Flat cable guide, method for manufacturing a flat cable guide, and piece for a flat cable guide

Abstract

To be flexible in adapting to circuit configurations. [Solution] The system comprises a plurality of pieces 10 arranged according to the power distribution route, and each piece 10 is of at least one type, comprising a base sheet member 20 molded into a flat plate shape from an electrically insulating synthetic resin material, and at least one conductive member 30 joined to one plane of the base sheet member 20, and two adjacent pieces 10 are physically and electrically connected at the ends of the conductive member 30 in one piece 10 and the conductive member 30 in the other piece 10.

Description

Technical Field

[0001] The present invention relates to a flat cable material, a method for manufacturing the flat cable material, and a piece for the flat cable material.

Background Art

[0002] Conventionally, as a cable material for connecting between electrical devices, etc., an electric wire bundle in which a plurality of electric wires are bundled is known. However, even if a plurality of electric wires are arranged flat, the electric wire bundle has a thickness and also has a weight. Furthermore, the electric wire bundle gets entangled during transportation, resulting in the need for disentangling work, or the need for cable laying work while restoring the deformed path to its original shape. Therefore, it cannot be said that it has excellent assembly workability. The flat cable material is a cable material that can improve all of these problems, and a flexible printed circuit board is known as a representative example thereof (for example, Patent Document 1 below).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, a flexible printed circuit board includes various films (base film and cover film) formed flat with flexibility as an insulating coating, and a circuit pattern such as a copper foil is formed on at least one of these various films (base film). However, the flexible printed circuit board is a dedicated product for each circuit pattern and cannot respond flexibly to circuit changes.

[0005] Therefore, an object of the present invention is to provide a flat cable material that can flexibly respond to circuit configurations, a method for manufacturing the flat cable material, and a piece for the flat cable material.

Means for Solving the Problems

[0006] The flat cable distribution material according to the present invention comprises a plurality of pieces arranged according to a power distribution path, and at least one type of piece is used, each comprising a base sheet member molded into a flat plate shape from an electrically insulating synthetic resin material and at least one conductive member joined to one plane of the base sheet member, wherein two adjacent pieces are physically and electrically connected at the ends of the conductive member in one piece and the conductive member in the other piece.

[0007] The present invention relates to a method for manufacturing a flat cable distribution material, comprising: a piece manufacturing step of installing a base sheet member molded into a flat plate shape from an electrically insulating synthetic resin material, placing at least one conductive member on one of the planes of the base sheet member, and joining the plane of the base sheet member with the conductive member to manufacture at least one type of piece; and a connection step of arranging a plurality of the pieces according to a power distribution path, and physically and electrically connecting the ends of the conductive member in one piece with the ends of the conductive member in the other piece between two adjacent pieces.

[0008] The flat cable guide piece according to the present invention comprises a base sheet member molded into a flat plate shape from an electrically insulating synthetic resin material, and at least one conductive member joined to one plane of the base sheet member, wherein the base sheet member is installed adjacent to an adjacent base sheet member molded into a flat plate shape from an electrically insulating synthetic resin material, and the conductive member is physically and electrically connected to the end of the adjacent conductive member joined to one plane of the adjacent base sheet member. [Effects of the Invention]

[0009] The flat cable routing material according to the present invention can create diverse circuit configurations to accommodate various power distribution routes by changing the combination and arrangement of multiple pieces (pieces for flat cable routing material). In other words, the flat cable routing material according to the present invention can flexibly adapt to circuit configurations corresponding to various power distribution routes. Furthermore, the manufacturing method and pieces for flat cable routing material according to the present invention can produce flat cable routing materials that achieve such effects. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is a plan view showing an example of a flat cable guide (before cover sheet assembly) and a piece for the flat cable guide according to the embodiment. [Figure 2] Figure 2 is a plan view showing an example of a flat cable guide (after the cover sheet member is assembled) and a piece for the flat cable guide according to the embodiment. [Figure 3] Figure 3 is an explanatory diagram illustrating part of the manufacturing process for flat-type cable guide pieces. [Figure 4] Figure 4 is a plan view showing an example of the first piece. [Figure 5] Figure 5 is a plan view showing an example of the second piece. [Figure 6] Figure 6 is a plan view showing an example of the third piece. [Figure 7] Figure 7 is a plan view showing an example of the fourth piece. [Figure 8] Figure 8 is a plan view showing another example of the flat cable guide (before cover sheet member assembly) and flat cable guide piece of the embodiment. [Figure 9] Figure 9 is a plan view showing another example of the flat cable guide (after the cover sheet member is assembled) and the piece for the flat cable guide according to the embodiment. [Figure 10] Figure 10 is a plan view showing another example of the first piece. [Figure 11] Figure 11 is a plan view showing another example of the second piece. [Figure 12] Figure 12 is a plan view showing another example of the third piece. [Figure 13]FIG. 13 is a plan view showing another example of the fourth piece. [Figure 14] FIG. 14 is a plan view showing another example of the flat cable member (before assembling the cover sheet member) and the piece for the flat cable member according to the embodiment. [Figure 15] FIG. 15 is a plan view showing another example of the flat cable member (after assembling the cover sheet member) and the piece for the flat cable member according to the embodiment. [Figure 16] FIG. 16 is a plan view showing another example of the first piece. [Figure 17] FIG. 17 is a plan view showing another example of the second piece. [Figure 18] FIG. 18 is a plan view showing another example of the third piece. [Figure 19] FIG. 19 is a plan view showing another example of the fourth piece. [Figure 20] FIG. 20 is a plan view showing another example of the fifth piece. [Figure 21] FIG. 21 is a plan view showing another example of the flat cable member (after assembling the cover sheet member) and the piece for the flat cable member according to the embodiment. [Figure 22] FIG. 22 is an explanatory view comparing the thickness of the piece for the flat cable member with the cable member using an electric wire. [Figure 23] FIG. 23 is an explanatory view comparing the thickness of the folded flat cable member with the cable member using an electric wire.

BEST MODE FOR CARRYING OUT THE INVENTION

[0011] Hereinafter, an embodiment of a flat cable member, a method for manufacturing the flat cable member, and a piece for the flat cable member according to the present invention will be described in detail based on the drawings. Note that the present invention is not limited by this embodiment.

[0012] [Embodiment] One embodiment of the flat cable member, the method for manufacturing the flat cable member, and the piece for the flat cable member according to the present invention will be described based on FIGS. 1 to 23.

[0013] Reference numeral 1 in Figures 1 and 2 indicates a flat cable routing member of this embodiment. This flat cable routing member 1 comprises a plurality of pieces 10 arranged according to the power distribution route.

[0014] Piece 10 comprises a base sheet member 20 formed into a flat plate shape and at least one conductive member 30 joined to one of the planes of the base sheet member 20 (Figures 1 and 2).

[0015] The base sheet member 20 is formed from an electrically insulating synthetic resin material into, for example, a rectangular flat plate shape. The conductive member 30 is formed from a metallic material such as copper or a copper alloy into a linear flat plate shape. The conductive member 30 may also be formed into a thin film shape, such as copper foil.

[0016] In the flat cable guide 1, adjacent pieces 10 are electrically connected to each other. That is, two adjacent pieces 10 are physically and electrically connected at the ends of the conductive members 30 of one piece 10 and the conductive members 30 of the other piece 10. For example, the foundation sheet member 20 of a certain piece 10 is placed adjacent to the foundation sheet member (or adjacent foundation sheet member) 20 of an adjacent piece 10. Then, the conductive member 30 of a certain piece 10 is physically and electrically connected at its end to the end of the conductive member (or adjacent conductive member 30) that is joined to one plane of the adjacent foundation sheet member 20.

[0017] In the flat cable guide 1, this piece 10 is a piece for the flat cable guide 1, and at least one type of piece 10 is used.

[0018] The flat cable guide 1 is molded into a flat plate shape that spans multiple connected pieces 10, and includes a cover sheet member 40 that covers the conductive members 30 provided by these pieces from the side opposite to the base sheet member 20 (Figure 2). This cover sheet member 40 is molded from an electrically insulating synthetic resin material. For example, this cover sheet member 40 is molded from the same synthetic resin material as the base sheet member 20. In the flat cable guide 1, all pieces 10 may be covered with a single cover sheet member 40. Alternatively, in the flat cable guide 1, all pieces 10 may be divided into multiple sections, and a cover sheet member 40 may be provided for each of these divided sections of connected pieces 10.

[0019] This flat cable material 1 is manufactured using a manufacturing method that includes a piece manufacturing process for manufacturing the piece 10, a connection process for connecting a plurality of pieces 10 arranged according to the power distribution route, and a cover assembly process for assembling the cover sheet member 40.

[0020] In the piece manufacturing process, a base sheet member 20 is placed, at least one conductive member 30 is placed on one plane of the base sheet member 20, and the plane of the base sheet member 20 and the conductive member 30 are joined to manufacture at least one type of piece 10. For example, in this piece manufacturing process, laser light is irradiated from a laser irradiation device 510 to join the conductive member 30 to one plane of the base sheet member 20 (Figure 3). Alternatively, in this piece manufacturing process, the plane of the base sheet member 20 and the conductive member 30 may be joined using an adhesive or other technique well known in the art.

[0021] In the connection process, multiple pieces 10 are arranged according to the power distribution path. In this connection process, the ends of the conductive members 30 in one piece 10 and the conductive members 30 in the other piece 10 are physically and electrically connected. For example, in this connection process, laser light is irradiated from a laser irradiation device 510 to join the ends of each conductive member 30. Alternatively, in this connection process, the ends of each conductive member 30 may be joined using other techniques known in the art, such as heat welding or ultrasonic bonding.

[0022] In the cover assembly process, a cover sheet member 40 is placed over a plurality of pieces 10 that are arranged and connected according to the power distribution route. Then, in the cover assembly process, each of the base sheet members 20 and the cover sheet member 40 on the plurality of pieces 10 are joined together, for example, by heat welding.

[0023] Figures 1 and 2 show a flat cable guide 1A made up of four types of pieces 10 (first piece 11A, second piece 11B, third piece 11C, and fourth piece 11D).

[0024] All four types of pieces 10 utilize a base sheet member 20 that is molded into a square, flat plate shape. In addition, in all four types of pieces 10, the conductive member 30 has one end and the other end protruding from the peripheral edge of the base sheet member 20.

[0025] The first piece 11A comprises six linearly shaped conductive members 30 (hereinafter referred to as "first conductive members 31A") (Figure 4). In this first piece 11A, the six first conductive members 31A are arranged at equal intervals along a pair of parallel sides 20a and 20b of the base sheet member 20. In this first piece 11A, one end of each of the six first conductive members 31A protrudes from one of the pair of sides 20a and 20b (hereinafter referred to as "first side") 20a, and the other end of each of the six first conductive members 31A protrudes from the other of the pair of sides 20a and 20b (hereinafter referred to as "second side") 20b (Figure 4).

[0026] The second piece 11B comprises six conductive members 30 (hereinafter referred to as "second conductive members 31B"), each molded into an L-shape of a different length (Figure 5). In this second piece 11B, the bent portions of the six second conductive members 31B are placed on the diagonal of the base sheet member 20 and arranged at equal intervals (Figure 5). The distance between two adjacent second conductive members 31B is the same as the distance between two adjacent first conductive members 31A in the first piece 11A. Furthermore, in this second piece 11B, one end of each of the six second conductive members 31B protrudes from one of the pair of orthogonal sides 20a, 20c of the base sheet member 20 (first side) 20a, and the other end of each of the six second conductive members 31B protrudes from the other side of the pair of sides (hereinafter referred to as "third side") 20c (Figure 5).

[0027] The third piece 11C comprises four first conductive members 31A and one L-shaped conductive member 30 (hereinafter referred to as "third conductive member 31C") (Figure 6).

[0028] In this third piece 11C, the four first conductive members 31A are arranged at equal intervals along a pair of parallel sides 20a and 20b of the base sheet member 20, just like in the first piece 11A, with one end of each of the four first conductive members 31A protruding from the first side 20a and the other end of each of the four first conductive members 31A protruding from the second side 20b (Figure 6). The spacing between two adjacent first conductive members 31A is the same as the spacing between two adjacent first conductive members 31A in the first piece 11A.

[0029] For example, in this third piece 11C, four first conductive members 31A are arranged such that the first conductive member 31A closest to the third side 20c is connected to the first conductive member 31A closest to the third side 20c in the first piece 11A.

[0030] Furthermore, in this third piece 11C, one end of the third conductive member 31C protrudes from the other side (hereinafter referred to as the "fourth side") 20d of the base sheet member 20 that is perpendicular to the pair of sides 20a and 20b, and the other end of the third conductive member 31C protrudes from the second side 20b (Figure 6). The third conductive member 31C is positioned on the base sheet member 20 with the shaft portion on the other end side spaced on the fourth side 20d side relative to the first conductive member 31A closest to the fourth side 20d. This spacing is the same as the spacing between two adjacent first conductive members 31A.

[0031] The fourth piece 11D comprises four first conductive members 31A and two L-shaped conductive members 30 of the same shape (hereinafter referred to as "fourth conductive member 31D") (Figure 7).

[0032] In this fourth piece 11D, the four first conductive members 31A are arranged at equal intervals along a pair of parallel sides 20a and 20b of the base sheet member 20, just like in the first piece 11A, with one end of each of the four first conductive members 31A protruding from the first side 20a and the other end of each of the four first conductive members 31A protruding from the second side 20b (Figure 7). The spacing between two adjacent first conductive members 31A is the same as the spacing between two adjacent first conductive members 31A in the first piece 11A.

[0033] Furthermore, in this fourth piece 11D, one end of one fourth conductive member 31D protrudes from the fourth side portion 20d of the base sheet member 20, and the other end of one fourth conductive member 31D protrudes from the second side portion 20b of the base sheet member 20 (Figure 7). One of the fourth conductive members 31D is positioned on the base sheet member 20 with the shaft portion on the other end side spaced on the fourth side portion 20d side relative to the first conductive member 31A closest to the fourth side portion 20d. This spacing is the same as the spacing between two adjacent first conductive members 31A. Also, in this fourth piece 11D, one end of the other fourth conductive member 31D protrudes from the third side portion 20c, and the other end of the other fourth conductive member 31D protrudes from the second side portion 20b (Figure 7). The other fourth conductive member 31D is positioned on the base sheet member 20 with its other end portion spaced apart from the first conductive member 31A on the third side 20c side. This spacing is the same as the spacing between two adjacent first conductive members 31A.

[0034] In this flat cable guide 1A, 20 first pieces 11A, 4 second pieces 11B, 1 third piece 11C, and 1 fourth piece 11D are arranged in an appropriate combination, and the ends of the conductive members 30 facing each other on two adjacent pieces 10 are physically and electrically connected (Figures 1 and 2). The ends of the conductive members 30 may be joined with them butting against each other, or they may be joined with them overlapping each other.

[0035] In this flat cable guide 1A, all of its pieces 10 are covered with a single cover sheet member 40 (hereinafter referred to as the "first cover sheet member 41") (Figure 2).

[0036] Here, in two adjacent pieces 10, the ends of the conductive members 30 protrude from the periphery of each base sheet member 20. Therefore, between two adjacent pieces 10, the ends of the conductive members 30 are exposed on the side opposite to the first cover sheet member 41.

[0037] Therefore, this flat cable guide 1A includes an intermediate sheet member 50 that fills the gap between the respective base sheet members 20 between two adjacent pieces 10, and joins the ends of the respective conductive members 30 that protrude from the respective base sheet members 20 in between (Figures 1 and 2). This intermediate sheet member 50 is molded into a flat plate shape from an electrically insulating synthetic resin material. In this case, it is molded into a rectangular flat plate shape.

[0038] In the manufacturing method of this flat cable member 1A, for example, the intermediate sheet member 50 is assembled in the connection step. In the connection step, for example, a plurality of pieces 10 are arranged according to the power distribution path, and the intermediate sheet member 50 is placed between two adjacent pieces 10. In this connection step, a laser beam is irradiated to join the ends of the conductive members 30 protruding from the base sheet member 20 to the intermediate sheet member 50, and then the output of the laser beam is increased to physically and electrically connect the ends of the conductive members 30. Conversely, in the connection step, a laser beam may be irradiated to physically and electrically connect the ends of the conductive members 30, and then the output of the laser beam may be decreased to join the ends of the conductive members 30 protruding from the base sheet member 20 to the intermediate sheet member 50.

[0039] In this flat cable routing material 1A, five first pieces 11A serve as the ends of the power distribution path, and connectors 60 are connected to the ends of the first conductive members 31A of these five first pieces 11A (Figure 2).

[0040] Thus, this flat cable guide 1A requires the placement of an intermediate sheet member 50 between every two adjacent pieces 10, which leads to an increase in the number of parts and a larger overall size. Therefore, Figures 8 and 9 show a flat cable guide 1B that improves upon this point. The flat cable guide 1B shown here has the same circuit configuration as the flat cable guide 1A.

[0041] The flat cable member 1B does not use an intermediate sheet member 50. Therefore, two adjacent pieces 10 abut each other at the peripheral edges of their respective base sheet members 20, and abut each other at the ends of their respective conductive members 30, thereby physically and electrically connecting their ends.

[0042] In this flat cable guide 1B, the first piece 11A, second piece 11B, third piece 11C, and fourth piece 11D in the flat cable guide 1A are replaced with the first piece 12A, second piece 12B, third piece 12C, and fourth piece 12D shown below (Figures 8 and 9). Then, in this flat cable guide 1B, the first cover sheet member 41 in the flat cable guide 1A is replaced with a cover sheet member 40 (hereinafter referred to as "second cover sheet member 42") that matches each of its pieces 10 (Figure 9). In this flat cable guide 1B, 20 first pieces 12A, 4 second pieces 12B, 1 third piece 12C, and 1 fourth piece 12D are arranged in the same configuration as each piece 10 in the flat cable guide 1A. In this flat cable guide 1B, all of its pieces 10 are covered by a single second cover sheet member 42.

[0043] In this flat cable guide 1B, all four types of pieces 10 (first piece 12A, second piece 12B, third piece 12C, and fourth piece 12D) use a base sheet member 20 that is formed into a square flat plate shape.

[0044] The first piece 12A comprises six linearly shaped conductive members 30 (hereinafter referred to as "first conductive members 32A") (Figure 10). In this first piece 12A, the six first conductive members 32A are arranged at equal intervals along a pair of parallel sides 20a and 20b of the base sheet member 20. The six first conductive members 32A are positioned on the base sheet member 20 with one end face aligned to the end face of the first side 20a and the other end face aligned to the end face of the second side 20b.

[0045] The second piece 12B comprises six conductive members 30 (hereinafter referred to as "second conductive members 32B"), each molded into an L-shape of a different length (Figure 11). In this second piece 12B, the bent portions of the six second conductive members 32B are placed on the diagonal of the base sheet member 20 and arranged at equal intervals. The spacing between two adjacent second conductive members 32B is the same as the spacing between two adjacent first conductive members 32A in the first piece 12A. The six second conductive members 32B are arranged on the base sheet member 20 with one end face aligned with the end face of the first side portion 20a and the other end face aligned with the end face of the third side portion 20c.

[0046] The third piece 12C comprises four first conductive members 32A and one L-shaped conductive member 30 (hereinafter referred to as "third conductive member 32C") (Figure 12).

[0047] In this third piece 12C, the four first conductive members 32A are arranged at equal intervals along a pair of parallel sides 20a and 20b of the base sheet member 20, just as in the first piece 12A. The spacing between two adjacent first conductive members 32A is the same as the spacing between two adjacent first conductive members 32A in the first piece 12A. The four first conductive members 32A are positioned on the base sheet member 20 with one end face aligned to the end face of the first side 20a and the other end face aligned to the end face of the second side 20b.

[0048] For example, in this third piece 12C, four first conductive members 32A are arranged such that the first conductive member 32A closest to the third side 20c is connected to the first conductive member 32A closest to the third side 20c in the first piece 12A.

[0049] Furthermore, in this third piece 12C, the third conductive member 32C is positioned on the base sheet member 20 with one end face aligned to the end face of the fourth side portion 20d and the other end face aligned to the end face of the second side portion 20b. The shaft portion of the third conductive member 32C is positioned on the base sheet member 20 with a gap between it and the first conductive member 32A closest to the fourth side portion 20d, with a gap between them on the fourth side portion 20d side. This gap is the same as the gap between two adjacent first conductive members 32A.

[0050] The fourth piece 12D comprises four first conductive members 32A and two L-shaped conductive members 30 of the same shape (hereinafter referred to as "fourth conductive member 32D") (Figure 13).

[0051] In this fourth piece 12D, the four first conductive members 32A are arranged at equal intervals along a pair of parallel sides 20a and 20b of the base sheet member 20, just as in the first piece 12A. The four first conductive members 32A are positioned on the base sheet member 20 with one end face aligned to the end face of the first side 20a and the other end face aligned to the end face of the second side 20b. The spacing between two adjacent first conductive members 32A is the same as the spacing between two adjacent first conductive members 32A in the first piece 12A.

[0052] Furthermore, in this fourth piece 12D, one end face of the fourth conductive member 32D is positioned on the base sheet member 20 with the end face of one end aligned with the end face of the fourth side portion 20d, and the end face of the other end aligned with the end face of the second side portion 20b. The other fourth conductive member 32D is positioned on the base sheet member 20 with the shaft portion of the other end positioned at a distance from the first conductive member 32A closest to the fourth side portion 20d, with a gap on the fourth side portion 20d side. This gap is the same as the gap between two adjacent first conductive members 32A. Furthermore, in this fourth piece 12D, the other fourth conductive member 32D is positioned on the base sheet member 20 with the end face of one end aligned with the end face of the third side portion 20c, and the end face of the other end aligned with the end face of the second side portion 20b. The other fourth conductive member 32D is positioned on the base sheet member 20 with its other end shaft portion spaced apart from the first conductive member 32A on the third side 20c side. This spacing is the same as the spacing between two adjacent first conductive members 32A.

[0053] In the connection process, the peripheral edges of the respective base sheet members 20 and the ends of the respective conductive members 30 are abutted together at two adjacent pieces 10, and the multiple pieces 10 are arranged according to the power distribution path. Then, in this connection process, the ends of the abutted conductive members 30 are joined together by irradiating them with laser light or the like.

[0054] Compared to the flat cable guide 1A, this flat cable guide 1B allows for a reduction in the number of parts and a smaller overall size.

[0055] Figures 14 and 15 show a flat cable routing member 1C made up of five types of pieces 10 (first piece 13A, second piece 13B, third piece 13C, fourth piece 13D, and fifth piece 13E). The flat cable routing member 1C shown here has the same circuit configuration as flat cable routing members 1A and 1B. In the flat cable routing member 1C shown here, all of the pieces 10 are covered with the second cover sheet member 42 of the flat cable routing member 1B.

[0056] The first piece 13A corresponds to two first pieces 12A of the flat cable member 1B being electrically connected. This first piece 13A comprises a rectangular flat base sheet member 20 (hereinafter referred to as the "first base sheet member 21") and six linear conductive members 30 (hereinafter referred to as the "first conductive members 33A") (Figure 16). In this first piece 13A, the six first conductive members 33A are arranged at equal intervals along a pair of parallel sides 21a, 21b extending in the short direction of the first base sheet member 21. The six first conductive members 33A are arranged on the first base sheet member 21 such that the end face of one end is aligned with the end face of one of the pair of side portions 21a, 21b (hereinafter referred to as the "first side portion") 21a, and the end face of the other end is aligned with the end face of the other side of the pair of side portions 21a, 21b (hereinafter referred to as the "second side portion") 21b.

[0057] The second piece 13B corresponds to three first pieces 12A of the flat cable member 1B connected electrically. This second piece 13B comprises a rectangular flat base sheet member 20 (hereinafter referred to as "second base sheet member 22") and six linear conductive members 30 (hereinafter referred to as "second conductive members 33B") (Figure 17). In this second piece 13B, the six second conductive members 33B are arranged at equal intervals along a pair of parallel sides 22a, 22b extending in the short direction of the second base sheet member 22. The spacing between two adjacent second conductive members 33B is the same as the spacing between two adjacent first conductive members 33A in the first piece 13A. The six second conductive members 33B are arranged on the second base sheet member 22 such that the end face of one end is aligned with the end face of one of the pair of side portions 22a, 22b (hereinafter referred to as the "first side portion") 22a, and the end face of the other end is aligned with the end face of the other side of the pair of side portions 22a, 22b (hereinafter referred to as the "second side portion") 22b.

[0058] The third piece 13C corresponds to the arrangement of adjacent flat wiring members 1B, where the third piece 12C, the first piece 12A, the first piece 12A, and the fourth piece 12D are electrically connected in the smallest possible circuit. This third piece 13C comprises a rectangular flat base sheet member 20 (hereinafter referred to as "third base sheet member 23"), three linear conductive members 30 (hereinafter referred to as "third conductive member 33C1"), one L-shaped conductive member 30 (hereinafter referred to as "fourth conductive member 33C2"), and two L-shaped conductive members 30 of the same shape but shorter in length than the fourth conductive member 33C2 (hereinafter referred to as "fifth conductive member 33C3") (Figure 18).

[0059] In this third piece 13C, the three third conductive members 33C1 are arranged at equal intervals along a pair of parallel edges 23a and 23b extending in the shorter direction on the third base sheet member 23, just as in the first piece 13A. The spacing between two adjacent third conductive members 33C1 is the same as the spacing between two adjacent first conductive members 33A in the first piece 13A. The three third conductive members 33C1 are positioned on the third base sheet member 23 such that the end face of one end aligns with the end face of one of the pair of edges 23a and 23b (hereinafter referred to as the "first edge") 23a, and the end face of the other end aligns with the end face of the other of the pair of edges 23a and 23b (hereinafter referred to as the "second edge") 23b.

[0060] Furthermore, in this third piece 13C, the fourth conductive member 33C2 is positioned on the third base sheet member 23 such that the end face of one end is aligned with the end face of one of the longitudinally extending sides (hereinafter referred to as the "third side") 23c of the third base sheet member 23, and the end face of the other end is aligned with the end face of the second side 23b. The fourth conductive member 33C2 is positioned on the third base sheet member 23 such that the shaft portion on one end is positioned towards the first side 23a, and the shaft portion on the other end is positioned at a distance from the third conductive member 33C1 closest to the third side 23c on the third side 23c side. This distance is the same as the distance between two adjacent first conductive members 33A in the first piece 13A.

[0061] Furthermore, in this third piece 13C, one of the fifth conductive members 33C3 is positioned on the third base sheet member 23 with one end face aligned to the end face of the third side portion 23c and the other end face aligned to the end face of the second side portion 23b. The other fifth conductive member 33C3 is positioned on the third base sheet member 23 with the shaft portion at one end closer to the second side portion 23b and the shaft portion at the other end spaced apart from the shaft portion at the other end of the fourth conductive member 33C2 towards the third side portion 23c. This spacing is the same as the spacing between the two adjacent first conductive members 33A in the first piece 13A.

[0062] Furthermore, in this third piece 13C, the other fifth conductive member 33C3 is positioned on the third base sheet member 23 such that the end face of one end aligns with the end face of the other side (hereinafter referred to as the "fourth side") 23d that extends longitudinally on the third base sheet member 23, and the end face of the other end aligns with the end face of the second side 23b. The other fifth conductive member 33C3 is positioned on the third base sheet member 23 such that the shaft portion on the one end side is closer to the second side 23b, and the shaft portion on the other end side is spaced further towards the fourth side 23d relative to the third conductive member 33C1 closest to the fourth side 23d. This spacing is the same as the spacing between two adjacent first conductive members 33A in the first piece 13A.

[0063] The fourth piece 13D corresponds to electrically connecting adjacent pieces in the flat cable member 1B in the order of second piece 12B, first piece 12A, first piece 12A, and second piece 12B. This fourth piece 13D comprises a third base sheet member 23 and six conductive members 30 that are molded into a crank shape and arranged at equal intervals (Figure 19). The six conductive members 30 are arranged on the third base sheet member 23 with one end face aligned with the end face of the third side 23c on the second side 23b side, and the other end face aligned with the end face of the fourth side 23d on the first side 23a side. The six conductive members 30 shown here are combinations of two of three different lengths and can be broadly classified into a sixth conductive member 33D1, a seventh conductive member 33D2, and an eighth conductive member 33D3.

[0064] The fifth piece 13E is similar to the fourth piece 13D, but differs from the fourth piece 13D in that the end faces of one end of the six conductive members 30 (two sixth conductive members 33D1, two seventh conductive members 33D2, and two eighth conductive members 33D3) are aligned on the same plane as the end face of the third side 23c on the first side 23a, and the end faces of the other ends are aligned on the same plane as the end face of the fourth side 23d on the second side 23b, and are placed on the third base sheet member 23 (Figure 20).

[0065] These flat wiring members 1 (1A, 1B, 1C) can be used to create diverse circuit configurations that correspond to various power distribution routes by changing the combination and arrangement of multiple pieces (pieces for flat wiring members) 10.

[0066] For example, the flat cable routing member 1B shown earlier divides the six circuits of the first piece 12A on the right side of the page into three directions using the fourth piece 12D. Here, by replacing the fourth piece 12D with the first piece 12A in this flat cable routing member 1B, another flat cable routing member 1D can be created in which the six circuits of the first piece 12A on the right side of the page are connected to the six circuits of the first piece 12A on the left side of the page (Figure 21). In this flat cable routing member 1D, a cover sheet member 40 (hereinafter referred to as the "third cover sheet member 43") is provided, and this third cover sheet member 43 covers all the pieces (pieces for the flat cable routing member) 10.

[0067] As described above, the flat cable guides 1 (1A, 1B, 1C, 1D) of this embodiment can easily accommodate various circuit configurations, for example, depending on the presence or absence of auxiliary equipment and other parts due to differences in vehicle specifications, or the presence or absence of optional equipment. Furthermore, the flat cable guides 1 (1A, 1B, 1C, 1D) of this embodiment can easily accommodate design changes in the circuit configuration, for example, from flat cable guide 1B to flat cable guide 1D. Therefore, the flat cable guides 1 (1A, 1B, 1C, 1D) of this embodiment can flexibly accommodate circuit configurations according to various power distribution routes. Thus, the flat cable guides 1 (1A, 1B, 1C, 1D) of this embodiment can be said to be suitable for high-mix, low-volume production.

[0068] Furthermore, the flat cable guides 1 (1A, 1B, 1C, 1D) of this embodiment allow the pieces (pieces for flat cable guides) 10 to be shared among various circuit configurations, thus reducing costs.

[0069] Furthermore, the flat cable routing material 1 (1A, 1B, 1C, 1D) of this embodiment is formed by arranging multiple pieces (pieces for flat cable routing material) 10 and physically and electrically connecting the ends of conductive members 30 between two adjacent pieces (pieces for flat cable routing material) 10. Therefore, the flat cable routing material 1 (1A, 1B, 1C, 1D) of this embodiment is more suitable for automating the production process compared to cable routing materials that require multiple wires to be routed according to the routing path and then bundled together.

[0070] Furthermore, the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment can suppress the thickness (thickness t2 < t1) of each piece (piece for flat cable material) 10 compared with the cable material We (thickness t1) formed by a wire bundle (FIG. 22), so that the thickness can be reduced. Therefore, the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment is easier to install in a narrow space in a vehicle or the like compared with the cable material formed by a wire bundle. In addition, the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment can suppress the occupancy rate in the space to be low compared with the cable material formed by a wire bundle, so that the space after installation can be used widely.

[0071] Furthermore, the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment does not require chemicals such as when forming the circuit pattern of a flexible printed board, and post-treatment such as disposing of the chemicals afterwards becomes unnecessary. Therefore, compared with such a flat cable material, it has high environmental performance.

[0072] Furthermore, when the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment is stored in a storage box and transported, the storage efficiency in the storage box is high compared with the cable material formed by a wire bundle, and the gap in the box can be reduced. Therefore, a large number of them can be transported at once.

[0073] Furthermore, the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment may become thicker compared to the flat cable material made of a flexible printed circuit board by providing thickness to the base sheet member 20 and the cover sheet member 40. However, since the thickness of the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment leads to an increase in the rigidity of the base sheet member 20 and the cover sheet member 40, the durability can be improved. And, compared to the cable material made of a wire bundle, the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment is easy to maintain its shape due to the rigidity of the base sheet member 20 and the cover sheet member 40 and does not get entangled during transportation, so it can be taken out of the storage box and immediately assembled to a vehicle or the like. That is, compared to the cable material made of a wire bundle, the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment can reduce the number of man-hours required for the assembly work and has excellent assembly workability.

[0074] Furthermore, the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment has flexibility in the base sheet member 20 and the cover sheet member 40 while giving the base sheet member 20 and the cover sheet member 40 enough rigidity to maintain a non-entangled shape, so that it can be stored in a storage box in a bent state.

[0075] Specifically, in the flat cable material 1 (1A, 1B, 1C, 1D) of the present embodiment, the ends of the conductive members 30 are physically and electrically connected between two adjacent pieces (pieces for flat cable material) 10, but the base sheet members 20 are not connected to each other. Therefore, the flat cable material 1 (1A, 1B, 1C, 1D) can be bent between two adjacent pieces (pieces for flat cable material) 10. For the flat cable material 1A, it is bent between two adjacent pieces (pieces for flat cable material) 10 around the intermediate sheet member 50. For example, the flat cable material 1 (in FIGS. 23) of the present embodiment can reduce its thickness (thickness T2 < T1) compared to the folded cable material made of a wire bundle (thickness T1) by folding two adjacent pieces (pieces for flat cable material) 10 between them.

[0076] Therefore, the flat cable routing material 1 (1A, 1B, 1C, 1D) of this embodiment further improves storage efficiency in the storage box, allowing for the transport of more at once. Furthermore, even if the flat cable routing material 1 (1A, 1B, 1C, 1D) of this embodiment is folded between two adjacent pieces (pieces for flat cable routing material) 10, it can be immediately returned to its original shape after being removed from the storage box. Compared to cable routing materials made of wire bundles, which may require unraveling, this embodiment reduces the number of work steps required before assembly and offers superior assembly workability.

[0077] In this example, the flat cable guides 1 (1A, 1B, 1C, 1D) are bent between two adjacent pieces (pieces for flat cable guides) 10 when transporting them. However, in this embodiment, the flat cable guides 1 (1A, 1B, 1C, 1D) may also be bent between two adjacent pieces (pieces for flat cable guides) 10 depending on the cable routing path when assembled to a vehicle, for example.

[0078] Furthermore, the flat cable guide 1C of this embodiment, compared to the flat cable guide 1B, has the same circuit configuration, but the number of required pieces (pieces for the flat cable guide) 10 can be reduced. Therefore, the flat cable guide 1C can reduce the number of connection points of the conductive member 30 compared to the flat cable guide 1B, thereby reducing the number of work hours required for manufacturing and lowering costs. [Explanation of Symbols]

[0079] 1,1A,1B,1C,1D Flat wiring material 10 pieces 11A, 12A, 13A First Piece 11B, 12B, 13B Second piece 11C, 12C, 13C Third piece 11D, 12D, 13D 4th piece 13E Piece 5 20 Foundation sheet member 21. First foundation sheet member 22 Second foundation sheet member 23 Third foundation sheet member 30 Conductive material 31A, 32A, 33A First conductive member 31B, 32B, 33B Second conductive member 31C, 32C, 33C1 Third conductive member 31D, 32D, 33C2 Fourth conductive member 33C3 Fifth conductive member 33D1 Sixth conductive member 33D2 7th conductive member 33D3 8th conductive member 40 Cover sheet component 41. First cover sheet member 42. Second cover sheet member 43 Third cover sheet member 50 Intermediate sheet member

Claims

1. It consists of multiple pieces arranged according to the power distribution route, The aforementioned piece comprises at least one type, which includes a base sheet member molded into a flat plate shape from an electrically insulating synthetic resin material, and at least one conductive member joined to one plane of the base sheet member. A flat cable material characterized in that two adjacent pieces are physically and electrically connected at the ends of the conductive member in one piece and the ends of the conductive member in the other piece.

2. The flat cable member according to claim 1, characterized in that the conductive member has one end and the other end protruding from the peripheral edge of the base sheet member.

3. The present invention provides an intermediate sheet member that fills the gap between each of the foundation sheet members between two adjacent pieces and joins the ends of each of the conductive members that protrude from each of the foundation sheet members in between, The flat cable material according to claim 2, characterized in that the intermediate sheet member is formed into a flat plate shape from an electrically insulating synthetic resin material.

4. The flat cable material according to claim 1, characterized in that two adjacent pieces abut each other at the peripheral edges of their respective base sheet members and abut each other at the ends of their respective conductive members.

5. The flat cable member according to claim 1, 2, 3, or 4, characterized in that it is molded from an electrically insulating synthetic resin material into a flat plate shape spanning a plurality of connected pieces, and comprises a cover sheet member that covers the conductive members provided therein from the side opposite to the base sheet member.

6. The flat cable material according to claim 1, 2, 3, or 4, characterized in that the conductive member is formed into a flat plate shape.

7. The flat cable member according to claim 1, 2, 3, or 4, characterized by being bent between two adjacent pieces.

8. A piece manufacturing process involves installing a base sheet member molded into a flat plate shape from an electrically insulating synthetic resin material, placing at least one conductive member on one of the planes of the base sheet member, and joining the plane of the base sheet member and the conductive member to produce at least one type of piece, A connection step involves arranging a plurality of the aforementioned pieces according to a power distribution path, and physically and electrically connecting the ends of the conductive member in one of the aforementioned pieces to the ends of the conductive member in the other of two adjacent aforementioned pieces. A method for manufacturing a flat cable material, characterized by having the following characteristics.

9. A base sheet member formed into a flat plate shape from an electrically insulating synthetic resin material, At least one conductive member is joined to one plane of the base sheet member, Equipped with, The aforementioned foundation sheet member is installed adjacent to an adjacent foundation sheet member that is molded into a flat plate shape from an electrically insulating synthetic resin material. The conductive member is a flat piece for cable rigging, characterized in that it physically and electrically connects its own end to the end of an adjacent conductive member joined to one plane of the adjacent foundation sheet member.

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