FFC hot melt aluminum foil lamination forming process

Abstract

The present application relates to the technical field of FFC flat cable manufacturing, and particularly relates to a FFC hot-melt aluminum foil bonding forming process, which comprises the following steps: outputting hot-melt aluminum foil by a first unwinding mechanism, and outputting a reinforcing plate by a second unwinding mechanism; high-temperature pressing the hot-melt aluminum foil and the reinforcing plate at a first pressing station to form an aluminum foil-reinforcing plate composite; placing a plurality of parallel conductive wires between an upper layer of insulating film and a lower layer of insulating film, and feeding the same into a second pressing station for heating and pressing to form a FFC main strip; synchronously feeding the aluminum foil-reinforcing plate composite and the FFC main strip into a third pressing station, and heating and pressing the same into an integrated strip; and after the integrated strip is subjected to slitting, spark insulation testing and winding, a FFC flat cable is obtained. By pre-combining the hot-melt aluminum foil and the reinforcing plate, and then fusing the same with the FFC main strip, the problems of stretching and deviation of the aluminum foil can be effectively avoided, and the product quality consistency and production continuity can be improved, thereby meeting the requirements of automatic and large-scale production.

Description

Technical Field

[0001] This invention relates to the field of FFC cable manufacturing technology, and in particular to a FFC hot-melt aluminum foil bonding molding process. Background Technology

[0002] The existing shielding layer forming process for flexible flat cables (FFC) generally adopts a post-attachment operation process: first, the FFC body is formed through a hot pressing process, then the operator manually aligns and attaches the self-adhesive aluminum foil to the FFC surface, and then the product with the aluminum foil initially attached is sent into a roller mechanism for rolling to achieve the pressing and fixing of the aluminum foil and the FFC body.

[0003] In the above process, the bonding process of the aluminum foil shielding layer is entirely dependent on manual operation, resulting in a fragmented production process. Furthermore, the bonding of the aluminum foil needs to be carried out separately after the FFC body is formed, and cannot be completed simultaneously with the body forming process. As a result, not only is the overall production efficiency reduced, but the alignment accuracy and bonding consistency of the aluminum foil are also highly dependent on the level of manual operation, which can easily lead to defects such as aluminum foil misalignment, warping, and bubbles. It is difficult to ensure the stability of product quality in mass production, and it cannot meet the development needs of large-scale and automated production.

[0004] Therefore, it is urgent for technical personnel to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide an FFC hot melt aluminum foil bonding molding process, which aims to solve the problems of dispersed processes, low efficiency, and the fact that the aluminum foil bonding accuracy and consistency are greatly affected by human intervention in the existing post-bonding aluminum foil process.

[0006] This invention relates to an FFC hot melt aluminum foil lamination molding process, comprising the following steps: S1. Hot melt aluminum foil is output from the first unwinding mechanism, and a reinforcing plate is output from the second unwinding mechanism. The hot melt aluminum foil and the reinforcing plate are aligned and conveyed to the first pressing station. S2. At the first pressing station, the hot-melt aluminum foil and the reinforcing plate are pressed together at high temperature to obtain an aluminum foil-reinforcing plate composite. S3. Place multiple parallel wires between the upper and lower insulating films and send them together into the second pressing station for heating and pressing to form the FFC main strip. S4. Simultaneously feed the aluminum foil reinforcing plate composite and the FFC main strip into the third pressing station and heat and press them together into an integral strip. S5. The integrated strip is sequentially slited, subjected to spark insulation testing, and wound up to obtain FFC cable.

[0007] As a further improvement to the technical solution disclosed in this invention, the first pressing station preheats the hot-melt aluminum foil and the reinforcing plate before high-temperature pressing, and the preheating temperature is lower than the pressing temperature.

[0008] As a further improvement to the technical solution disclosed in this invention, the preheating temperature is 80℃~110℃, and the pressing temperature of the first pressing station is 120℃~180℃.

[0009] As a further improvement to the technical solution disclosed in this invention, the aluminum foil-reinforcing plate composite is aligned and corrected by a position correction mechanism before entering the third pressing station, and the alignment deviation between the aluminum foil-reinforcing plate composite and the FFC main strip is no more than 0.2mm.

[0010] As a further improvement to the technical solution disclosed in this invention, the third pressing station adopts a segmented hot pressing structure, which is divided into a front hot pressing section and a rear pressure holding section.

[0011] As a further improvement to the technical solution disclosed in this invention, the temperature of the front hot pressing section is higher than the temperature of the rear pressure holding section, and the temperature difference is 20℃~40℃.

[0012] As a further improvement to the technical solution disclosed in this invention, the hot-melt aluminum foil is subjected to static elimination treatment after unwinding and before pressing, and the surface static value is not greater than 100V.

[0013] As a further improvement to the technical solution disclosed in this invention, the integral strip undergoes a cooling and shaping process before slitting, and the temperature of the strip after cooling is ≤40℃.

[0014] As a further improvement to the technical solution disclosed in this invention, the spark insulation test is an online high-frequency continuous detection with a test voltage of 1.5kV to 3kV, and the defect location is marked in real time during the detection process.

[0015] As a further improvement to the technical solution disclosed in this invention, the aluminum foil reinforcing plate composite is only attached to the plug-in parts at both ends of the FFC cable, while the aluminum foil reinforcing plate composite is not provided in the middle of the FFC cable.

[0016] In practical applications, the FFC hot-melt aluminum foil bonding and molding process disclosed in this invention can achieve at least the following beneficial technical effects, specifically: 1) The hot melt aluminum foil and the reinforcing plate are accurately aligned by the first unwinding mechanism and the second unwinding mechanism, and then conveyed to the first pressing station. The first pressing station is subjected to high temperature pressing treatment. The hot melt adhesive layer of the hot melt aluminum foil is fully activated and penetrated at the set temperature to form a tightly structured and dimensionally stable aluminum foil-reinforcing plate composite with the reinforcing plate. The two are firmly bonded in advance. This not only simplifies the production process, but also lays a solid foundation for the subsequent bonding with the FFC main strip. 2) By precisely controlling the temperature, pressure, and conveying speed of the first, second, and third pressing stations, the equipment ensures consistent operation at each station. The aluminum foil reinforcing plate composite produced in the first pressing station possesses sufficient rigidity, effectively preventing stretching and misalignment of the aluminum foil during the fusion process with the FFC main strip in the third pressing station. Simultaneously, the hot melt adhesive layer is reactivated in the third pressing station, achieving seamless bonding between the aluminum foil reinforcing plate composite and the FFC main strip, eliminating bonding gaps, preventing quality defects such as warping and bubbles, ensuring product uniformity and stability, and fully meeting the needs of large-scale, automated production. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the equipment structure and process flow of the FFC hot melt aluminum foil bonding molding process disclosed in this invention. Detailed Implementation

[0019] The technical solution disclosed in this invention will be further described in detail below with reference to specific embodiments. The FFC cable achieves seamless, integrated online forming through a multi-process coordinated hot-melt aluminum foil bonding process, resulting in aluminum foil bonding without misalignment, warping, or bubbles. This leads to high production efficiency, stable quality, and suitability for automated, large-scale production. Figure 1 As shown, the specific implementation is as follows: Example 1 The FFC hot melt aluminum foil lamination molding process specifically includes the following steps: S1. Hot melt aluminum foil is output by the first unwinding mechanism and reinforcing plate is output by the second unwinding mechanism. The hot melt aluminum foil is first treated by an electrostatic elimination device to ensure that the static electricity value on the surface of the aluminum foil is no more than 100V. Then the hot melt aluminum foil and the reinforcing plate are precisely aligned and transported to the first pressing station. S2. The first pressing station preheats the hot-melt aluminum foil and the reinforcing plate. The preheating temperature is set to 80℃. After preheating, high-temperature pressing is performed at a pressing temperature of 120℃. During the pressing process, the pressure and conveying speed are controlled to match, and the aluminum foil-reinforcing plate composite is obtained. S3. Arrange multiple parallel wires at regular intervals between the upper and lower insulating films, and send them together into the second pressing station. After heating and pressing, they are formed into a continuous FFC main strip. S4. The aluminum foil-reinforcing plate composite is aligned and corrected at the edges by the position correction mechanism to ensure that the alignment deviation with the FFC main strip is no more than 0.2mm. Then it is sent to the third pressing station simultaneously. The third pressing station adopts a segmented hot pressing structure. The temperature of the front hot pressing section is 130℃, and the temperature of the rear holding pressure section is 100℃, with a temperature difference of 30℃. The integrated strip is formed by heating and pressing. S5. The integrated strip is fed into the cooling and shaping device and cooled to the strip temperature ≤40℃. Then, it is slit and cut in sequence, and online high-frequency spark insulation test is performed. The test voltage is 1.5kV. During the test, the defect location is marked in real time. Finally, the qualified products are rolled up to obtain FFC cable. The aluminum foil-reinforcing plate composite is only attached to the plug-in parts at both ends of the FFC cable, while the middle part of the cable is not attached, thus meeting the requirements for plug-in strength and shielding.

[0020] Example 2 The process steps in this embodiment are basically the same as those in Embodiment 1, with the only differences being as follows: In S2, the preheating temperature is adjusted to 95℃, and the pressing temperature of the first pressing station is adjusted to 150℃. In S4, the temperature of the front hot pressing section of the third pressing station is 145℃, and the temperature of the rear pressure holding section is 115℃, with a temperature difference of 30℃. In S5, the spark insulation test voltage is adjusted to 2kV.

[0021] Example 3 The process steps in this embodiment are basically the same as those in Embodiment 1, with the only differences being as follows: In S2, the preheating temperature is adjusted to 110℃, and the pressing temperature of the first pressing station is adjusted to 180℃. In S4, the temperature of the front hot pressing section of the third pressing station is 160℃, and the temperature of the rear pressure holding section is 120℃, with a temperature difference of 40℃. In S5, the spark insulation test voltage is adjusted to 3kV, and the temperature of the integrated strip is controlled below 35℃ after cooling.

[0022] Comparative Example 1 This comparative example uses a traditional post-attached aluminum foil bonding process, and the specific steps are as follows: S1. The insulating film and parallel wires are hot-pressed to form the FFC main strip, which is then slit and wound up. S2. The operator manually aligns the self-adhesive aluminum foil with the reinforcing plate and then manually pastes it to the plug-in parts at both ends of the FFC body. S3. The product with the aluminum foil initially attached is fed into the roller mechanism for rolling and fixing. S4. Perform spark insulation testing and winding to obtain FFC cable.

[0023] Comparative Example 2 This comparative example uses a conventional online single-segment hot-press bonding process, without preheating or segmented pressing. The specific steps are as follows: S1. Unwinding output of hot-melt aluminum foil, reinforcing plate, insulating film and wire; S2. Aluminum foil and reinforcing plate are directly pressed together in a single section; S3, FFC main body is formed and then pressed together with aluminum foil-reinforcing plate in a single temperature step; S4. Cooling, slitting, testing, and winding are used to produce FFC cables.

[0024] The performance of the FFC cables prepared in Examples 1-3 and Comparative Examples 1 and 2 was tested. The test standards and results are shown in the table below: Test results show that the FFC cables prepared in Examples 1 to 3 are significantly superior to Comparative Example 1 and Comparative Example 2 in four core indicators: bonding accuracy, appearance yield, production efficiency, and peel strength, as detailed below: In terms of bonding accuracy, the aluminum foil alignment deviation of Examples 1 to 3 is consistently ≤0.2mm, which is much lower than that of Comparative Example 1 and Comparative Example 2, and the bonding positioning accuracy is greatly improved. In terms of appearance quality, the aluminum foil curling and bubble defect rate of Examples 1 to 3 were controlled below 0.3%, which is significantly lower than 8.6% of Comparative Example 1 and 4.2% of Comparative Example 2, and the product consistency was greatly improved. In terms of bonding strength, the peel strength of the insertion parts in Examples 1 to 3 all reached more than 18 N / cm, which is much higher than that in Comparative Example 1 and Comparative Example 2, indicating better product reliability and service life.

[0025] In terms of production efficiency, Examples 1 to 3 achieve integrated online molding, which is 2 to 3 times that of traditional manual processes, and can meet the needs of automated large-scale production. The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A process for bonding and molding FFC hot-melt aluminum foil, characterized in that, Includes the following steps: S1. Hot melt aluminum foil is output from the first unwinding mechanism, and a reinforcing plate is output from the second unwinding mechanism. The hot melt aluminum foil and the reinforcing plate are aligned and conveyed to the first pressing station. S2. At the first pressing station, the hot-melt aluminum foil and the reinforcing plate are pressed together at high temperature to obtain an aluminum foil-reinforcing plate composite. S3. Place multiple parallel wires between the upper and lower insulating films and send them together into the second pressing station for heating and pressing to form the FFC main strip. S4. Simultaneously feed the aluminum foil reinforcing plate composite and the FFC main strip into the third pressing station and heat and press them together into an integral strip. S5. The integrated strip is sequentially slited, subjected to spark insulation testing, and wound up to obtain FFC cable.

2. The FFC hot-melt aluminum foil lamination molding process according to claim 1, characterized in that, Before high-temperature pressing, the first pressing station preheats the hot-melt aluminum foil and the reinforcing plate, and the preheating temperature is lower than the pressing temperature.

3. The FFC hot-melt aluminum foil lamination molding process according to claim 2, characterized in that, The preheating temperature is 80℃~110℃, while the pressing temperature of the first pressing station is 120℃~180℃.

4. The FFC hot-melt aluminum foil lamination molding process according to claim 1, characterized in that, Before entering the third pressing station, the aluminum foil-reinforcing plate composite is aligned and corrected by the position correction mechanism, and the alignment deviation between the aluminum foil-reinforcing plate composite and the FFC main strip is no more than 0.2mm.

5. The FFC hot-melt aluminum foil lamination molding process according to claim 4, characterized in that, The third pressing station adopts a segmented hot pressing structure, which is divided into a front hot pressing section and a rear pressure holding section.

6. The FFC hot-melt aluminum foil lamination molding process according to claim 5, characterized in that, The temperature of the front hot pressing section is higher than that of the rear pressure holding section, and the temperature difference is 20℃~40℃.

7. The FFC hot-melt aluminum foil lamination molding process according to claim 1, characterized in that, The hot-melt aluminum foil undergoes static elimination treatment after unwinding and before pressing, and the surface static value is no greater than 100V.

8. The FFC hot-melt aluminum foil lamination molding process according to claim 1, characterized in that, Before being slit, the integral strip undergoes a cooling and shaping process, and the temperature of the strip after cooling is ≤40℃.

9. The FFC hot-melt aluminum foil lamination molding process according to claim 1, characterized in that, The spark insulation test is an online high-frequency continuous test with a test voltage of 1.5kV to 3kV, and the defect location is marked in real time during the test.

10. The FFC hot-melt aluminum foil lamination molding process according to claim 1, characterized in that, The aluminum foil reinforcing plate composite is only attached to the plug-in parts at both ends of the FFC cable, while the aluminum foil reinforcing plate composite is not installed in the middle of the FFC cable.

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