DE10164990B4 - Motor vehicle door with one or more line connections and method for mounting the line connections - Google Patents

Abstract

Method for assembling one or more electrical and / or optical line connections, which are used to connect at least one functional unit (11 to 19) fastened on a carrier plate (2) of a motor vehicle door to one or more further units or connections (4), characterized in that that at least some of the line connections are arranged and fastened independently of one another on the carrier plate (2) as individual line connections, in that a plastic sheath (37) of a line element (3, 31) of the respective single line connection is at least partially set into the plastic state.

Description

The invention relates to a method for assembling one or more electrical and / or optical line connections, which serve to connect at least one functional unit (eg door control unit, luminaire, loudspeaker) to one or more further units or terminals mounted on a carrier plate of a motor vehicle door , as well as a corresponding motor vehicle door.

From the DD 295 499 A5 and from the AT 231540 B For example, there are known a method of manufacturing wiring harnesses and a method of attaching bare wires to insulating materials made of thermoplastic resin substrates, particularly for the manufacture of printed circuits.

A method for producing a prefabricated door module for a motor vehicle door is known from DE 196 25 974 C1 known. In this case, a prefabricated vehicle door module with an electronic unit and a plurality of electrical components, such. As window motor, central locking, mirror adjustment and heating, switches, lights, speakers, Sidebag or the like produces, in a main assembly line, the equipment of the support plate with the provided for a particular vehicle door electrical components and their wiring by means of electrical cables. In this case, at least some of the electrical lines are prefabricated as individual conductor connections in a sibling cable production line with sequence accuracy for door module production in a packaging device and are arranged directly on the door module independently of one another in a main assembly line. The positioning, ie the attachment and contacting of the individual conductor connections is not or only very expensive solved.

From the DE 37 40 593 A1 It is known that wire harnesses for connecting a number of electrical devices mounted in a motor vehicle to flat, set to vehicle frame resin frame covers or directly to resin vehicle frame or even better to a resin vehicle body are arranged. This serves to facilitate the connection of the electrical equipment, to reduce the space required to accommodate the wiring harness without fasteners, and to automate harness manufacturing. The harness thus arranged is connected to the electrical equipment by connecting each set of wiring harness terminals to the respective contacts of the electrical equipment fixed to the vehicle frame. The metallic electrical conductors are sunk into the synthetic resin or structured by etching on the synthetic resin surface. The comprehensive insulation of exposed metallic conductors is very complex and time-consuming, in addition, a high energy consumption is required for the sinking of metallic conductors. Also, the process-safe isolation of an optionally only partially sunken conductor is fraught with risk.

The invention is therefore based on the object to provide a method for assembling electrical or optical line connections on a support plate of a motor vehicle door, which simplifies and process reliable automated assembly of a support plate of the motor vehicle door with electrical or optical single-line connections, and a motor vehicle door to this simplified installation indicate the electrical or optical line connections.

This object is solved by the features of independent claims 1 and 13. Advantageous developments of the invention can be found in the dependent claims.

Accordingly, one or more electrical or optical line connections are positioned on a support plate of a motor vehicle door, which is preferably previously at least partially made of plastic. At least one functional units are mounted on this carrier plate, wherein the electrical or optical line connections for connecting the functional unit with one or more other units, such as the functional units or the main terminal for the door electronics in the A-pillar of a motor vehicle serve. After the production of the carrier plate, at least a part of the line connections are positioned as individual line connections on the carrier plate independently of each other, at least partially displaced into a plastic state at least in a region of the line element for positioning a line element of the individual line connections. For this purpose, a plastic coating of the conduit element is preferably at least partially plasticized. If the pipe element is only partially plasticized for assembly, it has an area which, in the fastened state, is deformed by plasticization and connected in a material-bonded manner to the support plate.

An element of the single-line connection is, for example, a line element for conducting an electric current or for conducting light as an optical waveguide. Further associated elements of the single-line connection are electrical contact elements, adjusting elements for the optical waveguides or other plug housings or shielding elements for reducing the interference effects on electrical signal connections. This list is only an example, because in addition also all possible further Elements of the single line connection can be positioned according to the invention.

The carrier plate is generally used to hold functional units, such as a light or a display unit. In addition, it is possible that the carrier plate further functions, such as a design function, for example, as part of the door inner lining of the vehicle door takes over, in which case the lamp is mounted as a near field light for ground illumination. Advantageously, however, the carrier plate is part of a door module. In this case, the door module generally has mechanical, electrical and electromechanical functional units, such as, for example, a window lifter, an electromotive drive of the same and a part of a closing handle. In order to permanently ensure the function of the mechanical and electromechanical functional units, the carrier plate of the door module preferably has a corresponding mechanical strength.

Today's door plates for door modules are usually made of metal. Increasingly, plastic carrier plates or metal carrier plates with plastic insert parts are used, which allow an additional possibility for the integration of further functions, such as integrated window regulator guide rails. Such plastic carrier plates or plastic insert parts are produced for example in a plastic injection molding process. If a plastic outsert technique is used, for example, sheet metal stampings are placed in an injection mold for the carrier plate before injection molding.

If an automation of the positioning of the line connections sought, so at least a part of the line connections is positioned as a single line connections to the support plate independently. In order to arrange the individual line connections independently, in contrast to the conventional wiring harness, each electrical or optical single-line connections are laid individually by an automatic machine, whereby the machine can of course lay several individual line connections simultaneously in order to increase the overall process speed.

Due to the variety of equipment depending on the equipment variant of the support plate, for example, whether with or without speakers, electrically adjustable mirror, etc., the carrier plate equipped with individual line connections differently. This has the advantage compared to the previous wiring harnesses that a special cable harness is not needed for each equipment variant, but that the configuration of the wiring can be taken over by the machine. Accordingly, the individual line connections need only be supplied by the meter, which considerably reduces the logistics outlay and the risk of faulty installation.

In order to position a line element of the individual line connections on the carrier plate, preferably on plastic regions of the carrier plate, the line element is at least partially placed in the plastic state. The plasticization of the plastic of the line connection allows on the one hand a controllable deformation of the line connection for an enlarged mounting surface by the plasticized line element, preferably a plastic casing thereof, as a doughy, pasty mass is transformed by a mechanical device of the machine to an attachment of the element of the single line connection, in particular, by a material connection, but alternatively also by a positive engagement with the support plate to allow. For individual fastening points, the plastic sheath is plastified locally, while for a fastening along the entire single-line connection, the plastic is temporarily plasticized along this laying of the single-line connection for at least one section.

A line connection usually has a functional unit-side connection element, one or more line-side connection elements with an intermediate line element and one or more further unit-side connection elements. For an electrical line connection, the line element may have at least one electrical, usually metallic conductor and a protection and / or insulation thereof. An electrical connection element has a contact element, for example in the form of metallic springs and contact pins, and possibly a plug housing to improve the mechanical strength of the terminal and optionally to isolate a plurality of contact elements with each other and the environment.

The plastic casing of a preferred embodiment of the invention serves in double function for electrical or optical isolation of the electrical or optical conductor and for attachment of the conductor to the carrier plate by the attachment produced by plasticization. Furthermore, the plastic sheath serves the mechanical protection of the conductor. It is preferably ensured during the deformation of the region of the conduit element, which has been plasticized for attachment, that the insulation or the conductor itself is not damaged during the assembly process so that the function of the conductor or the insulation is impaired for the application.

A further development of the invention provides that the plastic casing of the line element of the motor vehicle door has at least two components. By means of these two components, the functions of the plastic coating can be separated and optimized in each case by using different materials with different properties. Preferably, the two components are firmly connected to one another at their interface. Alternatively, the outer component can embrace the inner, in particular form-fitting manner.

In an advantageous embodiment of this development of the invention, the two components have different melting temperatures for plasticization. As a result, the plasticized for attachment component of the plastic sheath is brought into material connection with the support plate, while the other component is not plasticized with a higher melting temperature and thus remains dimensionally stable. In particular, this other component has the function of isolation and it can be procedurally ensured that this insulation is not damaged during attachment of the conduit element.

In order to produce the line element by the meter, in an advantageous embodiment of the invention, the two components are extruded in layers one above the other. Also in this embodiment, the components are advantageously fixed to one another at their boundary surface. For fixing, the components are, for example, materially bonded together. To improve the fixation, positive closures between the components are advantageously provided. The layer of the component to be plasticized may include the other component or be arranged only on the side for fixing the conduit element on the support plate. The layer thickness of the respective component is assigned their function by the layer thickness of the insulating component of the insulation voltage is adjusted, and the thickness of the layer to be plasticized the surface, in particular the unevenness of the surface of the support plate adapted.

In an alternative embodiment of the invention, the exterior of the two components has a hotmelt adhesive, which in particular can also be connected to an advantageously rough metal surface. In a further embodiment of the invention, instead of the hot-melt adhesive, an adhesive is used as the second component which can be plasticized by pressure and then cured.

In addition, a local plasticization of the plastic of the support plate allows a material connection with another material, preferably the same or a similar plastic as the support plate or the conduit element which is miscible with the plastic of the support plate or the conduit element. Both variants, individually or in combination, can absorb the acceleration forces occurring in a motor vehicle door, for example during a slamming thereof, and thus improve a secure and reliable hold of the element of the individual line connection on or in the plastic of the carrier plate.

This example from the DE 35 29 660 C2 known injection of sheet-metal inscribed parts as electrical conductors in the plastic of the carrier plate slows down the production speed of the carrier plates considerably. By contrast, the laying of the individual line connections according to the invention can take place parallel to further production steps, for example the application of a seal. Conveniently, the positioning of the elements of the individual line connections takes place during the cooling phase of an injection-molded carrier plate. In this case, the heat of the carrier plate can be exploited after injection, so that only a small additional energy input is required for plasticization.

If the positioned elements are dimensionally stable line elements with sufficient mechanical stability, then these line elements optionally serve in a further function for enhancing the mechanical stability of the carrier plate. For this purpose, the attachment between the conduit member and the plastic of the carrier plate must be of sufficient strength.

In order to enable a simple recycling of the carrier plate, separable or recyclable plastics are selected without exception in combination. For example, it may be advantageous to use different plastics for the plastic of the line element or the carrier plate, depending on the mechanical stress. In this case, the areas for positioning the line elements of the individual line connections consist of an easily plasticized and easily deformed plastic, while areas for receiving large forces, such as those of the windows of the support plate, from a much stiffer, for example, reinforced with fibers, plastic. Complex carrier plates are also produced in a multi-component technique, for example in the 2K technique.

As plastic sheathing for electrical or optical lines nowadays PVC and PE are often used, the electrical or Optical wire protects against damage and can ensure electrical and possibly optical isolation. If PVC or a polyolefin is also used for the carrier plate, then the two plastics of the casing and of the carrier plate are connected in a material-locking manner. For this purpose, the plastic casing is plasticized at least on the side facing the carrier plate and connected the two plastics. The connection is further enhanced by an additional pressure applied to the conduit member. In addition to PVC and polyolefins, however, other plastic or plastic combinations for such a method are conceivable.

A plastic coated electrical conductor usually has one or more metallic wires, which may also be insulated from each other. A wire is provided, for example, as a shielding of the other wire against elektrottiagnetische interference. Both cores form in this case with the Ummantelfung the line element of the single line connection. Other line elements have, for example, a very flexible wire with many small electrically connected wires, which allow favorable laying characteristics of the line element and a low-loss high-frequency signal transmission.

End regions of a line element of the individual line connections fastened according to the invention can be at least partially introduced into plasticized plastic of the carrier plate. Optical conductors can be used only if the optically conductive area is not or only insignificantly damaged by the introduction into the plasticized plastic. By means of this development of the invention, the connections of the line element can be fixed as a contact in the plastic of the carrier plate. These conductors are supplied by energy, such as an electric current, ie by ohmic. Losses or inductively generated eddy currents, heated. The supplied energy plasticizes the carrier plate in the region of the electrical conductor and the conductor is pressed into the plastic material. In addition, a part of the plasticized plastic can be deformed for the purpose of insulating or fixing the conduit element. By this deformation is advantageously in the terminal region of a positive connection with the line element, in particular a bare electrical conductor achieved. An insulated conductive member of the single-conductor joints is at least partially fixed by an additive by bonding the additive with plasticized plastic of the backing plate or with the plasticized plastic jacket of the conductive member. The compound of the additive is made by material connection, adhesion or positive engagement.

A component of the invention to be combined is the electrical contacting of a line element. Beispielshaft the two following variants are described for contacting.

In the first variant is provided; in that an end region of the conduit element for contacting the functional unit outside the plastic of the carrier plate is positioned positioned to form a contact element of the functional unit. For this purpose, the end portion of the conduit member is either dimensionally stable, for example by a conductor of appropriate thickness and stiffness is used, or it is a flexible conductor, such as a strand, used, which is positioned by the attachment to the plastic of the support plate. For contacting the flexible conductor advantageously a cutting technique is used by at least one contact blade of the functional unit cuts through the insulation of the strand and so makes contact with the electrical line element.

In contrast, in the second variant, a contact element of the single-line connection is fastened in a region of the plasticized plastic of the carrier plate provided for the contact element. The contact element is preferably arranged with the same machine on the carrier plate in one operation with the line elements. In this case, in one embodiment of this variant, a flexible conduit element is struck against a plug contact as a contact element, and then the plug contact is fastened to the plastic of the carrier plate.

Alternatively, the conduit element is struck after the attachment of the contact element to the contact element or particularly advantageously the electrical contacting takes place simultaneously, ie in the same procedural step, for fastening the contact element. For fixing the contact element can be moved, for example, analogous to the fixation of the fastener for the line element. In this case, the contact element is fixed in an opening of the region whose dimensions correlate with those of the contact element, for positioning. For this purpose, in turn, a positive engagement or a frictional connection between the contact element and the plastic of the carrier plate can be produced.

If several individual line connections are required, for example both the power supply and the data lines of a bus system of the functional unit are contacted, in one embodiment of the invention plug contacts are fixed as contact elements of the line-side connection element by the plastic of the carrier plate and the plug contacts are positioned to each other plug contacts to summarize a plug that can be connected simultaneously by means of a mating connector of the functional unit for a connection of the functional unit.

As a contact element, a large variety of electrical contact elements for the application of the method is suitable. For example only, reference is made to some advantageous embodiments, such as pin and contact spring or locking, cutting edge and clamp or brim, and screw and nut as contact elements.

In order to put the plastic of the conduit element or the carrier plate in the plastic state, this is advantageously carried out by heating a metallic conductor or metallic contact element. For this purpose, the metallic conductor or the contact element is heated, for example by means of induction heating, by ohmic losses in the conductor or contact element or by an additional contact heating element.

In alternative methods for plasticizing the plastic by means of induction heating of metal particles in the plastic, hot air, or a standing in contact with the plastic heating element, a heat radiation, or ultrasound. Other options are the use of an additional heating resistor, a gas or plasma flame or a laser or a measles. Likewise, a friction heating, swelling or tempering of the plastic or heating in the high-frequency alternating field by dielectric losses are applicable methods. The specified methods are only exemplary. Particularly advantageously, a combination of several of the aforementioned methods for plasticization is used.

In the following the invention will be explained in more detail by means of exemplary embodiments with reference to drawings.

Showing:

1 a schematic representation of a door module of a motor vehicle door with a carrier plate made of plastic,

2 a schematic sectional view of a ribbing of the support plate,

3a and 3b 1 is a schematic sectional view of a positioned line element of a single line connection with additive,

4a and 4b a schematic sectional view of an introduced into the plastic of the carrier plate line element of a single line connection,

5 a schematic representation of a fastening for further positioning of a line element of a single line connection,

5AA a schematic sectional view along the section line AA of 5 .

6 a schematic representation of a further attachment of a conduit element of a single line connection,

7a and 7b a schematic sectional view of a positioned, insulated conduit element of a single line connection,

8th a schematic representation of an insulated line element of a single line connection, which is contacted by means of cutting contacts,

9 1 is a schematic sectional view of a line element with a connection contact element of a single line connection;

10a and 10b a schematic sectional view of a contact element and its attachment and electrical contact with a line element of a single line connection,

11 a schematic sectional view of a positioned contact element with a connector housing,

12 a schematic sectional view of another positioned contact element with a positioning aid of a functional unit-side connection element,

13 a schematic sectional view of an isolated junction of two electrical line elements of two individual line connections,

14 a schematic sectional view of a connecting element with a plurality of contact elements,

15 a schematic representation of another connecting element with a plurality of contact elements,

16 FIG. 2 a schematic sectional representation of a section of a single-line connection with a flat-ribbon electrical conductor element, FIG.

17 a schematic Dartstelllung a line-side connecting element with plug and contact elements,

18a and 18b schematic sectional views of the contacting of line elements of several individual line connections with a plug element, and

19a and 19b schematic sectional views of a positioned, insulated conduit element of a single line connection with a plastic sheath of two components.

In 1 a door module of a motor vehicle door is shown schematically. The door module has a self-supporting support plate 2 made of plastic. The carrier plate 2 In its three-dimensional geometry, it is essentially adapted to the geometry of the motor vehicle door into which it is to be installed. It is made in one piece from plastic, wherein the layer thickness of the carrier plate 2 can vary between 0.1 to 5 cm. On the carrier plate 2 are several functional units, such as woofers 11 , Tweeter 12 , Door control unit 13 , Window regulator drive 14 , Map pocket light 15 , Operator input 17 , Door opener 18 with a microswitch, apron or entry light 16 and door lock 19 , assembled. In addition, the door module plug 100 . 101 to the outside mirror ( 101 ) and to the A-pillar ( 100 ), which allow a connection to other functional units of the motor vehicle, such as the car battery.

Furthermore, the carrier plate knows 2 areas 21 for positioning of elements 3 of single-line connections for an electrical or optical connection of the functional units 11 to 19 or the plug 100 . 101 on. These separate areas 21 for the attachment of the element 3 the line connection are in the injection molding of the plastic of the carrier plate 2 with shaped. As an alternative to injection molding, for example, production methods such as embossing, pressing, internal gas pressure, cascade injection molding, foaming or slushing of the plastic are used. Furthermore, the mechanical strength of the carrier plate 2 through stiffening ribs 20 elevated. Further, in 1 not shown components to increase the strength of the carrier plate 2 are preferably punching plates, with the plastic of the carrier plate 2 be connected by means of an insert or outsert technique, ie a combination of stamping and injection molding.

As an integral part of the door module contains numerous functional elements made of plastic. The feature integral means that the functional elements with the carrier plate 2 be produced together, so need no additional manufacturing step. They can form a unit with metallic parts of the door module, so that they can not be detached from the metal bodies. An example of an integral functional element is the in 1 illustrated circumferential sealing profile 22 the carrier plate 2 in that, with a correspondingly introduced sealing compound, a sealing separation of the motor vehicle door into a wet space (N, 2 ) and a drying space (T, 2 ).

The fixation of the functional units 11 to 19 on the plastic of the carrier plate 2 takes place by adhesion, positive engagement or material bond, for example in the form of a primer. For a mechanical anchoring of the functional units are preferably screws for screwing to the support plate 2 used.

The in the 2 illustrated sectional view of the carrier plate 2 shows a change of the stiffening ribs 20 from the drying room T to the wet room N in the area 21 to the single line arrangement. In this area 21 are three pipe elements 3 different form represented by an additive 32 for fixing or insulating the line elements 3 are covered. In addition, at least one of the areas points 21 - in 2 not shown - a moisture sealed passage of one or more of the line connections from the dry room side T to the wet room side N on.

In the figures 7a and 7b two possibilities according to the invention are shown as a sectional view, such as an insulated with PVC electrical or PVC sheathed optical conduit element 3g . 3h on a plastic of the carrier plate 2g . 2h by plasticizing both the PVC jacket 37g . 37h as well as the plastic of the carrier plate 2g . 2h can be mounted. For this purpose, the two plastics, that of the carrier plate 2g . 2h and the PVC of the jacket 37g . 37h to be miscible with each other. While the conduit element 3g in 7a on a flat surface of the support plate 2g is fixed on the fabric fastener to the mounting surface, the PVC cable ( 37h . 3h ) in 7b in a groove 33h the carrier plate 2h laid. The sloping side walls of the groove 33h Depending on the equipment of the vehicle door allow the attachment of PVC cables ( 37h . 3h ) of different diameter in the groove 33h , The sheathed PVC cable ( 37h . 3h ) has two attachment surfaces 38h firmly bonded to the plastic. In one example of the combination of compatible materials, the sheath exists 37g . 37h made of PE (polyethylene) and the carrier plate 2g . 2h made of PP (polypropylene). If different, miscible plastics are used, a selection of materials according to the requirements of the corresponding function of the plastic, such as stability, flexibility, insulation, etc. is selected.

In 8th is a connection element 4i shown. The line-side connection element 4i exists in 8th only from a PVC cable ( 37i . 311 ) with a PVC jacket 37i and one electrical conductor 31i , The PVC jacket 37i of the PVC cable ( 371 . 311 ) is analogous 7a or 7b on the carrier plate 2i fixed. The functional unit-side connection element 10i has cutting 111i for contacting. The cutting cut through during assembly of the functional unit-side connection element 101 the PVC jacket 37i of the PVC cable ( 37i . 311 ), for what in the carrier plate 2i a shape 41i is provided.

The 19a and 19b show a conduit element with a plastic sheath in 2K technology. In 19a is the leader 31t of two layers 371T and 372T wrapped, which consist of different components. The inner component consists of a material with a higher melting temperature, so that this layer 372T is not plasticized and thus remains during the attachment substantially in their form. By contrast, the outer component 371T a lower melting point, so that this plasticizing with the support plate 2t forms. The interface between the inner component 372T and the outer component 371T is not mandatory for the mutual fixation of the components 371T and 372T designed with each other, since the outer component 371T the inner component 372T wrapped and thus localizes.

If, on the other hand, a fixation of the components to one another is desired, a material connection between the components can be used for improved strength. Additionally or alternatively, a positive connection between the components 371u and 372u made, like 19b shows. The illustrated interlocking elements can be integrated over the entire length or localized in the line element, or subsequently produced for example by forming or additional elements.

Incidentally, reference should be made to other types of fastening, which can be combined particularly favorable with the attachment according to the invention. It shows the 3a a schematic sectional view of an arranged line element 3a a single line connection with a the line elements 3a covering additive 32a , The pipe element 3 , For example, a light guide, optical fiber or an electrical conductor, is in a groove or groove 33a the carrier plate 2a arranged. The groove or groove 33a enables automated laying of the pipe element 3a in the designated areas 21 ( 1 . 2 ) by the groove or groove 33a at the same time it serves to guide a movable transfer head of the machine. In the fields of 21 can have several grooves 33a for the parallel laying of several pipe elements 3a be used. Assign electrical wiring 3a have their own insulation, or become optical line elements 3a used, multiple line elements of the same or different types in a groove or groove 33a be positioned.

The pipe element 3a the single line connections is by an applied additive 32a at least partially isolated and fastened. As an additive 32a Materials from the same plastic as the carrier plate are suitable 2a or other plastics containing the plastic of the backing plate 2a are compatible, so that in the plasticized state of the additive 32a and the plastic of the carrier plate 2a can be connected to each other.

The additive 32a is used as a powder or granules on and in the groove 33a with the already existing conduit element 3a fed, then the powder or granules and the groove 33a plastic plastic locally plasticized, that is put into a molten or pasty state, so that the additive 32a with the plastic of the carrier plate 2a in one piece the attachment and insulation of the conduit element 3a forms without affecting the structure or strength of the support plate 2a is only temporarily impaired. Alternatively, a plastic melt as additive 32a by a small extruder, or by a heated cannula applied or foamed, which is the application of adapted layer thicknesses of the additive 32a allows. The plasticized materials 2a . 32a then cure. In addition, in dual function of the cured additive 32a the strength of the carrier plate 2a elevated.

The 3b shows an alternative embodiment of a groove or groove 33b in a carrier plate 2 B a motor vehicle door in a sectional view. Also in this embodiment, the positioning of one or more electrical or optical line connections on a support plate 2 B , which is at least partially made of plastic, possible. The Elements 3b the single line connections are on the carrier plate 2 B positioned independently of each other. This in 3b illustrated line element 3b the single line connections is in the groove or groove 33b by means of a paint 32b or potting compound 32b , For example, a potting resin or a hot melt adhesive, or by means of a plastic foam as an additive 32b fixed.

Be one or more pipe elements 3b in the groove or groove 33b potted, is a plasticization of the plastic of the carrier plate 2 B not necessary, but can be supplemented additionally. Sufficient is the cohesive adhesive bond between the Vergussstoff 32b and the plastic of the carrier plate 2 B , which can also be designed as thermosets in this alternative. Also in In this case, the additive is used 32b as a fastening and / or as an insulator of the electrical line elements 3b , A pre-attachment of the conduit element 3b is caused by an elastic deformation of the groove side walls or by a plastic deformation of the plastic of the carrier plate 2 allows.

In 4a is a schematic section of one in the plastic of the carrier plate 2c introduced conduit element 3c a single line connection shown. The pipe element 3c is through the plastic of the carrier plate 2c at least partially isolated. The plastic of the carrier plate, preferably the edges of a 3a or 3b illustrated groove or groove 33a . 33b , is used for insulation or attachment of the conduit element 3c for a one-piece inclusion 35c of the conduit element 3c formed in the plastic state and then cured. Alternatively, in 4b shown that a conduit element 3d in the plastic of the carrier plate 2d is completely incorporated by a plasticization.

In the following figures 5 . 5AA and 6 are ways of attachment or pre-attachment of a conduit element 3e . 3f shown. In 5 is shown schematically in a 2D plan view that a line element 3e in the opening or groove 33e the plastic of the carrier plate 2e is attached. The groove 33e has adjustment ribs in this embodiment 36e on. The adjustment ribs 36e Be used for pre-fastening a solid electrical conductor 3e , For example, a copper wire, by introducing the conductor 3e deformed. For deformation, this becomes the copper wire 3e pointing end of the adjustment rib 36e at least partially, for example by the heat of the copper wire, plasticized. Such a deformed adjustment rib 36e is in the 5AA shown, which is a sectional view along the line AA of 5 shows.

Is the conduit element 3e In contrast, at least partially elastically deformable, the conduit element 3e without plastic deformation of the adjustment ribs 36e by pushing into the groove 33e prefastened. For improved pre-attachment, the adjustment ribs have a high surface roughness with a correspondingly high Rz value. A similar attachment is from the DE 195 21 735 A1 known for a vehicle lamp. However, the acceleration forces that occur in the motor vehicle door, for example, by slamming the same, but a release of the conduit element 3e cause. Only the solution analogous to the figures 3a to 4b can ensure lasting reliability of attachment.

In 6 is a further embodiment of the attachment or pre-attachment of the conduit element 3f by two opposite matching ribs 36f the carrier plate 2f shown. Along the groove 33f becomes the conduit element 3f misplaced by placing it in the gap between the two adjustment ribs 36f under plasticization of a part of the plastic of the adjustment ribs 36f is introduced. For simplified laying can (in 6 not shown) the upper portion of the adjustment ribs 36f Beveled.

In 9 is a particularly simple embodiment of the positioning of a conduit element 32j and a line-side terminal element 4y shown. The connection element 4y has at least one substantially dimensionally stable portion of a conduit element 31j as a contact element 42j on, to connect the functional unit (bsw. 11 to 19 ) made of the plastic of the carrier plate 2y protrudes. this section 42j of the conduit element 31j is isolated by the powder and subsequent plasticization (in 9 not shown). The contacts of the connection element of the functional unit then make contact with the section only during assembly 42j for example, by cutting the insulation.

In the figures 10a and 10b are two steps of positioning an electrical line-side contact element 43k shown. The contact element 43k has a shaft 433K with a knurling 434k as well as a disc 432k for contacting a line element 31k and / or as a mounting stop and a contact pin 431k for contacting with the functional unit-side connection element of a functional unit. For fixing is in the plastic of the support plate 2k an opening 44k provided, whose dimensions with the diameter of the shaft 433K correlate.

During the introduction of the contact element 43k is the plastic in the area of the opening 44k plasticized. After curing, the knurling with the plastic forms the opening 44k a positive connection for permanent fixation of the contact element 43k , In the in 10a and 10b shown process sections is the contact element 43k with the conduit element 31k simultaneously with the fixation of the contact element 43k electrically connected. Alternatively, in 10a or 10b not shown, the conduit element 31k previously to the contact element 43k posted and the contact element 43k only fixed below.

Instead of knurling 434k of the contact element 43k has the contact element 43k a self - tapping thread - in 10a or Mb not shown - on, which for attachment to the plastic of the carrier plate 2k is screwed.

In 11 is another embodiment of a line-side connection element 4L shown. The contact element 43L additionally has a spring element 431L for contacting a contact of a functional unit-side connection element. A plug housing 5L of the line-side connection element 4L the single line connections is integral with the plastic of the carrier plate 2L formed so that at least one element 5L the single line connection through the plastic of the carrier plate 2L is trained. On the connector housing 5L are additionally positive locking elements 51L molded for attachment of the functional unit-side connection element. By forced removal, the interlocking elements 51L with the injection molding of the carrier plate 2L produced at the same time. Alternatively, slides are used by injection molding to the interlocking elements 51L manufacture. The positive locking elements 51L serve for releasably securing the functional unit-side connection element.

12 shows an embodiment of a line-side connecting element 4m and a part of a corresponding functional unit-side connection element 10m , The line-side connection element 4m has a socket with contact springs 45m on, in the assembled state, the electrical contact to the functional unit via a contact pin 112m the functional unit-side connection element 10m to ensure. Einickig with the plastic of the carrier plate 2m is also a positioning aid 52m injection-molded, which also has other functions, such as stiffening rib 20 can fulfill.

In 13 is a crossing region of two electrical line elements 3n ' and 3n '' shown. The grooves in the carrier plate 2n arranged electrical line elements 3n ' and 3n '' be through the additive 32n electrically isolated from each other and from the environment.

Several contact elements 43o . 43pi to 43p3 are advantageously, as in 14 or in 15 represented, simultaneously fixed. in 14 are the contact elements 430 of the line-side connection element 4o through a plastic holder 49o positioned and fixed to each other. In addition, some of the contact elements 43o contact springs 45o for improved contact or positive engagement with a functional unit. In the plastic of the carrier plate 2o are according to the number of contact elements 43o openings 44o for receiving the contact elements 43o shaped, the upper edge to facilitate insertion of the contact elements 43o bevelled. Another part of the connector housing 5o is made by injection-molded plastic of the carrier plate 20 educated. 15 on the other hand shows a plan view of a plug housing 53p made of metal, which simultaneously serves to shield signal lines and / or as a ground contact. Some below the surface of the backing plate 2p laid pipe elements 3p are indicated by dashed lines. The contact elements 43p1 to 43p3 are pronounced differently thick according to the required current flow. The metallic connector housing 53p also has hooking elements 531P for the positive fastening of the functional unit-side connection element.

The 16 shows a further embodiment of a terminal connection of a single line connection. The functional unit-side connection element 10q has a spring contact 113q on. This spring contact 113q presses in the mounted state with its own spring force on a ribbon conductor 39q and thus establishes an electrical contact. Instead of the ribbon conductor 39q Advantageously, a flexible printed circuit board (FPC) is also used. The ribbon conductor 39q is by means of a fastener 46q , For example, a screw or a nail with knurling, fixed. For fixing the plastic of the carrier plate 2q temporarily plasticized in the area of the attachment. In addition, the ribbon conductor 39q through an additive 32q be attached and isolated.

The 17 shows a connector housing 5r with positioning aids 54r for positioning end regions of electrical line elements 43r as contact elements ( 43r ). The positioning of the end regions improves the contact reliability of an electrical contact to the functional unit-side connection element. Some below the surface of the backing plate 2r laid pipe elements 3r are indicated by dashed lines. In addition, the connector housing 5r Interlocking elements 55r for fastening the functional unit-side connection element.

In 18a and 18b it is shown that a connector housing 57s as an element of the single line connection by material connection with the plastic of the carrier plate 2s is attached. For this purpose, the connector housing 57s Ultrasonic welding noses 56s on, after the ultrasonic welding in one piece with the plastic of the carrier plate 2s are formed. In order to ensure the correct position in the attachment, are with the support plate 2s integrally formed positioning aids 52s intended.

In grooves 33s the carrier plate 2s are electrical conduction elements 31s provided for contacting with contact plates 47s the separate plastic connector housing 57s spring-mounted are. Alternatively, in 18a and 18b not shown, are the contact plates 47s the plastic connector housing for springing the electrical line elements 31s educated. The plastic connector housing 57s also shows with the plate contacts 47s Clamping springs connected by electrical lines 48s on, for electrical contact with contact pins 112s serve a functional unit-side connection element los.

To the functional unit-side connection element 10s with the plastic connector housing 57s mechanically connect, has the functional unit-side connection element 10s Plastic hooks 114s on, a positive engagement with hooking elements 55s made of plastic of the plastic connector housing 57s form in the assembled state.

For all embodiments, thermoplastic materials are used for the line elements, the functional units, the carrier plate and the plastic plug housing. In addition to standard polymers such as polyolefins such as polypropylene or polyethylene, plastics based on, polyamide, polyester, polyphenylene oxide, polyoxymethylene polyphenylene sulfide, polyurethane, polycarbonate or copolymers based on polystyrene such as acrylonitrile-styrene-acrylic ester graft polymers may also be mentioned Glass, steel, carbon, aramid or natural fibers can be reinforced. In particular, polyethylene terephthalate or polybutylene terephthalate can be used as the polyester. The fiber reinforcement is optionally effected with long fibers, short fibers, fiber flow and / or fiber mats It is also possible that the individual components of the door module made of different plastics or that the line member, the support plate, the housing and connection elements of the functional units consist of several different plastics. In this case, it may be necessary to carry out the process steps sequentially or simultaneously over several units.

LIST OF REFERENCE NUMBERS

101, 10m, 10q, 10s

Connecting element of the functional unit

11

woofer

12

tweeter

13

Door control unit

14

Power window

15

Light, map pocket

16

Light, apron

17

Bedienungstastertur

18

Door opener with microswitch

19

door lock

100

Plug to the A-pillar

101

Plug for side mirrors

111i

Cutting contacts of the functional unit-side connection element

112m, 112s

Contact pins of the functional unit-side connection element

113q

Spring contact of the functional unit-side connection element

114s

Plastic hooks

2, 2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i, 2j, 2k, 2L, 2m, 2n, 2o, 2p, 2q, 2r, 2s, 2t, 2u

support plate

20

Stiffening ribs of the carrier plate

21

Area of the carrier plate for single line arrangement

22

circumferential sealing profile of the carrier plate

3, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3n ', 3n ", 3p, 3r, 3t, 3u

line element

31i, 31j, 31k, 31L, 31m, 31s, 31t, 31u

electrical conductor as a conduit element

32, 32a, 32b, 32j, 32k, 32L, 32m, 32n, 32q

Additive for attachment or insulation of a conduit element

33a, 33b, 33e, 33f, 33h, 33s, 33t, 33u

Groove or groove for positioning a pipe element

34b

formation

35c

Reshaped plastic of the carrier plate

36e, 36f

adaptation ribs

37g, 37h, 37i

PVC insulation of a pipe element

371t, 371u

plastifiable component of the sheath of the conduit element

372t, 372u

non-plasticized, insulating component of the sheath of the conduit element

38g, 38h, 38i, 38t, 38u

Fastening surface of a fabric closure of two contractual plastics

39q

Ribbon cable conductors

4i, 4j, 4L, 4m, 4o

line-side connection element

41i

Shaping for cutting contacts

42j

Contact pin of the electrical conduction element as a contact element

43k, 43L, 43m, 43o, 43r, 43p1, 43p2, 43p3

electrical contact element

431k, 431L

Contact pin of the electrical contact element

431L

Spring element of the contact pin

432k, 432L, 432m

Disk of the electrical contact element

433k, 433L

Shank of the electrical contact element

434k, 434L, 434m, 434o

Knurling as positive locking element of the electrical contact element

44k, 44L, 44o

Opening in the plastic of the support plate for receiving the contact element

45m, 45o

Contact springs of the electrical contact element

46q

Screw as a fastener

47s

contact plates

48s

clamping spring

49o

Plastic holder for contact elements

5L, 5o, 5r

plug housing

51L

Positive locking elements of the connector housing

52m, 52s

Positioning aid of the plug housing

53p

 metallic connector housing

531P

Hooking elements of the metallic connector housing

54r

Positioning aids for the contact elements

55r, 55s

Interlocking elements made of plastic

56s, 56s'

Ultrasonic welding nose

57s

separate plastic connector housing

58s

electrical connection in plastic connector housing

Claims (25)

Method for mounting one or more electrical and / or optical line connections, which are used to connect at least one to a carrier plate ( 2 ) a motor vehicle door attached functional unit ( 11 to 19 ) with one or more further units or connections ( 4 ), characterized in that at least a part of the line connections as individual line connections on the carrier plate ( 2 ) are arranged and fixed independently of each other by a plastic casing ( 37 ) of a line element ( 3 . 31 ) of the respective individual line connection is at least partially placed in the plastic state. Method according to claim 1, characterized in that - the carrier plate ( 2 ) is at least partially made of plastic, - that in addition the plastic of the carrier plate ( 2 ) at the place of attachment of the conduit element ( 3 . 31 ) is placed in the plastic state, and - that for cohesive fastening the plastic casing ( 37 ) and the plastic of the carrier plate ( 2 ) are connected in the plastic state. Method according to claim 1 or 2, characterized in that - a part of the plasticized plastic of the carrier plate ( 2 ) for additional insulation and / or attachment of the conduit element ( 3 . 31 ) is deformed. Method according to one of the preceding claims, characterized in that the conduit element ( 3 . 31 ) at least partially by an additive ( 32 ) is attached by adding the additive ( 32 ) with the plasticized plastic of the carrier plate ( 2 ) and / or the plasticized plastic casing ( 37 ) of the conduit element ( 3 . 31 ) is connected. Process according to claim 4, characterized in that the additive ( 32 ) consists of the same plastic or a plastic miscible with the backing plate material, the additive ( 32 ) is also at least partially plasticized to the cohesive connection. Method according to one of the preceding claims, characterized in that before the plasticizing the line element ( 3 . 31 ) in a designated area ( 21 ) of the plastic of the carrier plate ( 2 ) is prefixed. Method according to one of claims 2 to 6, characterized in that in addition an end portion of the conduit element ( 3 . 31 ) to Contacting the functional unit ( 11 to 19 ) outside the plastic of the carrier plate ( 2 ) to a contact element ( 42 . 43 ) of the functional unit ( 11 to 19 ) is arranged. Method according to one of claims 1 to 6, characterized in that in addition one with the line element ( 3 . 31 ) connected contact element ( 42 . 43 ) of the single line connection in for the contact element ( 42 . 43 ) ( 21 ) of the plasticized plastic of the carrier plate ( 2 ) is attached. Method according to claim 8, characterized in that - a conductor ( 31L ) of the conduit element ( 3 . 31 ) to a plug contact ( 43L ) is struck as a contact element, and - that the plug contact ( 43L ) on the plastic of the carrier plate ( 2 ) is attached. A method according to claim 9, characterized in that by the plastic of the carrier plate ( 2 ) fixed plug contacts ( 43L ) of a line-side connection element ( 4L ) are arranged to each other. Method according to one of claims 1 to 10, characterized in that the plastic casing ( 37 ) of the conduit element ( 3 . 31 ) or the plastic of the carrier plate ( 2 ) by - an induction heating of a metallic conductor or a metallic contact element in the plastic, - an induction heating of metal particles in the plastic, - hot air, - a contact heater, - a heat radiation, - ultrasound, - a heating resistor, - a gas flame, - a plasma flame, a laser or a maser, - a heater heating, - swelling or tempering of the plastic, - a heating in the high-frequency alternating field by dielectric losses, or - a combination of several of the aforementioned plasticized. Method according to claim 11, characterized in that the plastic casing ( 37 ) has a pressure-sensitive adhesive, which by the action of pressure at least on the support plate ( 2 ) facing side is plasticized. Motor vehicle door with one or more electrical or optical line connections for connecting at least one on a support plate ( 2 ) mounted functional unit ( 11 to 19 ) with one or more further units or connections ( 4 ), characterized in that - at least a part of the line connections as individual line connections on the carrier plate ( 2 ) are arranged independently of each other, and - that a line element ( 3 . 31 ) of the respective individual line connection has at least one area deformed by plasticization, which for attachment to the carrier plate ( 2 ) is integrally connected. Motor vehicle door according to claim 13, characterized in that the area deformed by plastication comprises a plastic casing ( 37 ) of the conduit element ( 3 . 31 ). Motor vehicle door according to claim 14, characterized in that the plastic casing ( 37 ) at least two components ( 371T . 372T ) having. Motor vehicle door according to claim 15, characterized in that the two components ( 371T . 372T ) have different melting temperatures for plasticization. Motor vehicle door according to claim 15 or 16, characterized in that the two components ( 371T . 372T ) are extruded in layers one above the other. Motor vehicle door according to one of claims 15 to 17, characterized in that the exterior ( 371T ) of the two components ( 371T . 372T ) Has hot melt adhesive. Motor vehicle door according to one of claims 15 to 18, characterized in that the interior ( 372T ) of the two components ( 371T . 372T ) at least one electrical conductor ( 31t ) is isolated and not plastically deformed. Motor vehicle door according to one of claims 13 to 19, characterized in that the one element of the individual line connections by a plastic of the carrier plate ( 2 ) or by an applied additive ( 32a ) is at least partially isolated and / or fixed from the same or a cohesively connectable plastic. Motor vehicle door according to one of claims 13 to 19, characterized by separate, for the attachment of the conduit element ( 3 . 31 ) of the line connection (injection-molded) areas ( 21 ) of the plastic of the carrier plate ( 2 ). Motor vehicle door according to claim 21, characterized in that the carrier plate ( 2 ) divides the door interior into a dry space (T) and a wet space (N), the areas ( 21 ) a change of a ribbing ( 20 ) of the carrier plate ( 2 ) from the dry room side to the wet room side. Motor vehicle door according to claim 21 or 22, characterized in that at least one of the areas ( 21 ) comprise a moisture sealed passage of one or more of the line connections from the dry room side to the wet room side. Motor vehicle door according to one of claims 21 to 23, characterized in that the areas ( 21 ) one or more grooves or grooves ( 33 ) for pre-positioning of the line element ( 3 . 3 ) and for subsequent attachment of the same. Motor vehicle door according to one of claims 13 to 24, characterized in that a plug housing ( 57s ) a line connection at least one plastication deformed area ( 56s ), which is connected to the carrier plate ( 2 ) is integrally connected.

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