DE102013016073B4 - Device for signal transmission in a vehicle - Google Patents

Abstract

Device for signal transmission in a vehicle, with a plurality of signal conductors (2, 2a) and a multi-layer flat conductor (1), the signal conductors (2, 2a) each being applied to a flat surface of one of several layers (3a, 3b) of the flat conductor (1). are and in each case an insulation layer (4, 4a) surrounding the signal conductor (2, 2a) is interrupted to form a contact surface (7), the contact surface (7) being non-positively, positively or materially connected to a contact element (I, J, K , H) is connected, and wherein at least two signal conductors (2, 2a) are arranged on different levels and cross each other, the contact surface (7) protruding beyond the contours of the flat conductor (1) on the narrow or broad side, the contact surface (7) protrudes from a narrow side of the flat conductor (1) and is backed with only one layer (3c) of the flat conductor (1).

Description

TECHNICAL FIELD

The invention relates to a device for signal transmission in a vehicle with a multilayer flat conductor and at least one signal conductor which is applied to a flat surface of the flat conductor. This means that new combinations of power supply and signal transmission cabling can be implemented in a vehicle if appropriate contact options are made available. Such devices are particularly needed in vehicles in the automotive sector, in aviation, in rail transport and shipping.

BACKGROUND OF THE INVENTION

When using conventional cable harnesses in the form of round conductors in vehicle applications, long cable lengths with large diameters and correspondingly significant weights are used.

By using flat ladders, especially made of aluminum, the installation space and the weight of the ladder can be significantly reduced. The flat conductor is laid, for example, along the floor group contour from the rear compartment to the engine compartment.

Furthermore, the geometric shape of the flat conductors has electrical advantages over round conductors. In addition to the energy and signal supply, a multi-layer flat conductor can also be used for ground return, regardless of the body materials in the vehicle. The layered, flat structure also reduces the electromagnetic fields outside the multilayer conductor.

The DE 10 2012 214 161 Al describes the structure of multilayer conductors and ways to contact such multilayer conductors in order to connect consumers. The dimensioning of the flat conductors of a multilayer conductor is suitable for power supply, but represents over-dimensioning for signal transmission.

WO 2010/125 426 A1 proposes a metal bus bar for power supply, which is provided with a layer of printed circuits for signal line. The printed circuit is a flexible printed circuit that is arranged, for example, within two conductors of the busbar. JP S58- 105 320 A On the other hand, several current-carrying plates are glued together, with a printed circuit being located at least on the inside of one plate. DE 69 28 695 U shows a subrack for control systems, which consists of several metallic layers that are insulated from one another and serve to provide power. One of the metal layers is overmolded with insulating plastic, which serves as a carrier for conductor tracks.

However, the reliable contacting that is robust under the conditions of vehicles with vibrations and the accessibility of water and dirt has not been solved.

The WO 2006/ 082 238 A1 discloses an electrical cable for motor vehicles with an energy conductor formed as a ribbon conductor and surrounded by an insulating layer.

The EP 1 688 966 A1 discloses an electrical ribbon conductor for motor vehicles made of aluminum and with a profiled cross section.

The DE 200 23 435 U1 discloses a flexible flat cable for the internal wiring of electrical/electronic assemblies with several electrical conductors arranged parallel to one another on a carrier substrate.

The DE 10 2012 214 158 A1 discloses a method for contacting and connecting a single or multi-layer flat conductor with one or more conductors.

The EP 1 424 882 A1 discloses a flat conductor cable for use in vehicles with at least two electrical conductors and an insulation layer made of plastic material surrounding the conductors.

The DE 101 57 678 A1 discloses a foil cable whose conductor tracks have a meander-shaped structure.

The GB 1 258 702A reveals an electrical cable.

DESCRIPTION OF THE INVENTION

It is an object of the invention to provide a device for signal transmission that is suitable for use in vehicles and overcomes the aforementioned disadvantages.

The task is solved with a device having the features of claim 1. Advantageous embodiments of the device are listed in the further patent claims.

The device according to the invention for signal transmission in a vehicle contains a signal nalleiter, a multilayer flat conductor, the signal conductor being applied to a flat surface of one of several layers of the flat conductor and an insulation layer surrounding the signal conductor, which is interrupted to form a contact surface. The contact surface is non-positively, positively or materially connected to a contact element in order to produce standardized contacts. The multi-layer flat conductor and the additional insulation of the signal conductor offer good protection against mechanical stress on the signal lines in the vehicle and against unwanted electrical connections. The flat surface with applied signal lines requires hardly any additional installation space for the signal lines, which can be distributed over the entire width of the flat conductor and are hardly bulky. Only in limited places does the insulation layer have an interruption, which allows a contact surface.

The thickness of the signal conductor is advantageously a fraction of the thickness of the flat conductor in order to achieve a small additional installation height, for example 1/50 to 1/3, the width of the flat conductor is at least 2 cm, preferably 2 - 6 cm with a cross section of 40 - 60 mm ² for an aluminum conductor.

According to an advantageous development of the invention, the flat conductor serves to supply power to the vehicle and contains at least a ground conductor and a first power supply conductor, which are arranged in different layers. This results in capacitive shielding and a reduction in electromagnetic fields in the vehicle. The ground conductor is advantageously arranged on the side of the flat conductor facing the vehicle interior, so that the driver and passenger, as well as electronic devices in the vehicle interior, are shielded against any radiation from the power supply.

A further development of the invention provides that the flat conductor contains a second power supply conductor, the first power supply conductor carrying an on-board voltage of 12 V and the second power supply conductor, for example, carrying an on-board voltage of 48 V. The arrangement can therefore support several on-board electrical systems and advantageously also contain a power supply conductor that carries an on-board voltage of 12 V and serves consumers that have strong load fluctuations. This means that different types of consumers can be grouped within the power supply and provided with appropriate protection according to their profile. According to this version, each power supply conductor is assigned a separate ground conductor.

In order to achieve a weight reduction compared to conventional cable harnesses made of copper lines, according to a further development of the invention, at least one layer of the flat conductor is made of aluminum, surrounded by a first insulation layer.

The contact surface should be easy to produce on the one hand and well protected on the other. For improved accessibility, the signal conductor is applied to a cover layer of the multilayer flat conductor. The signal conductor is therefore easily accessible for making connections on the contact part. Furthermore, the layered structure of the flat conductors towards the outer sides of the multilayer flat conductor ensures very good electromagnetic shielding, which protects the signal conductors in particular from interference. Alternatively, the signal conductor is applied to a first layer located inside the multilayer flat conductor and covered by a second layer. The focus here is on protection against mechanical stress and weather influences.

If an inexpensive material is used, the signal conductor can be at least partially embedded in a compensating material without much additional effort in accordance with a further embodiment of the invention, which consists of a material made of thermoplastic or cross-linking plastics that differs from the insulation material and has a maximum layer thickness that is a thickness of the Signal conductor only slightly exceeds. This makes it possible to further reduce the entry of water and other undesirable media and improve the stability of the flat conductor, particularly for signal lines located in the interior of the multilayer flat conductor, especially if the compensating material levels different applications of one or more signal conductors to a uniform layer thickness between two layers of the flat conductor.

The signal conductors are firmly connected to the flat conductor at least at the points where the signal conductors are applied by any surface treatment of the flat conductor for printing or gluing, such as plasma treatment, corona treatment or adhesion promotion (priming), so that the flat conductor is without damage according to an advantageous embodiment of the invention the signal conductor is deformable and is deformed into a contour that is adapted to the interior of the vehicle, in particular the floor contour of the vehicle. Suitable procedures for this are in DE 10 2012 203 571 B3 shown.

Suitable methods for applying the signal conductor to the flat conductor are printing, spraying, and pouring. In such procedures, Conductor and insulation layer are applied one after the other. Alternatively, the signal conductor is part of a film that is glued or laminated to the flat conductor and comprises conductive layers and insulating layers. The film is prefabricated to match the dimensions of the flat conductor. It can consist of several layers and can therefore also accommodate complex circuits with switches, relays, signal transmitters or receivers and allow cable crossings.

In particular, printing technology or 3D printing technology (generative manufacturing processes) is suitable for producing signal conductor tracks, insulation, electromagnetic shielding, compensating layers and also contact elements.

For improved contactability, the contact surface according to the invention protrudes beyond the contours of the flat conductor on the narrow or broad side. The contact surface protrudes from a narrow side of the flat conductor and is at least partially backed with only one layer of the flat conductor. This creates mechanically solid contact structures to which standardized contacts can be attached. The strength and rigidity of the layer of the flat conductor is used for clamp contacting.

If contact from the broad side of the flat conductor is required, the layer of the flat conductor underlying the signal conductor is advantageously bent essentially orthogonally outside the structure of the flat conductor.

This results in a variety of contact options, with the contact element advantageously being clamped or clamped onto the contact surface of the signal line and surrounded by an insulating layer or placed on and materially connected to the signal line.

BRIEF DESCRIPTION OF THE FIGURES

• 1 shows a multilayer flat conductor.
• 2 and 3 show flat conductors with several signal lines on a cover layer.
• 4 shows a flat conductor with several signal lines on an internal layer.
• 5 shows a flat conductor not according to the invention with signal lines that contain contact elements.
• 6 and 7 show flat conductors according to the invention with signal lines that contain contact elements.
• 8a , 8b shows a film with signal lines that is applied to a flat conductor.
• 9 shows a flat conductor with signal lines on several layers and a contact element that taps these signal lines together.
• 10 shows a flat conductor adapted to the floor contour of a vehicle.

EXAMPLES OF EMBODIMENTS

1 shows schematically a multilayer flat conductor 1, which consists of four layers 3a, 3b, 3c, 3d. Each of these layers 3a, 3b, 3c, 3d consists of an aluminum conductor 9, which is surrounded by insulation 10, which protects the conductor mechanically and electrically. After installation in a motor vehicle, the conductor of a cover layer 3a faces the vehicle interior and carries the 12 V ground line. The conductor of the next layer 3b carries the 12 V power supply, the conductor of the third layer 3c carries the 48 V power supply and finally the conductor of the fourth layer 3d carries a 48 V ground line. Alternatively, the third layer 3c can also carry a 12 V power supply to which only consumers with high load fluctuations are connected. Layer 3d would then be the associated 12 V ground line.

The individual conductors in the multilayer composite are basically electrically insulated from the outside, so that a signal line can be applied directly to each of the layers.

2 shows an embodiment of the multilayer flat conductor with signal lines 2, which were applied to a flat surface O of the cover layer 3a. The flat conductor can later be deformed in the longitudinal direction of the flat conductor in accordance with the floor contour of the vehicle intended for installing the device. The signal lines 2 are covered with an insulating layer 4 at least in the direction facing away from the flat conductor. They can also be insulated from the flat conductor, either by the signal conductor-specific insulation 23 or a printed carrier layer or laminated carrier film 22. According to the embodiment 3 a carrier layer or carrier film 24 is applied over a large area to the surface of the flat conductor and additionally insulates all signal conductors 2 from the underlying aluminum conductor 9 of the flat conductor.

The multi-layer flat conductor 4 relocates the signal lines 2 inside the flat conductor between the layers 3b and 3c. A compensating material 5 fills the cavities that exist between the signal lines 2 including insulation 4 and carrier layers 24 and the insulation 10 of the conductors 9 of the two adjacent layers 3b, 3c. A signal conductor 2 is additionally enclosed with an electrical shielding 25 in order to be particularly disruptive to shield sensitive signals. The signal conductors 2 are therefore additionally protected against mechanical stress. The compensating material 5 ensures a uniform layer thickness regardless of the individual signal conductor characteristics.

The device for signal transmission not according to the invention with a multi-layer flat conductor 5 shows an example of three contacting variants that can be used together or alternatively with different contact elements H, I, K. The signal lines 2a are applied to the cover layer 3a, with the cover layer being angled perpendicular to the transverse direction of the flat conductor in the region of one end and with an additional insulation layer over the entire surface 4a is covered, which in the angled area has a non-insulated contact surface 7 connected to a signal conductor 2a, to which a contact terminal I is non-positively connected. For this purpose, the contact terminal I has two clamping jaws, which enclose the angled flat conductor on both sides and are expanded in such a way that a counterforce is created, which establishes a secure connection between the contact terminal I and the contact surface 7.

Furthermore, a contact pin K is placed on a second contact surface 7 and thus connected to a signal line 2a. This connection is cohesive; the contact pin K was attached to the contact surface 7 by soldering or welding.

As a third type of contacting, a contact element H is undercut on a signal conductor 2a and is electrically contacted with it. This is a form-fitting connection, which can also be designed to be cohesive if signal conductor 2a and contact element H are soldered, welded or glued. The contact element H is surrounded by insulation 4a except for a contact tab protruding from the surface of the flat conductor.

The signal conductors 2a with the contact elements can be applied to a film or carrier layer 24 before being connected to the cover layer 3a.

The device according to the invention for signal transmission 6 arranges the signal conductors 2 between two layers 3b, 3c of the multilayer flat conductor. The signal conductors 2 are as follows 4 explained individually by insulation layers 4 isolated from each other and the flat conductor. In addition, the cavities are filled with a compensating material 5. The signal lines 2 closest to the narrow sides of the flat conductor have a first contact surface 7 in the direction of the closest narrow side, which is in contact with an electrically conductive intermediate element 8 as a contact element which has a second contact point 7 outside the contour of the flat conductor. The intermediate element 8 is clamped between the layers 3b, 3c of the flat conductor and can be formed in one piece with the signal conductor 2, ie manufactured in one operation with the signal conductor 2. A contact terminal I, J is plugged or clamped onto this contact surface 7 in a force-fitting and/or form-fitting manner.

The device according to the invention for signal transmission according to 7 comprises signal lines 2 arranged between the layers of the flat conductor, which were printed onto an insulating carrier film 24 or a printed insulating carrier layer 24 or inserted as a film. A printed insulation 26 is also provided between the signal conductors 2, which electrically insulates the signal conductors 2 from one another. Resting on a carrier film 24 and additionally backed by an extension of a flat conductor layer for a contact pin K, intermediate elements 8 connect selected signal conductors 2 to contact elements. The intermediate elements 8 lead out of the contour of the flat conductor and connect these signal conductors 2 via a respective contact surface 7 with a contact pin K or a contact terminal I, which is as follows 5 explains how to establish electrical contact with other electrical conductors or assemblies.

By applying the signal conductors 2 to a flat surface of a flat conductor, see 8a With a top view of the flat conductor, which has a width of at least 2 cm, there are a variety of options for interconnecting signal conductors with other components 30, for example switches, relays, transmitters, receivers, contact plugs, fuses. The signal conductors 2 can be arranged on levels one above the other, so that crossings of the signal conductors 2 are also possible. Freely accessible contact areas 41 are provided on the side of the flat conductors, which, as explained above, make signal conductors 2 accessible for an electrical connection directly or via intermediate elements. The contact surfaces 7 lie above an insulating carrier film 24, which also covers a contacting area 41, and under an insulating carrier film 26, which leaves the contacting area 41 free.

8b shows the associated side view of the flat conductor, with the second layer 3b protruding in width beyond the remaining layers 3a, 3c, 3d. An aluminum conductor 9 is surrounded by insulation 10 in each layer. An insulating carrier film 24, which carries signal conductors 2 and a contact surface 7, is applied to the second layer. These are in turn covered by a compensating material 5. Adjoining the first layer 3a is a second insulating carrier film 26 additional signal conductors 2 are provided. The second carrier film 26 and the compensating material 5 are aligned with the edge of the first layer 3a and leave part of the contact surface 7 free for later contacting.

9 shows a variant of the flat conductor 6 , however, in which signal conductors 2 are arranged on several levels, ie separated by at least one layer with aluminum conductor and associated insulation. As in the previous exemplary embodiments, the signal conductors 2 are applied to insulating carrier films 24 and/or surrounded by an insulation layer 4 and compensating material 5. Selected signal conductors 2 are additionally surrounded by an electrical shielding 25. The special feature of the flat conductor 9 is the increase in the area available for fastening signal conductors 2, which means that fewer crossing points are necessary and the contacting is simplified. After 9 In particular, a contact pliers I is provided with clamping jaws containing two contact conductors, which rest on different contact surfaces 7 and thus separately contact two signal conductors 2.

The 2 to 9 show a variety of ways to attach signal conductors to flat conductors according to the invention. The specific number, individual arrangement, insulation and shielding of the signal conductors and contact means can be selected from the combination options shown.

10 shows the installation of the flat conductor 1 according to the invention in a vehicle. To do this, each layer of the flat conductor is first manufactured separately, ie a straight, elongated aluminum profile is surrounded with insulation material, the signal conductors are applied and surrounded with insulation, shielding, contact surfaces, contact elements and compensating material according to individual requirements. The layers are then packaged into a multilayer flat conductor.

The multilayer flat conductor 1 is subsequently, for example according to the teaching of DE 10 2012 203 571 B3 brought into a shape that follows the floor contour 40 of a vehicle. Free spaces 42 for components, such as air ducts, etc., are provided between the flat conductor 1 and the floor contour 40. The flat conductor 1 therefore does not continuously follow the floor contour 40. For contacting the power supply and ground conductors, discrete housings or contacting areas 41 are provided, which form the connection areas for the flat conductor on-board network or consumers. It is advantageous to also arrange the contacts of the signal conductors in these housings or contacting areas 41, since this also creates a seal against the entry of unwanted media.

Claims (22)

Device for signal transmission in a vehicle, with several signal conductors (2, 2a) and a multi-layer flat conductor (1), wherein the signal conductors (2, 2a) are each applied to a flat surface of one of several layers (3a, 3b) of the flat conductor (1) and an insulating layer (4, 4a) surrounding the signal conductor (2, 2a) to form a contact surface (7) is interrupted, wherein the contact surface (7) is non-positively, positively or materially connected to a contact element (I, J, K, H), and at least two signal conductors (2, 2a) are arranged on different levels and cross each other, the contact surface (7) protrudes beyond the contours of the flat conductor (1) on the narrow or broad side, with the contact surface (7) coming from a narrow side of the flat conductor (1). protrudes and is backed with only one layer (3c) of the flat conductor (1). Device according to Claim 1 , characterized in that the flat conductor (1) serves to supply power to the vehicle and contains at least one layer (3a) as a ground conductor and one layer (3b) as a first power supply conductor. Device according to Claim 2 , characterized in that the ground conductor is arranged on the side of the flat conductor (1) facing the vehicle interior. Device according to one of the preceding claims, characterized in that the flat conductor (1) contains a second power supply conductor in a further layer (3c), the first power supply conductor having an on-board voltage of 12 V and the second power supply conductor having an on-board voltage of 48 V or an on-board voltage of 12 V, whereby the on-board voltage of 12 V serves consumers that have strong load fluctuations. Device according to Claim 4 , characterized in that the flat conductor (1) contains a second ground conductor for the second power supply conductor in a further layer (3d). Device according to one of the preceding claims, characterized in that at least one layer of the flat conductor (1) consists of aluminum (9), which is surrounded by a first insulation layer (10). Device according to one of the preceding claims, characterized in that the contact surface (7) is located inside the multilayer flat conductor (1). Device according to Claim 7 , characterized by a compensating material (5) which at least partially embeds the signal conductors (2), consists of a material that differs from an insulating material (4) and has a maximum layer thickness which only slightly exceeds a thickness of the signal conductors (2), whereby the compensation material (5) levels different applications of one or more signal conductors (2, 2a) to a uniform layer thickness. Device according to one of the preceding claims, characterized in that the flat conductor (1) is deformable and is deformed into a contour after the signal conductors (2, 2a) have been applied. Device according to Claim 9 , characterized in that the deformation of the flat conductor (1) is adapted to a floor contour (40) of the vehicle. Device according to one of the preceding claims, characterized in that one of the signal conductors (2, 2a) is applied to a cover layer (3a) of the flat conductor (1). Device according to one of the Claims 1 until 10 , characterized in that one of the signal conductors (2, 2a) is applied to a first layer (3c) located inside the flat conductor (1) and is covered by a second layer (3b). Device according to one of the preceding claims, characterized in that the at least two signal conductors (2, 2a) are applied to different layers of the flat conductor (1) and are separated by at least one power supply or ground conductor. Device according to one of the preceding claims, characterized in that the signal conductors (2, 2a) are applied to the flat conductor (1) by printing, spraying or pouring. Device according to one of the Claims 1 until 13 , characterized in that one of the signal conductors (2, 2a) is part of a film (24) which is glued to the flat conductor (1) and has conductive layers (2a) and insulating layers (4a). Device according to one of the preceding claims, characterized in that the layer (3a) of the flat conductor (1) underlying the signal conductor (2, 2a) is bent orthogonally outside the structure of the flat conductor (1). Device according to one of the preceding claims, characterized in that the contact element (I, J, K, H) is clamped (I, J) or clamped onto the contact surface (7) of one of the signal lines (2a) and covered with an insulating layer (4, 4a ) is surrounded or placed and is connected (K, H) flush with the signal line (2, 2a) via the contact surface (7). Device according to Claim 17 , characterized in that the contact element (I) has at least two clamping jaws which simultaneously contact at least two signal conductors (2, 2a) arranged on different surfaces of the flat conductor (1). Device according to one of the preceding claims, characterized in that electrical components (30) are printed onto the flat conductor (1) or are connected to the flat conductor (1) by foil. Device according to one of the preceding claims, characterized in that the thickness of the flat conductor (1) is a multiple of the thickness of one of the signal conductors (2, 2a). Device according to one of the preceding claims, characterized in that the surface (O) of a layer (3a, 3c) of the flat conductor (1) is treated with plasma, corona, flame treatment, a bonding agent (primer) or with adhesive surfaces. Device according to one of the preceding claims, characterized in that the width of the flat conductor (1) is greater than or equal to 2 cm.

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