Patent Grant
10403418
The present invention relates to a multicore cable having multiple coaxial cables arranged in parallel and a method for manufacturing the multicore cable.
With popularization of electronic equipment such as a laptop computer, a mobile phone, and a small-sized video camera, size reduction and weight reduction in these types of electronic equipment have been demanded. In addition, a higher speed and higher image quality have been also demanded. Conventionally, an extremely-thin coaxial cable has been used for, e.g., connection between an equipment body and a liquid crystal display unit and wiring in equipment. Because of easy wiring, a harness-shaped multicore cable including multiple assembled and integrated coaxial cables has been used (e.g., Patent Literature 1).
For the electronic equipment, cost reduction has been demanded in addition to size reduction, weight reduction, the higher speed, and the higher image quality. Thus, cost reduction has been also demanded for a multicore cable mounted on the electronic equipment.
An object of the present invention is to provide a multicore cable configured so that cost reduction can be realized and a method for manufacturing the multicore cable.
A multicore cable according to the present invention includes: multiple coaxial cables arranged in parallel; and a ground member conductively connected with the coaxial cables. Each coaxial cable includes an internal conductor, an internal insulating layer covering an outer peripheral surface of the internal conductor, an external conductor covering an outer peripheral surface of the internal insulating layer, a covering layer covering an outer peripheral surface of the external conductor, a removed portion formed in such a manner that part of the covering layer in a circumferential direction is removed such that the external conductor is exposed, and a conductive member filling the removed portion, and the ground member is conductively connected with the conductive member filling the removed portion.
According to the above-described configuration, part of the covering layer is removed, and therefore, the frequency of damaging the coaxial cable upon removal of the covering layer is more reduced as compared to the case of removing the entire circumference of the covering layer. Thus, a yield rate is improved. Consequently, cost reduction in the multicore cable can be realized.
The removed portion in the present invention may be formed in a hole shape.
According to the above-described configuration, the removed portion can be, with high accuracy, easily formed at a desired position by punching with a drill or a laser beam.
The removed portion in the present invention may be formed in a truncated pyramid shape having the maximum diameter on an outer peripheral side of the covering layer.
According to the above-described configuration, the process of filling the removed portion with the conductive member is facilitated.
In at least one of the coaxial cables in the present invention, the internal conductor may be further exposed through the removed portion.
According to the above-described configuration, the internal conductor and the external conductor are exposed through the removed portion. Thus, the internal conductor and the external conductor are in electric conduction with each other through the conductive member filling the removed portion. Consequently, the multicore cable can be formed using the same coaxial cable. In addition, in at least one of the coaxial cables, the total of the cross-sectional area of the internal conductor and the cross-sectional area of the external conductor can be a current flow path cross-sectional area. Thus, the multicore cable of the present invention can be used as a ground short circuit cable exhibiting reduced electric resistance.
The ground member and the conductive member in the present invention may be formed from conductive paste.
According to the above-described configuration, the process of connecting the ground member with the external conductor can be completed by one step as compared to the case of using a plate-shaped ground bar as the ground member. That is, filling the removed portion with the conductive member and connection of the ground member with the coaxial cable can be completed using the conductive paste by one step. Thus, excellent workability is exhibited.
In the present invention, the internal insulating layer in each coaxial cable may contain modified polyphenylene ether or a resin mixture of cycloolefin resin and styrene-butadiene copolymer.
The modified polyphenylene ether is easily evaporated by an excimer laser beam. Thus, according to the above-described configuration, the removed portion can be easily formed by excimer laser processing.
A method for manufacturing a multicore cable according to an embodiment of the present invention is a method for manufacturing a multicore cable that includes multiple coaxial cables arranged in parallel and a ground member conductively connected with the coaxial cables. The method includes: forming a removed portion in such a manner that part of a covering layer of each coaxial cable including an internal conductor, an internal insulating layer covering an outer peripheral surface of the internal conductor, an external conductor covering an outer peripheral surface of the internal insulating layer, and the covering layer covering an outer peripheral surface of the external conductor is removed in a circumferential direction such that the external conductor is exposed, and subsequently filling the removed portion with a conductive member; and conductively connecting the ground member with the conductive member filling the removed portion in a state in which the coaxial cables are arranged in parallel.
According to the above-described configuration, part of the covering layer is removed, and therefore, the frequency of damaging the coaxial cable upon removal of the covering layer is more reduced as compared to the conventional case of removing the entire circumference of the covering layer. Thus, the yield rate is improved. Consequently, cost reduction in the multicore cable can be realized.
The removed portion in the present invention may be formed by a laser beam.
According to the above-described configuration, the removed portion can be easily formed.
A method for manufacturing a multicore cable according to another embodiment of the present invention is a method for manufacturing a multicore cable that includes multiple coaxial cables arranged in parallel and a ground member conductively connected with the coaxial cables. The method includes: forming a removed portion in such a manner that part of a covering layer of each coaxial cable including an internal conductor, an internal insulating layer covering an outer peripheral surface of the internal conductor, an external conductor covering an outer peripheral surface of the internal insulating layer, and the covering layer covering an outer peripheral surface of the external conductor is removed in a circumferential direction such that the external conductor is exposed, and subsequently filling the removed portion with conductive paste to form a conductive member in a state in which the coaxial cables are arranged in parallel while forming the ground member from the conductive paste.
According to the above-described configuration, the removed portion of the covering layer is used as a mark so that determination of the axial positions of the coaxial cables arranged in parallel can be easily performed with high accuracy. Further, the removed portions of the coaxial cables arranged in parallel are filled with the conductive paste. Thus, a conductive member is formed. In addition, a ground member is also formed. With this configuration, the process of connecting the ground member with the external conductor can be completed by one step as compared to the case of using a plate-shaped ground bar as the ground member. That is, filling the removed portion with the conductive member and connection of the ground member with the coaxial cable can be completed using the conductive paste by one step. Thus, the multicore cable manufacturing method of the present invention exhibits excellent workability.
According to the present invention, the frequency of damaging the coaxial cable upon removal of the covering layer is reduced. Thus, the yield rate is improved. Consequently, cost reduction in the multicore cable can be realized.
Hereinafter, a preferable embodiment of the present invention will be described with reference to the drawings.
(Multicore Cable 10)
As illustrated in
The multicore cable 10 has internal conductors 11a of the coaxial cables 11 bent as necessary. Each internal conductor 11a is, at a soldering portion 30c, soldered to a corresponding one of multiple connection target portions 30b provided at a connection target member 30. Note that in a case where the connection target member 30 is not a substrate but a connector, i.e., a case where the multicore cable 10 is a connector-equipped multicore cable, a metal plate shell having a backwards C-shaped cross-section is soldered onto the ground member 15 on one side to cover the ground member 15. The shell is soldered onto the ground member 15 in such a manner that solder is injected through a solder injection hole arranged at an upper surface of the shell. Moreover, both tip ends of the shell are connected to a connection target portion of the connector for grounding. Thus, the ground member 15 is grounded.
Note that the multicore cable 10 may employ various forms such as a form in which a connector is provided at each end portion and a form in which a connector is provided at one end portion and a substrate is connected at the other end portion.
The coaxial cable 11 has the internal conductor 11a, an internal insulating layer 11b covering an outer peripheral surface of the internal conductor 11a, an external conductor 11c covering an outer peripheral surface of the internal insulating layer 11b, a covering layer 11d covering an outer peripheral surface of the external conductor 11c, a removed portion 11e formed in such a manner that part of the covering layer 11d in a circumferential direction is removed such that the external conductor 11c is exposed, and a conductive member 21 filling the removed portion 11e. The ground member 15 is conductively connected to the conductive member 21 filling the removed portion 11e.
In the multicore cable 10 configured as described above, the removed portion 11e of the coaxial cable 11 is formed by removal of part of the covering layer 11d. Thus, cost reduction can be realized. A reason for realizing cost reduction will be described in detail below. In the case of removing part of the covering layer 11d, external force on the coaxial cable 11 is more reduced as compared to the case of removing the entire circumference of the covering layer 11d. Moreover, a removal amount is reduced. Thus, resistive force against the external force increases. Consequently, the probability of damaging the coaxial cable 11 in a process in which the external force is on the coaxial cable 11, such as the process of removing the covering layer 11d or a terminal process after removal, is reduced. As a result, the yield rate of the coaxial cable 11 is improved. Thus, cost reduction in the multicore cable 10 can be realized.
Further, the multicore cable 10 configured as described above uses, as a mark, the removed portions 11e or the conductive members 21 filling the removed portions 11e so that the conductive members 21 of the coaxial cables arranged in parallel can contact the ground members 15, 16 and can be conductively connected with the ground members 15, 16. In this manner, a positional relationship in the axial direction of the coaxial cable 11 among the ground members 15, 16 and the coaxial cables 11 can be determined with high accuracy. Moreover, the multicore cable 10 uses, as a mark, the removed portions 11e or the conductive members 21 filling the removed portions 11e so that the coaxial cables 11 can be arranged in parallel. In addition, the conductive members 21 of these coaxial cables can contact the ground members 15, 16, and can be conductively connected with the ground members 15, 16. Note that in the present embodiment, a case where the conductive members 21 of the coaxial cables arranged in parallel can contact the ground members 15, 16 will be described. Note that the present embodiment is not limited to this case.
(Multicore Cable 10: Coaxial Cable 11)
As described above, the coaxial cable 11 is formed in such a manner that the internal conductor 11a, the internal insulating layer 11b, the external conductor 11c, and the covering layer 11d are coaxially arranged from an inner peripheral side to an outer peripheral side. A process of removing a portion of the internal insulating layer 11b to expose the internal conductor 11a by a length sufficient for the connection is performed on an end portion of the coaxial cable 11. In this manner, the coaxial cable 11 is configured such that the internal conductor 11a and the internal insulating layer 11b are, in this order from a tip end side, exposed in a stepwise manner by predetermined lengths.
For example, the internal conductor 11a is formed from twisted seven copper alloy wires. The internal insulating layer 11b is formed in such a manner that an outer surface of the internal conductor 11a is covered by an insulating material such as Teflon (registered trademark) resin as fluorine resin. Preferably, “modified polyphenylene ether resin” or a “resin mixture of cycloolefin resin and styrene-butadiene copolymer” is used for the internal insulating layer 11b. This is because these resins are easily evaporated by an excimer laser beam, and therefore, the removed portion 11e can be easily formed by excimer laser processing. Details will be described later.
For example, the external conductor 11c is formed from a copper alloy wire horizontally wound in a spiral manner. For example, the covering layer 11d can be formed in such a manner that two polyester tapes lap-wound around an outer surface of the external conductor 11c are fused to each other. Note that the internal conductor 11a may be formed from a copper wire. The internal insulating layer 11b may be, in addition to the fluorine resin, made of a resin mixture of polyvinyl chloride (PVC), modified polyphenylene ether (m-PPE), or cycloolefin resin (COP) and styrene-butadiene copolymer. The external conductor 11c and the covering layer 11d can be formed in such a manner that a copper-deposited PET tape is wound around the outer peripheral surface of the internal insulating layer 11b with a copper-deposited surface facing inside. Alternatively, the external conductor 11c may be formed from two layers wound in a direction opposite to a winding direction of the copper alloy wires of the internal conductor 11a. As another alternative, the external conductor 11c may be formed to have other structures. The external conductor 11c may be formed from conductive paste such as Ag paste. The covering layer 11d can be made of fluorine resin, urethane resin, or polycarbonate resin.
One example of the coaxial cable 11 will be specifically described. A cable corresponding to AWG42 of American Wire Gage (AWG) standards is used as the coaxial cable 11. The outer diameter of the AWG42 coaxial cable 11 is set to 0.31 mm. For example, the internal conductor 11a is formed in such a manner that seven tin-plated copper alloy wires having an outer diameter of 0.025 mm are twisted. The internal insulating layer 11b is formed in such a manner that the outer peripheral surface of the internal conductor 11a is covered by fluorine resin such as perfluoroalkoxy fluorine resin (PFA). The outer diameter of the internal insulating layer 11b is set to 0.17 mm. The external conductor 11c is formed in such a manner that a tin-plated copper alloy wire having an outer diameter of 0.03 mm is spirally wound around the outer peripheral surface of the internal insulating layer 11b. The outer diameter of the external conductor 11c is set to 0.23 mm. The covering layer 11d is formed in such a manner that the outer peripheral surface of the external conductor 11c is covered by fluorine resin such as PFA.
(Multicore Cable 10: Coaxial Cable 11: Removed Portion 11e)
In the removed portion 11e, the outer peripheral surface of the external conductor 11c is exposed in such a manner that part of the covering layer 11d in the circumferential direction is removed. “Removal of the covering layer 11d” as described herein may be performed by any processing method. For example, a laser beam and a drill may be used. “Exposure of the external conductor 11c” as described herein means that at least one of the outer peripheral surface of the external conductor 11c as an outer peripheral surface in a radial direction, an inner peripheral surface of the external conductor 11 c as an inner peripheral surface in the radial direction, and an end surface of the external conductor 11c as a cut surface is exposed. “Exposure” means that an outer peripheral structure such as the covering layer 11d is removed from an inner peripheral structure, such as the external conductor 11c, covered by the outer peripheral structure so that filling with a filler such as the conductive member 21 from an external space is possible.
As illustrated in
Note that the removed portion 11e may be in a hole shape having a peripheral edge portion surrounded by the covering layer. That is, the hole shape of the removed portion 11e is not limited to the oval shape. The hole shape may be a circular shape, a triangular shape, a rectangular shape, or a polygonal shape.
(Multicore Cable 10: Coaxial Cable 11: Variations of Removed Portion 11e)
In the present embodiment, a case where the removed portion 11e is formed in the hole shape has been described. Note that the present embodiment is not limited to this case. Specifically, as illustrated in
As illustrated in
Alternatively, as illustrated in
In the present embodiment, a case where the removal depth of the removed portion 11e is set to such an extent that the outer peripheral surface of the external conductor 11c is exposed as illustrated in
In the present embodiment, the removed portion 11e is formed in such a manner that the laser beam 40 is irradiated such that the top of the coaxial cable 11 and the center of the laser beam 40 are coincident with each other. Note that irradiation with the laser beam 40 is not limited to above. Specifically, as illustrated in
Alternatively, as illustrated in
(Multicore Cable 10: Ground Coaxial Cable 12)
As illustrated in
According to the above-described configuration, the internal conductor 12a and the external conductor 12c are exposed through the removed portion 12e. Thus, the internal conductor 12a and the external conductor 12c are in electric conduction with each other through the conductive member 21 filling the removed portion 12e. Accordingly, the multicore cable can be formed using the same coaxial cable 11 while the total of the cross-sectional area of the internal conductor 11a (12a) and the cross-sectional area of the external conductor 11c (12c) can be a current flow path cross-sectional area in at least one coaxial cable 11 (the ground coaxial cable 12). Thus, the ground coaxial cable 12 can be used as a ground short circuit cable exhibiting reduced electric resistance.
In the ground coaxial cable 12, the covering layer 12d, the external conductor 12c, and the internal insulating layer 12b are removed such that the laser beam 40 reaches the internal conductor 12a. Thus, the removed portion 12e is formed in a region from the surface of the covering layer 12d irradiated with the laser beam 40 to the internal conductor 12a. That is, the removed portion 12e is formed to have a depth corresponding to the radius of the ground coaxial cable 12 and to reach the internal conductor 12a. Note that as illustrated in
(Multicore Cable 10: Coaxial Cable 11: Conductive Member 21)
The conductive member 21 is formed from a member exhibiting conductivity, such as conductive paint or solder. Note that it is demanded for easily filling the removed portion 11e with the conductive member 21 that the conductive member 21 is in a paste state upon filling and is in a solid state upon use of the multicore cable 10. For example, the conductive member 21 includes solder thermally changeable to a molten state or a solid state.
Alternatively, the conductive member 21 may be, upon filling, conductive paste such as a conductive adhesive, conductive ink, or conductive paint in a paste form. Specifically, paste obtained by mixing of metal particles, an organic solvent, and resin can be applied as the conductive paste. Examples of the metal particle include silver and silver-coated copper powder (a spherical shape and a flake shape). Examples of the organic solvent include ethyl acetate, toluene, acetone, ethyl methyl ketone, and hexane. Examples of the resin include epoxy resin and phenol resin. In this case, the process of connecting the ground members 15, 16 with the external conductor 11c, i.e., filling the removed portion 11e with the conductive member 21 and connection of the ground members 15, 16 with the coaxial cable 11, can be completed using the conductive paste by one step. Thus, the multicore cable 10 exhibits excellent workability.
(Multicore Cable 10: Ground Members 15, 16)
As illustrated in
(Method for Manufacturing Multicore Cable)
Next, the method for manufacturing the multicore cable 10, i.e., the method for manufacturing the multicore cable 10 including the coaxial cables 11 arranged in parallel and the ground members 15, 16 conductively connected with the coaxial cables 11, will be described.
In the method for manufacturing the multicore cable 10, part of the covering layer 11d of each coaxial cable 11 including the internal conductor 11a, the internal insulating layer 11b covering the outer peripheral surface of the internal conductor 11a, the external conductor 11c covering the outer peripheral surface of the internal insulating layer 11b, and the covering layer 11d covering the outer peripheral surface of the external conductor 11c is first removed in the circumferential direction such that the external conductor 11c is exposed. In this manner, the removed portion 11e is formed. Thereafter, the removed portion 11e is filled with the conductive member 21. In this manner, the ground members 15, 16 are conductively connected with the conductive members 21 filling the removed portions 11e in a state in which the coaxial cables 11 are arranged in parallel.
According to the above-described manufacturing method, part of the covering layer 11d is removed, and therefore, the frequency of damaging the coaxial cable 11 upon removal of the covering layer 11d is more reduced as compared to the conventional case of removing the entire circumference of the covering layer 11d. Thus, the yield rate is improved. Consequently, cost reduction in the multicore cable 10 can be realized.
Note that the removed portion is preferably formed by the laser beam. This is because the removed portion 11e can be easily formed in this case.
The above-described manufacturing method will be specifically described. As illustrated in
Next, as illustrated in
Next, as illustrated in
As illustrated in
Thereafter, the multicore cable 10 configured such that the end portions are assembled and integrated is connected to the connection target member 30 such as a connector terminal or a substrate (e.g., an FPC), as illustrated in
In a case where the connection target member 30 is the connector, the metal plate shell covering an upper side of the ground member 15 on one side is soldered. That is, the shell is connected with the connection target portion of the connector for grounding, and the ground member 15 is grounded. Moreover, both end portions of the ground members 15, 16 are electrically connected by soldering. In this manner, the multicore cable 10 is in a form as the connector-equipped multicore cable.
(Method for Manufacturing Multicore Cable: Variation)
In the present embodiment, the coaxial cables 11 and the ground coaxial cable 12 are arranged between the plate-shaped ground members 15, 16. The soldering step of conductively connecting the ground members 15, 16 and the conductive members 21 of the coaxial cables 11 and the ground coaxial cable 12 with each other in this state has been described. That is, in the present embodiment, the manufacturing method using the plate-shaped ground members 15, 16 has been described. Note that the present embodiment is not limited to this manufacturing method.
Specifically, as illustrated in
According to the above-described manufacturing method, the following effect is obtained in addition to the effect in the case of using the plate-shaped ground members 15, 16. That is, the conductive paste filling the removed portions 11e of the coaxial cables 11 arranged in parallel forms the conductive members 21. In addition, the ground member is formed. Thus, the process of connecting the ground member to the external conductor 11c, i.e., filling the removed portion 11e with the conductive member 21 and connection of the ground member with the coaxial cable 11, can be completed using the conductive paste 60 by one step. Thus, as compared to the case of using the plate-shaped ground members 15, 16, the above-described manufacturing method exhibits excellent workability.
(Relationship between Laser Beam and Workability)
Next, study has been conducted on whether or not a difference in work quality is caused due to the material of each portion of the coaxial cable 11 or the type of laser beam in the case of forming the removed portion 11e at the coaxial cable 11 by the laser beam 40. Such study results will be described below.
A study method (an experimental method) will be described in detail. First, a square sheet-shaped sample piece corresponding to each portion of the coaxial cable 11 and having 100 mm (in length)×100 mm (in width) was prepared using a material of Table 1. Specifically, each sample piece corresponding to the internal insulating layer 11b was prepared in such a manner that each of fluorine resin, polyvinyl chloride resin (PVC), modified polyphenylene ether resin (m-PPE), cycloolefin resin (COP), a resin mixture of COP (100 per hundred rein (phr)) and styrene-butadiene copolymer (10 phr), a resin mixture of COP (100 phr) and styrene-butadiene copolymer (25 phr), and a resin mixture of COP (10 phr) and styrene-butadiene copolymer (100 phr) is formed into a square sheet shape having a thickness of 50 μm.
Sample pieces corresponding to the external conductor 11c were prepared in such a manner that a m-PPE square sheet (50 μm) is coated with Ag paste having a thickness of 100 μm and that copper foil having a thickness of 35 μm is formed in a square sheet shape. Each sample corresponding to the covering layer 11d was prepared in such a manner that each of fluorine resin, urethane resin, and polycarbonate resin is formed into a square sheet shape having a thickness of 50 μm.
Workability of each sample piece was studied when each of the above-described sample pieces was irradiated with each of a CO2 laser beam, a YAG laser beam, and an excimer laser beam. Laser beam irradiation conditions are an irradiation time of five seconds and a rectangular irradiation area of 250 μm (in length)×250 μm (in width). The same conditions are set for all of the laser beams. The workability described herein was classified into three evaluation levels including evaluation (favorable indicated by a white circle) that the irradiated laser beam penetrates the sample piece in a thickness direction, evaluation (good indicated by a white triangle) that the laser beam does not penetrate the sample piece in the thickness direction, and evaluation (poor indicated by a cross mark) that the sample piece does not react to the laser beam.
As a result, as shown in Table 1, it has been found that the excimer laser beam exhibits favorable workability (evaluation as favorable) for the m-PPE sample piece, the Ag paste sample piece, the urethane resin sample piece, and the polycarbonate resin sample piece. Moreover, it has been found that the excimer laser beam exhibits low workability (evaluation as poor) for 100% of the COP resin. However, it has been found that the excimer laser beam exhibits favorable workability (evaluation as favorable) for the sample pieces with the resin mixture of the COP and the styrene-butadiene copolymer (100:10, 100:25, 10:100).
Thus, the coaxial cable 11 was formed from the internal insulating layer 11b of the m-PPE or the resin mixture of the COP and the styrene-butadiene copolymer, the Ag paste external conductor 11c, and the covering layer 11d of the urethane resin or the polycarbonate resin. Consequently, it has been found that in the case of processing the coaxial cable 11 with the excimer laser beam, the removed portion 11e can be favorably formed.
In the detailed description above, characteristic contents have been mainly described for the sake of more easy understanding of the present invention. However, the present invention is not limited to the embodiment described in detail above. The present invention is also applicable to other embodiments. Moreover, the scope of such application shall be interpreted as broad as possible.
Moreover, terms and phrases used in the present specification are used for accurately describing the present invention. That is, these terms and phrases are not used for limiting interpretation of the present invention. Further, those skilled in the art easily arrive at, e.g., other configurations, systems, and methods included in the concept of the present invention from the concept of the invention described in the present specification. Thus, it shall be recognized that description of the claims include equivalent configurations without departing from the technical idea of the present invention. In addition, for the sake of sufficiently understanding the object and advantageous effects of the present invention, e.g., already-disclosed documents need to be sufficiently taken into consideration.
This application claims priority from Japanese Patent Application No. 2016-069049 filed with the Japan Patent Office on Mar. 30, 2016, the entire contents of which are hereby incorporated by reference.
Specific embodiments of the present invention have been described above by way of example. These embodiments shall not be intended to be comprehensive or to limit the present invention to the described forms as they are. It is obvious to those skilled in the art that many variations and changes are available in light of the above-described contents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-069049 | Mar 2016 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2017/006280 | 2/21/2017 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2017/169294 | 10/5/2017 | WO | A |
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| Number | Date | Country |
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| 2007-280772 | Oct 2007 | JP |
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| Number | Date | Country | |
|---|---|---|---|
| 20190115124 A1 | Apr 2019 | US |
