DE102006021560B4 - Overmoulded ribbon cable with hot stamped circuit - Google Patents

Abstract

Ribbon cable conductors with several conductor wires (2a, 2b, 2c, 2d), with insulation (3) and with a hot embossing, contacted with at least one of the conductor wires (2a, 2b, 2c, 2d) electrical circuit (12), characterized in that the insulation (3) of the ribbon conductor (1) with a plastic base (5) overmoulded is, and that the electrical circuit (12) on the plastic base (5) imprinted is.

Description

The The invention relates to a ribbon conductor having a plurality of conductor wires, with an insulation and with a fixed by hot stamping, with at least one of the conductor wires contacted electrical circuit as well a method for setting an electrical circuit to a Ribbon conductor with several conductor wires and with insulation.

Ribbon cable conductors are due to their flat and thus space-saving training used in a variety of technical applications. Due to the high flexibility Flat-band conductors are preferred for use in automotive technology. Ribbon conductors or cable harnesses made of ribbon conductors are differentiated according to their manufacturing technology. In so-called FPC cable sets the copper conductor cores etch-technically analogous to the traditional circuit board manufacturing process made of copper laminated base films and then with glued to a cover sheet. For FFC cables are rolled or even cut copper conductor wires in a continuous process wrapped by extrusion with thermoplastic or extrusion laminated between two adhesive-laminated foils. Is common all ribbon conductors a plurality of juxtaposed Conductor cores surrounded by insulation.

since prolonged there are efforts because of the increasing share of electronics in vehicles, coupled with the desire for on-site electronic intelligence of actuators, in flat-ribbon conductors decentralized electrical circuits too integrate. There is the difficulty, especially FFC-based Ribbon conductor with electrical circuits to equip.

In an article by Dr. Ing. W. John in the magazine "PLUS - Production of printed circuit boards and systems of "the Eugen G. Lenze publishing house, bath Saulgau, P. 154 to 160 from 1/2006 is discloses electrical circuits by hot stamping directly on the insulation of flat ribbon conductors apply. This is a circuit layout from a specially prepared copper foil by means of a punching and embossing tool sheared out and under pressure and heat with the under the film connected ribbon cable connected. To improve the connection From electrical circuit and ribbon conductor it is known that the ribbon side facing the copper foil with a roughened, galvanically produced, so-called "cauliflower structure" to provide, in which is at the imprint liquefying Plastic can anchor very well when it cools down. A major disadvantage is the fragility the insulation in the known method. The insulation can in the hot stamping process, in the subsequent contacting the conductor wires with the electrical Circuit in micro-welding process or in the final assembly of the assembled Ribbon conductor damaged which causes short circuits, especially between adjacent conductor wires can occur. Further disadvantageous is the unavoidable waviness of the ribbon conductor, a permanent and accurate attachment of the electrical circuit difficult. To protect the electrical circuit from moisture it is known, the electrical circuit including the ribbon cable with a separate housing to provide. In general, this will be two latchable plastic half shells used, sealed with a plastic soft component become.

From the EP 1 424 882 A1 It is also known to arrange a circuit directly on the surface of a flat conductor, which brings the disadvantages explained above with it.

The DE 101 01 957 A1 describes an electrical component which is produced by molding a lead frame with plastic, wherein a plurality of conductor tracks are applied to the plastic extrusion.

From the DE 103 33 967 A1 is the provision of grooves in plastic sockets with applied conductor tracks for fixing a housing known.

Of the Invention is based on the object, an improved, lasting and interference-free connection between a ribbon conductor and an electrical circuit and a method for establishing an electrical circuit to propose on a ribbon cable.

These Task is in a ribbon conductor of the type mentioned solved by that the isolation of the ribbon conductor with a plastic base is overmoulded, and that the electrical circuit on the plastic base imprinted is.

Further the problem is solved by a method in which a section of the Insulation is overmolded with a Kunsstoffsockel and in the the electrical circuit is hot stamped on the plastic base.

The invention is based on the idea not to fix the electrical circuit directly by hot stamping on the insulation of the ribbon conductor, but to overmold the ribbon conductor in at least one section with a plastic base and to secure the electrical circuit by hot stamping on this plastic base. In contrast to the ribbon conductor, the plastic base is rigid, whereby the area on which the electrical circuit is arranged, is not bendable. As a result, breaking of the insulation, in particular during installation of the equipped with the electrical circuit ribbon conductor is advantageously avoided. Furthermore, because of the provision of the rigid plastic base, ripples can be avoided, whereby the electric circuit can be fastened or positioned much more easily and accurately and rests on the plastic base over the whole area. Due to the provision of a plastic base, it is also possible to apply electronic components in the vapor phase, which was not possible with conventional ribbon conductors due to the low melting point of the insulation. As electrical circuits, for example, pure conductor tracks or even with electrical or electronic, passive and / or active components equipped printed conductors can be used. Preferably, the printed conductors used are conductor surfaces punched out of a metal foil, in particular a copper foil, which are melted down in the plastic base by the application of suitable pressures and temperatures in the hot embossing process.

advantageous Further developments of the invention are specified in the subclaims.

In Embodiment of the invention is provided with advantage that the Plastic base part of an electrical circuit surrounding housing is. Preferably, the plastic base forms the bottom of a housing, so that on a separate caseback can be waived.

From It is particularly advantageous that the electrical circuit on a the flat strip conductor facing away from the top of the plastic base is arranged. This opens up the possibility of electrical Circuit on a relatively large area, flat and to arrange in a further development of the invention flat surface, whereby the Durability and stability the connection of ribbon cable and electrical circuit on elevated becomes.

In Further development of the invention is provided that in the top the plastic base a, preferably circumferential groove introduced is. This groove serves for the positive reception of a housing cover. housing cover and plastic sockets together make up the circuit from shock and moisture protective Casing.

Around a particularly tight connection between the housing cover and the plastic base to provide, is provided in an embodiment of the invention that the housing cover welded to the plastic base, preferably ultrasonically welded. Due to the welding the two components can be dispensed with a separate sealant become.

Around for one permanent and unbreakable contact between at least one Ladder wire and the electrical circuit to provide, is in development The invention advantageously provided that at least one section stripped at least one of the conductors and stripped to the top led the plastic base is. The contacting thus does not take place at the flat conductor level, but on plastic base level, spaced from the ribbon conductor level instead of.

With Advantage is the stripped portion of the conductor wire not laterally along the plastic base to the top of the plastic base, but by one for this provided opening guided in the plastic base.

Around one possible large-area contacting between the stripped portion of the conductor wire and the electrical To create circuit and thus low contact resistance hold is according to one advantageous aspect of the invention provided that the stripped Section of the conductor wire at least partially parallel to the top the plastic base runs. Preferably runs the outer surface of the stripped portion of the conductor vein flush with the outer surface of the Plastic base, leaving the outer surface of the stripped section the conductor core and the top of the plastic socket a common Form level. This avoids that portions of the electrical Circuit must protrude into the plastic base.

According to the inventive method for Determining an electrical circuit on a ribbon conductor will be first a section of the insulation with a plastic base, whereupon the electrical circuit in the hot stamping process on the plastic base is applied. In doing so, the insulation of the ribbon conductor must be not necessarily full to be overmoulded. It is enough if only one flat side or one Area of a flat side is provided with the plastic base.

Embodiments of the invention will now be described below with reference to the drawing. This is not necessarily to scale the embodiments, but the drawing, where appropriate for explanation, executed in a schematized and / or slightly distorted form. With regard to additions to the teachings directly recognizable from the drawing reference is made to the relevant prior art. It should be noted that various modifications and changes can be made regarding the shape and the detail of an embodiment without departing from the general idea of the invention. The disclosed in the description, in the drawing and in the claims features of the invention may be essential both individually and in any combination for the development of the invention. The general idea of the invention is not limited to the exact embodiment or limited to an article that would be limited in comparison to the subject-matter claimed in the claims. For the given design ranges, values within the stated limits should also be disclosed as limit values and be arbitrarily usable and claimable.

It demonstrate:

1 a ribbon conductor having a raised stripped portion;

2 a ribbon conductor overmolded with a plastic base;

3 a ribbon conductor overmolded with a plastic base with an electrical circuit impressed in the hot embossing process; and

4 A flat strip conductor with an overmolded plastic base with a housing cover attached thereto.

In the figures are the same components and components with the same function marked with the same reference numerals.

In 1 is a ribbon cable 1 shown. The ribbon conductor 1 includes four parallel juxtaposed and in the longitudinal direction of the ribbon conductor 1 running, flat conductor wires 2a to 2d with rectangular cross section. The conductor wires 2a to 2d are over most of their longitudinal extent with a plastic insulation 3 made of a thermoplastic material, in particular polyurethane or PBT. The plastic insulation insulates the conductor wires 2a to 2d from each other and from the environment. The conductor wires 2a to 2d consist in this embodiment of copper with a thickness between about 100 and 200 microns. The thickness of the art fabric insulation 3 is typically between 100 and 175 microns, wherein the Shore hardness is approximately between 50 and 60.

In a section 4 of the ribbon conductor 1 are the conductor wires 2a to 2d stripped, so exposed and bent so that the conductor wires 2a to 2d in the stripped section 4 partially raised above the plastic insulation 3 are. In particular, a middle region of each conductor core 2a to 2d within the stripped section 4 runs parallel and at a distance to the plastic insulation 3 or to the underlying conductor wires 2a to 2d ,

In 2 It can be seen that by injection molding a plastic base 5 on the ribbon cable 1 was applied. For this purpose, the ribbon conductor 1 or the plastic insulation 3 of the ribbon conductor 1 molded with plastic. How out 2 it can be seen, the encapsulation was not complete, but only on the upper flat side in the plane of the drawing 6 of the ribbon conductor 1 , Between the conductor wires 2a to 2d provided grooves 7a to 7c improve the connection between plastic base 5 and ribbon conductors 1 because of the liquid plastic when spraying the plastic base 5 in these grooves 7a to 7c flows in and anchors there.

The plastic base 5 has a flat top 8th on, the flat-band conductor 1 turned away and runs parallel to this. In the top 8th Edge is a circumferential groove 9 introduced laying down an in 4 shown housing cover 10 serves. In the front of the plane of the drawing in the plastic base 5 are four parallel and juxtaposed openings 11a to 11d for receiving the stripped conductor wires 2a to 2d in the section 4 of the ribbon conductor 1 brought in. It can be seen that the conductor wires 2a to 2d with its stripped section flush with the top 8th of the plastic base 5 run and thus contacting a in 3 shown electrical circuit 12 facilitate.

In 3 is the electrical circuit 12 already in the hot stamping process on the top 8th of the plastic base 5 established. When hot stamping melts the top 8th of the plastic base 5 in the field of electrical circuit 12 and holds it after cooling down. In the embodiment shown, there is the electrical circuit 12 only from a variety of copper lines 13 which were punched out of a copper foil. The electrical wires 13 can serve to receive active and / or passive electrical or electronic components, in a further, not shown, manufacturing step on the electrical lines 13 can be applied. The advantage of providing the plastic base 5 consists inter alia in that the ribbon conductor 1 or the plastic insulation 3 in the application of these active and passive components can not be damaged, regardless of the applied application method. The electrical wires 13 the electrical circuit 12 are in the range of the section 4 of the ribbon conductor 1 with the conductor wires 2a to 2d , in particular contacted by welding. Because the contact on the top 8th of the plastic base 5 takes place, damage to the Plastic insulation 3 of the ribbon conductor 1 avoided with advantage.

After the electrical circuit 12 is finished, is a housing cover 10 like this in 4 it can be seen on the plastic base 5 applied. The plastic base 5 forms the bottom of the case, so that can be dispensed with a separate case bottom. The housing cover 10 is with a circumferential, not shown, complementary spring in the circumferential groove 9 recorded and ultrasonically welded to the plastic base. This creates a tight connection between the plastic base 5 and housing cover 10 created, whereby a moisture in the area of the electrical circuit 12 is avoided with advantage.

Claims (13)

Ribbon conductor with several conductor wires ( 2a . 2 B . 2c . 2d ), with insulation ( 3 ) and with a hot embossing, with at least one of the conductor wires ( 2a . 2 B . 2c . 2d ) contacted electrical circuit ( 12 ), characterized in that the insulation ( 3 ) of the ribbon conductor ( 1 ) with a plastic base ( 5 ) and that the electrical circuit ( 12 ) on the plastic base ( 5 ) is imprinted. Ribbon conductor according to claim 1, characterized in that the plastic base ( 5 ) Part of an electrical circuit ( 12 ) surrounding housing ( 5 . 10 ). Ribbon conductor according to one of the preceding claims, characterized in that the electrical circuit ( 12 ) on a ribbon conductor ( 1 ) facing away from the top ( 8th ) of the plastic base ( 5 ) is arranged. Ribbon conductor according to claim 3, characterized in that the upper side ( 8th ) is just. Ribbon conductor according to one of claims 3 or 4, characterized in that in the top ( 8th ) a, preferably circumferential, groove ( 9 ) for fixing a housing cover ( 10 ) is introduced. Ribbon conductor according to claim 5, characterized in that the housing cover ( 10 ) with the plastic base ( 5 ), preferably ultrasonically welded, is welded. Ribbon conductor according to one of Claims 3 to 6, characterized in that at least one section ( 4 ) at least one of the conductor wires ( 2a . 2 B . 2c . 2d ) and stripped to the top ( 8th ) of the plastic base ( 5 ) is guided. Ribbon conductor according to claim 7, characterized in that the stripped portion ( 4 ) the conductor wire ( 2a . 2 B . 2c . 2d ) through an opening ( 11a . 11b . 11c . 11d ) in the plastic base ( 5 ) to the top ( 8th ) of the plastic base ( 5 ) is guided. Ribbon conductor according to one of claims 7 or 8, characterized in that the stripped portion ( 4 ) the conductor wire ( 2a . 2 B . 2c ) at least in a region parallel to the top ( 8th ) of the plastic base ( 5 ), preferably flush with the top ( 8th ) of the plastic base ( 5 ), runs. Method for determining an electrical circuit ( 12 ) on a ribbon conductor ( 1 ) with several conductor wires ( 2a . 2 B . 2c . 2d ) and with insulation ( 3 ) comprising the following steps: • overmolding a section of the insulation with a plastic base ( 5 ), • hot embossing of the electrical circuit ( 12 ) on the plastic base ( 5 ). A method according to claim 10, characterized in that during encapsulation of the insulation ( 3 ) with the plastic base ( 5 ) at least one opening ( 11a . 11b . 11c . 11d ) in the plastic base ( 5 ) for carrying out at least one of the conductor wires ( 2a . 2 B . 2c . 2d ) is omitted. Method according to one of claims 10 or 11, characterized in that during encapsulation of the insulation ( 3 ) with the plastic base ( 5 ) at least one groove ( 9 ) on a ribbon conductor ( 1 ) facing away from the top ( 8th ) of the plastic base ( 5 ) is omitted. Method according to one of claims 10 or 12, characterized in that a housing cover ( 10 ) with the plastic base ( 5 ) is welded, preferably ultrasonically welded.