Flat flexible cable is a type of cable widely used in the fields of electronics and electrical engineering, which has the advantages of simple structure, easy bending, light weight, and small space occupation. This article will provide a detailed introduction to the production process and workflow of flat flexible cables.

Flat flexible cableProduction process and workflow

1. Preparation of conductors

The conductor of a flat flexible cable is mainly formed by drawing copper or aluminum rods multiple times. Firstly, copper or aluminum rods are drawn through multiple drawing dies to gradually reduce their cross-sectional area and achieve the desired wire diameter. During this process, attention should be paid to controlling the drawing speed, mold temperature, and lubrication to ensure a smooth and crack free surface of the conductor.

2. Preparation of insulation layer

The insulation layer is the core component of flat flexible cables, which directly affects the electrical and mechanical performance of the cable. Firstly, the polymer material is mixed and prepared into insulating rubber particles. Then, evenly apply insulating adhesive particles onto the surface of the conductor and heat cure it in an oven to form an insulating layer. During this process, attention should be paid to controlling the coating thickness, oven temperature, and baking time to ensure uniform insulation layer thickness and no bubbles.

3. Preparation of shielding layer

To prevent electromagnetic interference and signal leakage, flat flexible cables usually require the addition of shielding layers. The shielding layer is mainly composed of metal wires or metal mesh. Firstly, weave metal wire or mesh onto the surface of the insulation layer, and then fix it onto the cable through high-temperature welding or adhesive bonding. During this process, attention should be paid to controlling the weaving density and welding quality to ensure that the shielding layer has good electromagnetic shielding effect.

4. Preparation of outer sheath

The outer sheath is the external protective layer of flat flexible cables, mainly used for waterproofing, moisture resistance, corrosion resistance, and other purposes. Firstly, the polymer material is mixed and prepared into sheath rubber particles. Then, evenly apply the sheath adhesive particles on the surface of the shielding layer and heat cure it in an oven to form the outer sheath. During this process, attention should be paid to controlling the coating thickness, oven temperature, and baking time to ensure a smooth and bubble free surface of the outer sheath.

5. Finished product inspection and packaging

Finally, the completed flat flexible cables undergo visual inspection, electrical performance testing, voltage withstand testing, and other inspection items to ensure that the product quality meets the standard requirements. Then label the packaging for customer use.