DE102005011252A1 - Method and device for producing an electrical conductor traction structure, and a conductor traction structure produced therewith - Google Patents

Abstract

Leiterzugstruktur and a device and a method for producing such with the following steps: DOLLAR A - stacking in the correct position two, more electrical conductor tracks (14) exhibiting conductor plates (12) with an interposed insulating layer (32, 34, 35) DOLLAR A - mechanical jamming DOLLAR A - pairwise electrical connection of the conductor tracks (14) between the two conductor plates (12) to a double-conductor disc (13) DOLLAR A - stacked in the correct position stacking of at least two double-conductor discs (13) with each in between arranged insulation layers (32, 34, 35) DOLLAR A - permanent fixing all conductor plates (12) to each other by means of hot pressing DOLLAR A - pairwise electrical connection of the conductor tracks (14) between the respective double-conductor discs (13) to a Leiterzugstruktur (10).

Description

The The invention relates to a method and an apparatus for the production an electrical Leiterzugstruktur by means of hot pressing, as well as a conductor traction structure made therewith according to the preamble of the independent claims.

With the US 3,450,918 is a Leiterzugstruktur has become known in which a plurality of stamped metallic conductor plates are arranged with intermediate insulating layers.

there First, the conductor tracks welded together by two conductor disks and then two such double discs after free punching again by means of contact bridges between the individual conductor tracks welded together. Such Leiterzugstruktur, which only by welding the individual conductor tracks mechanically connected is sufficient not the high demands regarding the vibration load and the thermal load of fast rotating thin rotor disks. Such a Leiterzugstruktur is not dimensionally stable under these conditions, which the conductor tracks to be damaged can, or the arranged on a wave Leiterzugstruktur does not rotate evenly.

Advantages of invention

The inventive method and the device for producing a Leiterzugstruktur, as well the Leiterzugstruktur produced hereby with the features of independent claims have the advantage that by the hot pressing of the individual conductor layers after curing a dimensionally stable conductor traction structure is created which also withstands high temperature and vibration loads withstands. As the individual conductor disks together with the insulation layers first mechanically together can be jammed all needed Ladder discs in a single heat-bonding process at once which, in industrial mass production, results in considerable energy, area-, and capital expenditure can be saved. When using For example, four conductor plates, the inventive method instead of three separate hot press lines a single hot press line in a production line for the Leiterzugstruktur be used.

The Isolation layers between the individual conductor disks have preferably a fast-curing Reaction resin on which is suitable for hot pressing. Advantageous is the use of glass fiber mats soaked with epoxy resin and crosslink only when heated and then curing. Is particularly favorable the hot pressing process Perform by means of a prepreg resin, as in the PCB technology is used.

To the hot pressing be the correct position stacked dual-conductor discs with the Insulation layers between two plates of the hot pressing line pressed and heated to a reaction temperature, and then again cooled. Through this single hot glue process the production line are thus cost-effective all conductor plates in a work process in a stable way.

Especially Cheap is to form the conductor plates of a good conductive metal in such a way a variety of circuit traces spaced from each other in a circuit board are arranged. This For example, by free-punching or eroding the distances between the circuit traces, or by a casting process will be realized. The individual conductor tracks are at the beginning connected by holding portions of the conductor plates, wherein the holding areas in the later Course of the procedure to be removed.

Around to fix the conductor disks in advance of each other before the hot pressing These are first pressed together with the insulation layers against each other.

These mechanical jamming, for example, by annular clamping elements or press-stamp is realized, is maintained until the conductor runs the conductor discs punched free and then electrically together are contacted. The electrical contact, for example by Welding, simultaneously provides a mechanical connection between the circuit boards ago, whereby a prefixing is realized until the conductor plates by means of hot pressing finally dimensionally stable interconnected.

There between the individual conductor disks a plurality of conductor tracks space must be electrically connected to each other, are suitable for These contacting special welding methods, such as laser welding, flame welding or Plasma welding, By means of which a variety of welds in a short time on the smallest Room can be attached.

To electrically connect the individual conductor tracks with each other, the mechanically clamped conductor plates are advantageously provided by a central recess and / or at the outer Um fang freed from the holding areas of the conductor disks. As a result, the ends of the conductor tracks are exposed and can be electrically and mechanically connected to each other.

Thereby is the Leiterzugstruktur after completion of the electrical contacts as an annular disc formed, which advantageously arranged on a shaft as a rotor disk can be.

By the electrical connection of the conductor tracks of the individual conductor disks arise annular Loops that lie in the plane of the conductor layers of the conductor disks. As the individual conductor tracks are each formed as half waves or half loops, arise after the electrical contact approximately circular or oval or hexagonal Conductor loops, which are between the central recess and the outer circumference the conductor traction structure are arranged. Depending on the number of conductor disks has such a conductor loop according to several windings on. The many - above the Perimeter arranged side by side - Conductor loops can overlap.

The inventive device for the industrial production of Leiterzugstrukturen has advantageous just exactly one hot press line on in the prefixed dual-conductor discs with the insulating discs be inserted. In such a production line, all Conductor discs in a single hot press at the same time dimensionally stable glued together.

The by means of the method according to the invention and the device according to the invention manufactured Leiterzugstruktur can be advantageous in electro-acoustic Converters used in solenoids or electric drives, where high vibration loads and high thermal loads occur.

at Such a conductor traction structure according to the invention can a plurality of conductor plates as a very flat rotor disk which are good for drives with a very flat Construction and a high speed is suitable.

Especially Cheap it is, on the outside of an outer conductor disks to form a specific area of the tracks as a collector, which can be supplied with at least one sprung carbon brush. hereby deleted the extra Production and assembly of a commutator.

drawings

In The drawings are embodiments of a ladder structure according to the invention, and a production method according to the invention shown and explained in more detail in the following description.

It demonstrate:

1 a schematic sequence of the manufacturing method according to the invention,

2 and 3 the view and the section through an embodiment of a Leiterzugstruktur,

4a to 4c the arrangement of the conductor tracks of Leiterzugstruktur and

5 a production line according to the invention for a Leiterzugstruktur.

Beschreibing the embodiments

In 1 is the inventive scheme for producing a Leiterzugstruktur 10 shown. First, into two metallic conductor disks 12 individual conductor tracks 14 formed substantially radially from a center point 16 run outwards. The conductor tracks 14 for example, by spacing distances 18 in a tin plate 20 , For example, a copper sheet produced. In the exemplary embodiment, the conductor disks 12 formed at the beginning quadrangular, with an outer area 22 and a central area 24 as holding areas 26 are formed, which are the individual conductor tracks 14 connect with each other at the beginning. Subsequently, two conductor disks 12 stacked in such a way that the conductor tracks 14 with their inner ends 28 are arranged one above the other in the correct position. Around the two conductor disks 12 to bring exactly to cover each other, these centering 27 in which, for example, centering pins are inserted. Between the conductor disks 12 becomes an insulation layer 32 arranged, consisting of a heat-pressable reaction resin 34 and glass fibers 36 is formed. The insulation layer 32 For example, it is annular, so that it is the area of the punched conductor tracks 14 covered. The two conductor disks 12 with the intervening insulation layer 32 are pressed together mechanically and then a central recess 38 from the conductor disks 12 cut out so that the inner ends 28 the conductor tracks 14 exposed. The inner free ends 28 Now each pair between the two conductor plates 12 electrically connected to each other. A such electrical contacting 40 For example, can be made by welding, in particular by laser welding or plasma welding. By the electrical connection of the individual conductor tracks 14 are also the two conductor disks 12 with the intervening insulation layer 32 mechanically fixed to each other. Therefore, now the mechanical jamming, for example by two parallel plates 42 dissolved and you get a prefixed dual-conductor disc 13 , Subsequently, two double-conductor discs 13 with another insulation layer 32 in the correct position in a hot press 66 stacked and heated until the reaction resin 34 the insulation layers 32 melts and the individual conductor disks 12 glued together in an insulating way. After curing of the reaction resin 34 , For example, an epoxy resin 35 , creates a dimensionally stable rotor body 44 which also withstands high vibration loads and thermal loads. After the hot pressing, the outer holding areas become 22 . 26 separated, so that the conductor tracks 14 with their outer ends 30 on an outer circumference 46 the conductor disks 12 exposed. Subsequently, the individual ends 30 the conductor tracks 14 electrically interconnect such that in the Leiterzugstruktur thus produced 10 closed conductor loops 48 arise.

In 2 is an example of a ladder train structure 10 represented by the method according to 1 is made. The ladder train structure 10 is circular with a central recess 38 formed, for example, for receiving a hub or a shaft 50 serves. On the top conductor plate 12 are the individual conductor tracks 14 shown approximately radially from the central recess 38 to the outer circumference 46 run. Between the conductor tracks 14 is the hardened insulation layer 32 to recognize the conductor tracks 14 both in the circumferential direction 47 as well as axially isolated from each other. As binding resin 34 Here is, for example, a prepreg resin 35 used that together with the fiberglass structure 36 a very stable rotor body 44 forms.

In 3 is the same ladder structure 10 as in 2 shown in section III - III. The upper and the lower double conductor plate 13 is each by means of electrical contacts 40 at the central recess 38 connected. In the area of the outer circumference 46 are the two double conductor disks 13 also by means of electrical contacts 40 - For example, by welding, soldering or pressing - connected to each other. This creates closed conductor loops 48 that is radial between the central recess 38 and the outer circumference 46 are arranged. To power these conductor loops 48 is a part of the field 52 an outer conductor plate 12 as a collector 52 formed, for example, in an electrical machine 54 with axially arranged carbon brushes 56 interacts. In the electric machine 54 are also axial to the rotor disk 14 magnets 58 arranged, whereby the energized conductor loops 48 the ladder train structure 10 relative to the magnets 58 set in rotation.

In 4a to 4c is schematically the layer sequence of, for example 6 wafers 12 illustrated, wherein for simplicity, the annular conductor plates 12 partially as a rectangle 60 are shown. In 4a are the radially arranged conductor tracks 14 With 1 designated. These ladder trains 1 the first conductor plate 12 are as well as the conductor tracks 2 the second conductor plate 12 as (angular) wave trains 62 formed, which together a first double-conductor disc 13 form. In a second double-conductor disc 13 are in 4b in addition, the conductor tracks 3 and 4 as two (angular) half loops 64 formed after the electrical contact 40 a closed conductor loop 48 form. In 4c comes the third double conductor plate 13 with the conductor cables 5 and 6 as another closed conductor loop 48 so that in total a double conductor loop 48 . 64 with the two connections a, 62 arises. About the scope 46 the ladder train structure 10 is then a variety of such conductor loops 48 arranged, which - as in 4a - 4c - also indicated in the circumferential direction 47 overlap. The conductor loops 48 for example, as in 3 represented by means of a commutator 52 trained area 52 the conductor tracks 1 and 2 over carbon brushes 56 powered. Of course, the arrangement according to 4b as a complete ladder train structure 10 with a total of four conductor disks 12 or a ladder train structure 10 with more than six conductor disks 12 be prepared by the method according to the invention.

5 shows a production line according to the invention 70 by means of these ladder structures 10 can be prepared by the process according to the invention. The production line 72 comes with prestructured blanks as conductor disks 12 fed. In a first punching module 72 become the conductor disks 12 with an insulating layer in between 32 between the clamping plates 42 mechanically strained and then the ends 28 or 30 the conductor tracks 14 punched. Subsequently, the individual conductor tracks 14 in the mechanically clamped state in several contacting modules 74 electrically contacted and thus mechanically prefixed. Thereafter, the thus prefixed dual-conductor discs 13 together with an additional insulation layer 32 in the hot press 66 stacked. By heating the reaction resin 34 become the individual conductor disks 12 to a solid rotational body 44 connected. After this Hot pressing will be the other ends 30 or 28 the conductor tracks 14 punched free and then again in other Kontaktiermodulen 74 by means of electrical contacts 40 connected with each other.

It should be noted that, with regard to the exemplary embodiments shown in the figures, a variety of possible combinations of the individual features are possible with one another. For example, the concrete shape of the conductor plates 12 and the arrangement of the conductor tracks 14 adapted to the specific application. Likewise, for the heat-compressible insulation layer 32 Different materials are used, depending on the stability requirements and process speed, the material parameters are selected accordingly. For electrical contacting of the conductor tracks 14 Various methods such as welding, brazing, folding or pressing are also considered. In this case, in the manufacture of the double-conductor discs 13 the two conductor disks 12 mechanically pressed against each other, however, is such a jamming after Heißverkleben for the electrical contact between the double-conductor discs 13 is no longer necessary. With the described method, a plurality of Leiterzugstrukturen 10 simultaneously in a large matrix (eg 50 to 100 pieces at the same time). Preferably, the conductor plates 12 first in the area of the central recess 38 electrically contacted and then the dual-conductor discs 13 after hot pressing in the area of the outer circumference 46 contacted. The conductor traction structure according to the invention 10 is suitable for a variety of applications, in particular for the formation of flat, dimensionally stable rotor disks 44 for inductive generation of magnetic fields.

Claims (14)

Method for producing an electrical conductor traction structure ( 10 ) comprising the following steps: - stacked stacked two electrical conductor tracks ( 14 ) having conductor disks ( 12 ) with an insulating layer ( 32 . 34 . 35 ) - Mechanical jamming of the two conductor disks ( l2 ) to each other - pairwise electrical connection of the conductor tracks ( 14 ) between the two conductor disks ( 12 ) to a dual-conductor disc ( 13 ) - Stacked stacking of at least two double conductor discs ( 13 ) with insulating layers ( 32 . 34 . 35 ) - Permanent fixing of all conductor plates ( 12 ) to each other by means of Heißverpessen - Pairwise electrical connection of the conductor tracks ( 14 ) between the respective double-conductor disks ( 13 ) to a ladder train structure ( 10 ) Method according to claim 1, characterized in that the insulating layer ( 32 . 34 . 35 ) from a heat-pressable reaction resin ( 34 ) - in particular with in epoxy resin ( 35 ) impregnated glass fibers ( 36 ) - is formed. Method according to one of claims 1 or 2, characterized in that the conductor disks ( 12 ) with the insulating layers ( 32 . 34 . 35 ) are pressed for hot pressing at least against a heatable plate. Method according to one of the preceding claims, characterized in that the conductor disks ( 12 ) made of a highly electrically conductive metal ( 20 ) - for example, punched, cast or eroded - be. Method according to one of the preceding claims, characterized in that the conductor disks ( 12 ) and / or double-conductor disks ( 13 ) by means of two plates ( 42 ) of a press mechanically prefixed to each other. Method according to one of the preceding claims, characterized in that after the mechanical jamming and / or after the hot pressing the conductor tracks ( 14 ) and then between the conductor disks ( 12 ) are electrically connected to each other. Method according to one of the preceding claims, characterized in that on the conductor tracks ( 14 ) by means of welding - in particular laser welding, flame welding or micro plasma welding - electrical contact bridges ( 40 ) are formed. Method according to one of the preceding claims, characterized in that the conductor disks ( 12 ) after the electrical contacting of the conductor tracks ( 14 ) are formed annularly with a central recess. Method according to one of the preceding claims, characterized in that the conductor disks ( 12 ) at its outer periphery ( 46 ) and / or at the edge of the central recess ( 38 ) are punched free for electrical contact. Method according to one of the preceding claims, characterized in that the electrically connected conductor tracks ( 14 ) of the conductor disks ( 12 ) circular - in particular hexagonal-shaped - conductor loops ( 48 ) formed radially between the central recess ( 38 ) and the outer circumference ( 46 ) are arranged. Contraption ( 70 ) for the serial production of conductor tensile structures ( 10 ) by means of Heißverpres sen according to one of the preceding claims, wherein in a production line next to modules ( 72 ) for punching the conductor disks ( 12 ) and modules ( 74 ) for electrically contacting the conductor tracks ( 14 ) only exactly one hot press ( 66 ) for the simultaneous hot pressing of the individual conductor disks ( 12 ) and the dual-conductor discs ( 13 ) is arranged. Conductor traction structure ( 10 ) for the inductive generation of magnetic fields produced by the method and / or with the device according to one of the preceding claims, characterized by use in electroacoustic transducers, in lifting magnets or in electric drives ( 54 ). Conductor traction structure ( 10 ) for the inductive generation of magnetic fields according to claim 12, characterized by the design as a flat rotor disk ( 44 ), which has several heat-bonded conductor disks ( 12 ) with radially arranged, punched-out conductor tracks ( 14 ), wherein the conductor tracks ( 14 ) with axially arranged working magnet ( 58 ) of the electric drive ( 54 ) can work together. Conductor traction structure ( 10 ) for the inductive generation of magnetic fields according to claim 12 or 13, characterized by a central recess ( 38 ) for receiving a rotor hub or shaft ( 50 ), whereby on the conductor tracks ( 14 ) a plan commutator ( 52 ) is formed, the axially with carbon brushes ( 56 ) of the electric drive ( 54 ) is contactable.