DE102005034083A1 - Method for applying electrical conductor structures to a target component of plastic - Google Patents

Abstract

The invention relates to a method for applying electrical conductor structures (1) to a target component (9) made of plastic, the invention providing that a transfer medium on which the conductor structures (1) are detachably arranged is converted into a molded part (3, 8) are inserted and the molded part (3, 8) is filled with a PUR layer (5), the finished target component (9) being removed from the molded part (3, 8) after the foaming process.

Description

The The invention relates to a method for applying electrical Ladder structures on a target component made of plastic according to the features of the preamble of claim 1.

It is known to manufacture target components made of plastic. That's the way it is For example, known in vehicles, flat components, such as hoods, Roofs, To make boot lid and the like made of plastic for weight reduction reasons. Likewise Attachments, such as fenders, Doors, bumpers and the like of vehicles made of plastic. Next weight reduction, these plastic components have the advantage that they are facing Steel components can not rust.

at Such components of vehicles, it is also known, even electrically introducing or applying conductive structures (conductor structures), the the transmission of energy or signals. In this case, previously known methods applied to the application of the ladder structures, where initially the Target component is manufactured, giving it its final shape reached. Only then are the ladder structures applied, for Example by clipping in wires or stamped and bent parts. This procedure of the subsequent However, the application of the ladder structures is disadvantageous, since a complex coordination process between the material of the ladder structure and the target material required is and in the subsequent Operation of the vehicle required durability of the conductor structures not guaranteed on the target component is. Furthermore is disadvantageously a complex Motageprozess required. There are also big ones Problems with the subsequent Applying the conductor structures on the target component, as this in the Usually complex, for example arched, bent or the like, is. As a result, the subsequent application of conductor structures, if at all possible is, then very complicated is.

Of the The invention is therefore based on the object, a method for applying of electrical conductor structures on a target component made of plastic to provide that is easy to implement and that the beginning avoids described disadvantages. In addition, a should after the procedure manufactured target component with electrical conductor structures for disposal stand.

These The object is solved by the features of claim 1.

According to the invention, it is provided a transfer medium on which the conductor structures are detachably arranged are to be inserted into a molding and the molding with a PUR layer (PUR foam) filled being, after the foaming process the finished target component is removed from the molded part.

This Method has the advantage that initially the conductor structures on a transfer medium, wherein in a particular embodiment the invention, the transfer medium is a plastic film. The use of a transfer medium has the additional advantage that it must have only such dimensions, in whose area the conductor structures available. This makes it much easier to handle. There is also the advantage that the material of the transfer medium and the material the ladder structures is so coordinated that it at least during the Adhere the target component to each other, if necessary after the production of the target component but also a removal of Transfer medium possible is. Another advantage is that the transfer medium with the conductor structures arranged thereon not yet the final form of the Must have target components, because this form only after insertion into the molding and the subsequent filling of the Form part can be done with plastic material. This will be the design freedom for the target component and its rational production in an advantageous manner supported. Especially for the case that after the production of the target component, the transfer medium is removed, the inventive method offers the advantage that then the conductor structures facing away from the transfer medium surfaces are surrounded by the plastic material and thus permanently and are fixedly arranged on the target component, so that they during later operation of the target component can no longer dissociate from this. If the transfer medium is removed, is further given the advantage that a smooth surface of the Target components has emerged, especially in a subsequent Paint no longer needs to be processed and the Ladder structures no longer over the surface protrude the target component. This also facilitates the attachment a carrier or holding member (for example, a frame) of other modules (for Example electronic modules) or a contacting essential.

Overall, the filling of the foamable plastic material offers great freedom on the one hand with respect to the design and the manufacturing costs of the target component, on the other hand, the plastic material can also be selected after application of the target component. For example, foamable plastic materials are preferred when it comes to weight savings on Installation location of the target component goes.

In Further development of the invention is provided that the transfer medium before or during of the refilling process is transformed. Since before inserting the transfer medium into the molding whose forms may differ, but need not, is it is advantageous to transfer medium before or during the refilling process to transform, that is, the negative shape of the molded part, the outer shape of the finished target component corresponds to adapt. This can be done, for example, mechanically, with vacuum, with the help of electrostatic charge in the molding or the like respectively. Important for the insertion process of the transfer medium in the molded part, independent of whether the transfer medium before or during the refilling process is transformed or its original Maintains shape, it is that the transfer medium is fixed in the molding so the transfer medium appears on its outer surface after production of the target component, this means, at least partially or completely forms its surface.

In Further development of the invention is provided that during or after refilling the entire target component is deformed. That means the target component by the shape of the molding already its final form receives or at first through the padding of the molded part with the plastic material, the target component a first Shaping receives. After removing the finished target component from the mold is it then plastically deformed by suitable methods, in particular by Action of heat and pressure exercise in his final Brought form. It is important to ensure that during this subsequent forming the Conductor structures not damaged especially to avoid interruptions.

In Further development of the invention, the transfer medium is a film which has the particular advantage that easy, fast and inexpensive the Ladder structures can be applied to it and provide adequate support flexibility when inserting into the molding offers.

In Further development of the invention is provided that the transfer medium after the completion of the target component either as a protective layer this remains, is partially removed (the remaining part provides a protective layer while in the remote area of the transfer medium, the conductor structures in order further processing, in particular contacting, exposed) or Completely Will get removed. The partial or complete removal of the transfer medium offers the possibility, that the ladder structures are then exposed and further processing to disposal stand. The further processing may be an electrical contact with electrical or electronic components on the target component be arranged there to an electronic device, for example an antenna amplifier of a vehicle. additional or alternatively the conductor structures also pure electrical connections for power supply or signal transmission be and have a connector in their end. Consequently let yourself in a preferred Ausgestal tion of the invention, therefore, a target component with conductor structures arranged thereon, on which subsequently electrical, electronic and connecting components are arranged, the one electronic device form.

In Development of the invention, the transfer medium is a fiber composite, In particular, the transfer medium is a paper. Paper is extremely cheap and is delivered on roll. It is also easy to print. waxed Paper can for the transfer particularly favorable be. Fabric is another, very tear-resistant fiber composite. Besides are also other fiber composites conceivable

In Further development of the invention, the transfer medium is an integral part of the molding. In this embodiment, the conductor patterns by suitable methods on the inner surface of the molding applied, the connection between the conductor structures and to choose the molding so is that after filling the molded part with the plastic material and the removal of the molded part the conductor structures remain on the finished target component and thus detach from the molding.

In Another particular embodiment of the invention is the target component according to the inventive method manufactures, wherein the target member is characterized by his Application as a component of a vehicle, in particular a vehicle roof. This means that as a plastic material for the production of the target component translucent or opaque. In addition, the plastic material according to the place of installation, already finished in color or afterwards with a color layer are provided.

embodiments for the The invention, to which, however, is not limited, are as follows described and explained with reference to the figures.

It demonstrate:

1 : electrical conductor structures which are applied to a transfer medium,

2 : a mold for holding the Transfer medium,

3 : the closed mold after the introduction of the foamable PUR material,

4 : fragmentary the finished target component,

5 : the target component before and after removing the transfer medium.

The 1 shows ladder structures 1 on a transfer medium, especially a thin film 2 , are applied.

When Ladder structures are pastes, for example silver polymer pastes, Cu pastes (copper) or the like. As foils are PET, PMMA and general Plastic films usable that do not completely bond with the PUR foam received. Applying the conductor structures on the film can by means of Screen printing, pad printing and all common printing methods, which you too applies to paint (spray or sputtering). Here are the aforementioned lists only as an example and not exhaustive.

Such in 1 shown foil 2 with attached ladder structures 1 either already has the final geometric design of the later finished target component or can be brought before or during the production of the target component in the final form.

2 shows a mold for receiving the transfer medium. As a rule, the molding tool consists of two or more parts so that it is possible to insert the transfer medium into the molding tool. In this example, Ausfüh is a first molded part 3 present, in which a lacquer layer, in particular a paint film 4 , is introduced. This lacquer layer may, but need not, be present. After the introduction of the lacquer layer or, if this is not present, for the first time, a foamable plastic, in particular a PUR layer, by means of an application tool 6 in the first molding 3 brought in. In this case, the foamable plastic material, for. B. by means of a nozzle 7 of the application tool 6 in the first molding 3 introduced flat or otherwise. The foamable plastic material is the paint film 4 adapt in terms of compatibility and coefficient of expansion. The expansion coefficients of paint film 4 and foam should be precisely matched so that no bimetal effect occurs.

3 shows the closed mold after the introduction of the foamable PUR plastic material. After the foamable plastic material in the first molding 3 has been introduced, the mold is closed, here by means of at least one further molded part 8th , Before closing, the transfer medium (foil 2 with applied conductor structures 1 according to 1 ) introduced into the mold, including, for example, on the PUR layer 5 is applied or on the inside of the further molded part 8th liable. In an alternative embodiment, the transfer medium may also be through the further molded part 8th be formed, then the ladder structures 1 wearing. After the mold has been closed, the PUR foam begins 5 to swell, creating heat and pressure, so that either the conductor structure 1 on the slide 2 or the ladder structure 1 on the molding 8th is foamed. In this process, the amount of filled plastic material is selected so that the entire interior of the mold, including the inserted conductor structures, (and possibly the inserted film 2 ) is completely filled during foaming. In the event that a larger amount is selected, it may be necessary to provide an outlet opening in the mold.

4 shows in detail the finished target component, wherein it is shown here that the permanently adhering to the PUR layer conductor structures 1 from the transfer medium (here the film 2 , alternatively z. B. the molding 8th ) Will get removed. This is the ladder structures 1 at least partially free and can be subjected to further processing, in particular painting or attachment of electrical, electronic and the like components.

5 shows the target component before and after the removal of the transfer medium. Here is shown that a finished target component 9 in a partial area, as described above, with the conductor structures 1 has been provided. If it is assumed that the transfer medium is the film 2 is used, this adheres to the removal of the target component 9 from the mold still on this. This is advantageous if z. B. the target component 9 manufactured at a supplier of a vehicle manufacturer and delivered to a vehicle manufacturer for final assembly. In such a case, the film offers 2 the ladder structures 1 Protection, especially against corrosion or oxidation and mechanical protection. The same applies in the event that the target component 9 was prepared prior to its further processing, in particular the contacting of the conductor structures 1 with other electronic components, but only needs to be stored. Also in this case offers the temporary whereabouts of the film 2 on the target component 9 a protection of existing conductor structures there 1 , This is in the left half of the 5 shown while in the right half of the 5 shown is that the film 2 completely (although partially conceivable) was removed. This is the ladder structures 1 open on the surface of the target component 9 , while it should be noted that the surface of the target component 9 and the surfaces of the conductor structures present there 1 are arranged in one and the same level, so that the ladder structures 1 not from the surface of the target component 9 take off or lie underneath.

At this point it should be mentioned that after the removal of the target component 9 this has the final shape or can still be made to measure. It is advantageous that it is processed so that at the end of the individual conductor structures 1 a contacting area 10 results.

1.

conductor structures

Second

foil

Third

first molding

4th

lacquer

5th

PUR-layer

6th

application tool

7th

jet

8th.

additional molding

9th

target component

10th

contacting

Claims (10)

Method for applying electrical conductor structures ( 1 ) to a target component ( 9 ) made of plastic, characterized in that a transfer medium on which the conductor structures ( 1 ) are detachably arranged, in a molded part ( 3 . 8th ) are inserted and the molded part ( 3 . 8th ) with a PUR layer ( 5 ), wherein after the foaming process the finished target component ( 9 ) the molded part ( 3 . 8th ) is taken. Method according to claim 1, characterized in that that the transfer medium before or during the refilling process is transformed. Method according to claim 1, characterized in that that the target component during or after the refilling process is deformed. Method according to one of the preceding claims, characterized in that the transfer medium comprises a film ( 2 ). Method according to one of the preceding claims, characterized characterized in that the transfer medium after completion of the target component is not, partially or completely removed. Method according to one of the preceding claims, characterized in that the transfer medium is a fiber composite, in particular paper, is. Method according to one of the preceding claims, characterized in that the transfer medium is a component of the molded part ( 3 . 8th ). Target component ( 9 ) prepared by the method according to one of the preceding claims. Target component ( 9 ) according to claim 8, characterized by its application as a component of a vehicle. Target component ( 9 ) according to claim 8 or 9, characterized in that the component of the vehicle is a vehicle roof.