 It is a schematic diagram of the cross-sectional structure of the PVC film produced by the second processing flow of the present invention.

[0059] The corresponding relationship between the reference numerals and the components is as follows:

[0060] 10: Ultra-soft flat cable; 101: Original cable; 102: Semi-finished flat cable; 11: Copper wire; 111: Gold finger; 12: Insulation layer; 121: Opening; 13: Reinforcement board; 20: Ultra-soft flat cable; 21: Copper wire layer; 211: First surface; 212: Second surface; 213: First gold finger; 214: Second gold finger; 22: First insulation layer; 23: Second insulation layer; 24: First opening; 25: Second opening; 26: First reinforcement board; 27: Second reinforcement board; 30: Rolling operation equipment; 31: Traction roller; 32: first hot pressing wheel group; 33: second hot pressing wheel group; 34: third hot pressing wheel group; 40: conductor; 50: film material; 51: first film layer; 52: second film layer; 60: punching; 70: gold finger area; 80: reinforcement plate; P1: punching position; P2: reinforcement plate bonding position; P3: cutting position; X: X direction; A: PVC glue; B: solvent; C: container; D: release film; E: injection molding machine; E1: feeding port; E2: heating section; E3: discharge pipe; E4: rolling wheel. DETAILED DESCRIPTION

[0061] Detailed specific embodiments of the present invention will be disclosed herein. However, it should be understood that the disclosed embodiments are only typical examples of the present invention, and the present invention can be implemented in a variety of alternative forms. Therefore, the specific structural and functional details disclosed herein are not restrictive, but are only based on the claims as a representative principle to illustrate different embodiments to those skilled in the art.

[0062] To facilitate understanding of the present invention, the following description is provided in conjunction with the accompanying drawings and embodiments.

[0063] See also Figures 7 to 14 The present invention provides a method for preparing a super-soft flat cable structure and a specific structure of the super-soft flat cable 20. In the embodiment of the present invention, a full-process roll-up operation method is adopted to form a super-soft flat cable with high precision, high efficiency and good durability through continuous lamination, punching, cutting and reinforcement processes. The preparation method and specific structure of the super-soft flat cable structure are described below.

[0064] 《Preparation method of ultra-soft flat cable structure》

[0065] In the preparation method of the present invention, Figure 7 , Figure 8 As shown, the production of the ultra-soft flat cable 20 mainly includes the following steps:

[0066] First, in the conductor preparation step, a conductor 40 as a wire arrangement core is provided, and the conductor 40 is arranged on the production process line through the traction roller 31 in the roll operation device 30, so that the conductor 40 is extended along the X direction.

[0067] Next, in the film material providing step, a film material 50 as an insulating layer is provided. The film material 50 includes a first film layer 51 and a second film layer 52. The two layers of film are arranged on the production line through several hot pressing wheel groups of the roll-to-roll operation device 30, ready to be bonded with the conductor 40.

[0068] In the punching process step, punching is performed at a designated punching position P1 on the film material 50 to remove a portion of the film material 50 to form a punching hole 60 so that a portion of the conductor 40 overlapping the punching hole 60 can be exposed to facilitate subsequent formation of a gold finger region 70 .

[0069] Then, in the step of hot pressing the thin film material, the first film layer 51 and the second film layer 52 are respectively attached to the upper and lower sides of the conductor 40. The first film layer 51 and the second film layer 52 are hot pressed by the hot pressing wheel group in the roll-type operation device 30, so that the two layers of film are tightly combined on the upper and lower sides of the conductor 40 to form a composite layer structure. At the same time, the conductor 40 area at the punching hole 60 is exposed to form a gold finger area 70.

[0070] In the reinforcing plate laminating step, the reinforcing plate 80 is aligned with the position of the gold finger area 70 and is laminated on the film material 50 on the other side of the composite layer structure to enhance the mechanical strength of the structure and ensure the durability of the product.

[0071] Finally, in the cutting step, the composite layer structure after punching and hot pressing is cut at the middle part of the overlapping area of ​​the gold finger area 70 and the reinforcing plate 80 to form an independent piece of ultra-soft flat cable 20 finished product of a specified length.

[0072] The above preparation method simplifies the production process, improves production efficiency and effectively reduces processing errors through full roll operation.

[0073] In the embodiment of the present invention, the conductor 40 may be a tinned flat copper wire, but is not limited thereto.

[0074] In the embodiment of the present invention, the film material 50 can be selected from one of PVC, TPE or TPU film materials.

[0075] In the embodiment of the present invention, Figure 7As shown, the roll-type working equipment 30 includes, in addition to the traction roller 31, a first hot pressing wheel group 32, a second hot pressing wheel group 33 and a third hot pressing wheel group 34; wherein, the first hot pressing wheel group 32 is arranged after the punching position P1, and is used to hot-press and bond the first film layer 51 and the second film layer 52 to the outside of the conductor 40; the second hot pressing wheel group 33 is arranged after the first hot pressing wheel group 32 and before the reinforcement plate bonding position P2, and is used to strengthen the hot pressing and bonding of the composite layer structure; the third hot pressing wheel group 34 is arranged between the reinforcement plate bonding position P2 and the cutting position P3, and is used to hot-press and bond the reinforcement plate 80 to the composite layer structure.

[0076] In the embodiment of the present invention, flush cut surfaces are provided at both ends of the ultra-soft flat cable 20 along the X direction, and these flush cut surfaces are formed by laminating and cutting the conductor 40, the corresponding film layer and the reinforcing plate. The flush cut surface design is used to ensure the neatness and smoothness of the flat cable ends, and improve the quality and aesthetics of the finished product.

[0077] In one embodiment, the structure of the ultra-soft flat cable 20 may be that the end surface of one end is formed by stacking and cutting the conductor 40, the first film layer 51 and the reinforcing plate 80, and the end surface of the other end is formed by stacking and cutting the conductor 40, the second film layer 52 and the reinforcing plate 80. This structure enables the ultra-soft flat cable to have uniform protection and support effects at both ends, and improves the durability of the flat cable during actual use.

[0078] In another embodiment, the end surfaces of both ends of the structure of the ultra-soft flat cable 20 can be formed by stacking and cutting the conductor 40, the first film layer 51 and the reinforcing plate 80. This structure has a high degree of consistency during the manufacturing process, is suitable for application scenarios where both ends are symmetrically designed, and can effectively improve production efficiency.

[0079] In another embodiment, the end faces of the ultra-soft flat cable 20 can be formed by stacking and cutting the conductor 40, the second film layer 52 and the reinforcing plate 80. This structure also provides a consistent end face effect, which is suitable for application scenarios that require the second film layer 52 to provide external protection, ensuring the mechanical strength and durability of the flat cable.

[0080] In the embodiment of the present invention, the insulating film material 50 of the ultra-soft flat cable is preferably selected as a PVC film. The PVC film has good flexibility, durability and insulation performance, can provide reliable protection for the ultra-soft flat cable 20, and improve the durability and service life of the flat cable. The following is a method for preparing the PVC film, which specifically includes two preferred manufacturing methods:

[0081] In method 1, if Fig.11 , Fig.12As shown, the method for preparing a PVC film includes mixing a PVC rubber compound A (or other similar materials such as TPE or TPU) with a plurality of solvents B in a container C. The mixed rubber compound is applied to a release film D through a uniform coating process. After coating, the rubber compound is dried at a specific temperature to ensure that the solvent is completely volatilized to obtain a PVC film (film material 50) with a specified thickness and width. This method can control the final thickness of the film by adjusting the thickness of the coating layer, thereby ensuring that it is suitable for different application requirements. This preparation method is suitable for scenarios where the thickness of the film needs to be precisely controlled, and can produce a film with high consistency and stability.

[0082] In method 2, if Fig.13 , Fig.14 As shown, the preparation method of the PVC film includes feeding PVC rubber material A (or TPE, TPU) into an injection molding machine E, wherein the injection molding machine E is provided with a feeding port E1, a heating section E2 and a discharge pipe E3, so that the fed PVC rubber material A passes through the discharge pipe in sequence, and then the thickness of the film material 50 is limited by the control of two rolling wheels E4. Specifically, the gap between the rolling wheels E4 can be precisely adjusted to ensure that the film reaches the required thickness standard. This method realizes thickness control by mechanical restriction, is suitable for large-scale production, and can improve production efficiency while ensuring uniform film thickness.

[0083] Both of the above methods can produce PVC films that meet the requirements of the present invention and ensure that the films provide excellent mechanical strength and electrical insulation performance during use. When producing the ultra-soft flat cable 20, these films will be attached to the upper and lower surfaces of the conductor 40 through a hot pressing process to provide good protection and support for the flat cable, so that the ultra-soft flat cable of the present invention has high reliability and durability in various application environments.

[0084] 《The structure of ultra-soft flat cable》

[0085] The ultra-soft flat cable 20 of the present invention includes a copper wire layer 21 extending along the X direction. The copper wire layer 21 has a first surface 211 and a second surface 212 on opposite sides, which are respectively used to be attached to the first insulating layer 22 and the second insulating layer 23. The first insulating layer 22 is attached to the first surface 211 of the copper wire layer 21 and extends along the X direction to form a protective layer; the second insulating layer 23 is attached to the second surface 212 of the copper wire layer 21 to provide further insulation and protection functions.

[0086] Openings are provided at both ends of the ultra-soft flat cable 20 along the X direction, namely, a first opening 24 and a second opening 25. The first opening 24 is formed at the end of the first insulating layer 22 or the second insulating layer 23, exposing the end of the copper wire layer 21, forming a first gold finger 213 for electrical connection. Similarly, the second opening 25 is formed at the end of the insulating layer at the other end, exposing the other end of the copper wire layer 21, forming a second gold finger 214.

[0087] like Fig. 9 , showing an embodiment in which the first opening 24 and the second opening 25 are both formed at the two ends of the second insulating layer 23, so that the first gold finger 213 and the second gold finger 214 are both formed on the same side (the second surface 212) of the copper wire layer 21. Fig.10 , it is shown that the first opening 24 is formed at the end of the second insulating layer 23, and the second opening 25 is formed at the end of the first insulating layer 22, so that the first gold finger 213 and are respectively formed on the opposite sides of the copper wire layer 21. It should be understood that Fig. 9 , Fig.10 The structure is not used to limit the structure of the ultra-soft flat cable of the present invention.

[0088] like Fig. 9 , Fig.10 In order to enhance the mechanical strength of the gold finger area, reinforcing plates are attached to the positions of the first opening 24 and the second opening 25, respectively. The first reinforcing plate 26 is attached to the first insulating layer 22 or the second insulating layer 23 corresponding to the first opening 24, and the second reinforcing plate 27 is attached to the insulating layer corresponding to the second opening 25. The provision of the reinforcing plate effectively enhances the structural strength of the gold finger area and prevents bending or damage during use.

[0089] In addition, the end face of the ultra-soft flat cable 20 is formed into a flush cut surface by the aforementioned manufacturing method to enhance the consistency and structural stability of the product. The end face can be formed by stacking and cutting the first insulating layer 22 and the copper wire layer 21, or by stacking and cutting the second insulating layer 23 and the copper wire layer 21, depending on the design requirements.

[0090] The ultra-soft flat cable of the present invention achieves high-precision and low-error production through reasonable structural design and process improvement, and is suitable for application scenarios of high-frequency bending and stable electrical connection.

[0091] The present invention is described in detail above in conjunction with the accompanying drawings and embodiments. A person skilled in the art can make various variations of the present invention according to the above description. Therefore, certain details in the embodiments should not constitute a limitation of the present invention, and the scope of protection of the present invention shall be defined by the scope of the attached claims.

Claims

1. A super-soft flat cable structure, comprising: A copper wire layer extending along an X direction, wherein the copper wire layer has a first surface and a second surface opposite to each other; a first insulating layer, attached to the first surface of the copper wire layer along the X direction; a second insulating layer, attached to the second surface of the copper wire layer along the X direction; a first opening, located at one end of the ultra-soft flat cable along the X direction and formed at an end of the first insulating layer or the second insulating layer; the first opening exposes one end of the copper wire layer and forms a first gold finger; a second opening, located at the other end of the ultra-soft flat cable along the X direction and formed at the end of the first insulating layer or the second insulating layer; the second opening exposes the other end of the copper wire layer and forms a second gold finger; A first reinforcing plate, attached to the first insulating layer or the second insulating layer corresponding to the position where the first opening is opened; A second reinforcing plate, attached to the first insulating layer or the second insulating layer corresponding to the position where the second opening is opened; It is characterized in that The ultra-soft flat cable has two opposite ends extending along the X direction, wherein the end face of one end is formed by a flush cut surface formed by overlapping and cutting the first insulating layer and the copper wire layer; the end face of the other end is formed by a flush cut surface formed by overlapping and cutting the second insulating layer and the copper wire layer; or, the end faces of both ends are formed by flush cut surfaces formed by overlapping and cutting the first insulating layer and the copper wire layer; or, the end faces of both ends are formed by flush cut surfaces formed by overlapping and cutting the second insulating layer and the copper wire layer.

2. The structure of the ultra-soft flat cable according to claim 1, characterized in that: The ultra-soft flat cable also includes a first reinforcement plate and a second reinforcement plate; wherein, The first reinforcing plate is attached to the first insulating layer or the second insulating layer corresponding to the position where the first opening is opened, and the first reinforcing plate and the first opening are located on two opposite sides of the copper wire layer; The second reinforcing plate is attached to the first insulating layer or the second insulating layer corresponding to the opening position of the second opening, and the second reinforcing plate and the second opening are located on two opposite side surfaces of the copper wire layer.

3. The structure of the ultra-soft flat cable according to claim 2, characterized in that: The ultra-soft flat cable has two opposite ends extending along the X direction. The end face of one end is formed by a flush cut surface formed by stacking and cutting the first insulating layer, the copper wire layer and the first reinforcing plate; the end face of the other end is formed by a flush cut surface formed by stacking and cutting the second insulating layer, the copper wire layer and the second reinforcing plate; or, The end faces at both ends are formed by cutting and stacking the first insulating layer, the copper wire layer and the first reinforcing plate to form a flush cut surface; or, The end faces at both ends are formed by the flush cut surfaces formed by overlapping and cutting the second insulating layer, the copper wire layer and the second reinforcing plate.

4. A method for preparing a super-soft flat cable structure, characterized in that: The method steps include: Conductor preparation step: providing a conductor as a wire core, and arranging the conductor on a production process line through a traction roller of a coiling operation device; The film material providing step includes providing a film material as an insulating layer, wherein the film material includes a first film layer and a second film layer, and arranging the first film layer and the second film layer on a production process line through a plurality of hot pressing wheel groups of a roll-to-roll operation device; Punching processing step: removing the film material at a designated punching position on the film material to form a punching hole; The step of hot pressing the film material: laminating the first film layer and the second film layer on the upper and lower sides of the conductor respectively, and hot pressing the first film layer and the second film layer by a hot pressing wheel group of a roll-type operation equipment, so that the first film layer and the second film layer are tightly combined on the upper and lower sides of the conductor to form a composite layer structure; the local conductor area of ​​the composite layer structure is exposed from the punching hole to form a gold finger area; A reinforcing plate laminating step: laminating the reinforcing plate relative to the gold finger area onto the film material on the other side of the composite layer structure; Cutting step: cutting the composite layer structure after punching and hot pressing from the middle part of the gold finger area and the overlapping area of ​​the reinforcement plate to form an independent piece of ultra-soft flat cable finished product.

5. The method for preparing the structure of the ultra-soft flat cable according to claim 4, characterized in that: The conductor is a conductive material selected from tinned flat copper wire, oxygen-free copper wire, aluminum wire or aluminum foil Mylar tape.

6. The method for preparing the structure of the ultra-soft flat cable according to claim 4, characterized in that: The film material is selected from one of PVC, TPE or TPU.

7. The method for preparing the structure of the ultra-soft flat cable according to claim 4, characterized in that: The roll-to-roll processing equipment includes a first hot-pressing wheel group, a second hot-pressing wheel group and a third hot-pressing wheel group; wherein the first hot-pressing wheel group is arranged after the punching position, and is used to hot-press and bond the first film layer and the second film layer to the outside of the conductor; the second hot-pressing wheel group is arranged after the first hot-pressing wheel group and before the reinforcement plate bonding position, and is used to strengthen the hot-pressing and bonding of the composite layer structure; the third hot-pressing wheel group is arranged between the reinforcement plate bonding position and the cutting position, and is used to hot-press and bond the reinforcement plate to the composite layer structure.

8. The method for preparing the structure of the ultra-soft flat cable according to claim 4, characterized in that: The ultra-soft flat cable has two opposite ends extending along the X direction, wherein an end face of one end is formed by a flush cut surface formed by stacking and cutting the conductor, the first film layer and the reinforcing plate; and an end face of the other end is formed by a flush cut surface formed by stacking and cutting the conductor, the second film layer and the reinforcing plate.

9. The method for preparing the structure of the ultra-soft flat cable according to claim 4, characterized in that: The ultra-soft flat cable has two opposite ends extending along the X direction, and the end faces of the two ends are formed by the conductor, the first film layer and the reinforcing plate being stacked and cut to form a flush cut surface.

10. The method for preparing the structure of the ultra-soft flat cable according to claim 4, characterized in that: The ultra-soft flat cable has two opposite ends extending along the X direction, and the end faces of the two ends are formed by the conductor, the second film layer and the reinforcing plate being stacked and cut to form a flush cut surface.

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