DE102016003325B4 - Method for producing a plastic component having a plurality of carrier parts with at least one electrical conductor track and thus produced plastic component - Google Patents

Abstract

A method for producing a plastic component (10), wherein a plurality of carrier parts (11) are made of plastic, of which at least some carrier parts (11) each have at least one conductor track (12), wherein the carrier parts (11) by means of an injection molding process and the Conductor tracks (12) are produced successively by means of a metal casting or metal injection process, wherein the later formed component is molded onto the previously formed component and wherein the support members (11) are so encapsulated in a subsequent process step with an electrically insulating sheath (16) made of plastic in that connection elements (20) of the conductor track (12) are accessible from the outside of the plastic component (10), characterized in that the carrier parts (11) are stacked on one another in a predetermined relative position before application of the sheath (16) and then with the carrier Enclosure (16) fixed and wrapped.

Description

The invention relates to a method for producing a plastic component according to the preamble of claim 1. Furthermore, the invention relates to a plastic component with at least one electrical conductor track according to the preamble of claim 15.

For the transmission of electrical signals, such as signal currents plastic components are often used as an alternative to a cable, are inserted and fixed in the prefabricated conductor tracks, which are stamped from a metal sheet. These prefabricated stamped tracks often have complex geometric configurations. A branching point is formed by stacking two prefabricated stamped conductor tracks and connecting them at the contact point in an additional work step. The design of the prefabricated interconnects are set narrow limits by the nature of the production and the necessary high material consumption.

The handling of the prefabricated tracks is cumbersome and makes the production of the plastic component consuming and expensive. In addition, the tracks for stabilization must have breakpoints that need to be resolved in a later section of the process again. Overall, this type of production of a plastic component with electrical conductor tracks is complicated and cost-intensive due to the many successive, fundamentally different method steps.

From the US 2004/0003908 A1 It is known to first inject a carrier part made of plastic and then aufzuspritzen or cast a metal component to form a conductor. In a subsequent method step, the carrier part carrying the conductor track is encapsulated with an electrically insulating sheath made of plastic in such a way that connecting elements of the conductor track are accessible from the outside of the plastic component. With this method, however, only geometrically simple configurations of printed conductors can be achieved.

From the US 6,601,296 B1 discloses a method of manufacturing a component in the form of an electrical connection with an injection-molded plastic carrier and a pattern of injection-molded metal terminals, one of which is molded onto the other component.

The EP 0 051 378 A2 shows a circuit carrier having grooves, are cast in the metal traces. The conductor tracks can penetrate the carrier.

The DE 10 2014 115 597 A1 shows a method of forming a semiconductor device package.

From the DE 10 2007 046 493 A1 For example, a three-dimensional electrical circuit carrier structure is known, which has a plurality of interconnected carrier plates, which are assembled into a spatial body.

The invention has for its object to provide a method for producing a plastic component having at least one electrical conductor, with the complicated spatial configurations of interconnects can be formed. In addition, a corresponding plastic component to be created with at least one conductor, which has a simple structural design.

This object is achieved in procedural terms by a method having the features of claim 1. It is provided in a known manner that the carrier part by means of an injection molding process and the at least one conductor by means of a metal casting or metal spraying process are produced successively, wherein the later formed component is molded onto the previously formed component, and wherein the conductor carrying the carrier part in a Subsequent process step is encapsulated with an electrically insulating sheath made of plastic so that connection elements of the conductor track are accessible from the outside of the plastic component.

The production of the carrier part and the at least one conductor track preferably takes place one after the other in a combined injection molding tool, with which both a plastic material and, independently thereof, a liquid metal alloy or a metal alloy can be processed and sprayed. In this way, it is possible to produce the carrier part together with the conductor track in a uniform method quickly and inexpensively.

In order to achieve spatially complicated configurations of interconnects and a multilayer interconnect architecture, the invention provides that several, preferably different carrier parts are produced, of which at least some carrier parts and preferably all carrier parts each have at least one conductor track. The carrier parts are then aligned before application of the envelope in a predetermined relative position and in particular stacked or stacked on each other. Finally, the carrier parts or the carrier part stack are encapsulated with the envelope and thereby fixed and encapsulated.

In individual or all carrier parts prefabricated electronic components can be used, which are connected via the conductor tracks with the external connection elements.

The profile of the conductor tracks in the individual carrier parts is preferably such that at least some conductor tracks come into contact with one another in the arrangement of the carrier parts in the predetermined relative position, so that an electrical connection is made between conductor tracks of different carrier parts.

In a preferred embodiment of the invention it is provided that the carrier parts are connected to one another via connecting elements which form joints. The connecting elements may be integrally formed webs or hinges which are formed during the production of the carrier parts. After the carrier parts are provided with the conductor tracks, the carrier parts are pivoted relative to each other around the webs or hinges and brought into abutment with each other, whereby a desired relative position between the carrier parts is reliably achieved by the webs and hinges.

Preferably, in a first step, the carrier part is injection molded from plastic, to which subsequently the electrical conductor track is molded. However, this order can also be reversed if it allows the component geometry, i. that first the electrical conductor track is produced and then the carrier part is molded onto the conductor track.

In the following, it is assumed by way of example that first of all the carrier part made of plastic is injected and then one or more strip conductors of the metal material are sprayed onto the carrier part. However, the invention is not limited thereto.

In order that the conductor track exactly complies with a predetermined geometric course, one or more grooves can be formed in the carrier part on at least one side, which grooves are then filled with a metallic material forming the conductor track. It is preferably provided that the carrier part has corresponding grooves on a plurality of sides and in particular on opposite sides, so that it is also possible to achieve complicated geometric progressions for the conductor tracks, in which the conductor runs, for example, through the carrier part.

In a possible embodiment of the invention can be provided that the support member is formed as a flat or spatially curved or spatially stepped plate. In this case, corresponding channel-like grooves for receiving the metal material forming the conductor tracks can be provided both on the upper side of the plate and on the underside of the plate.

In a preferred embodiment of the invention it is provided that the metal material or the subsequently formed component is positively secured to the support member or to the previously formed component. This can be achieved, for example, by forming undercuts in the previously formed component, for example the carrier part, which are engaged behind by the later formed component, for example the printed conductor.

Alternatively or additionally, it can be provided that the subsequently formed component, for example the conductor track, is firmly bonded to the previously formed component, for example the carrier part. For this purpose, the material properties and the process parameters can be coordinated so that the two components weld together, i. make a molecular bond. Alternatively or additionally, at least one surface adhesion may be provided between the two components, which is achieved, for example, by gluing the subsequently formed component, for example the metal material of the conductor track, to a superficial melting of the material of the previously formed component, for example the Plastic of the carrier part, comes.

As the material for the support member of any injectable plastic, such as polypropylene or polyamide can be used. As a metal component for the conductor track, a metal alloy can be used, which is flowable from a temperature of 180 ° C to about 500 ° C and which may be, for example, an Sn alloy.

According to the invention, it is provided that the carrier part carrying the conductor track is encapsulated with an electrically insulating sheath made of plastic in a subsequent method step. As the material for the envelope, the same plastic material can be used as for the support member, in which case the support member and the enclosure can enter into a cohesive connection and optionally also a positive connection. Even if a plastic material other than for the carrier part is used for the casing, it can be provided that the casing and the carrier part are connected to one another in a form-fitting and / or material-locking manner.

The envelope is arranged so that it preferably completely surrounds the carrier part and encapsulates. The conductor track is connected to prefabricated connection elements, for example plugs or sockets, which are integrated in particular during the injection process of the metal material of the conductor track in this. The envelope preferably surrounds the carrier part and the strip conductors so far that only the connection elements of the strip conductors protrude on the outside of the plastic component and are accessible from this outside.

The carrier part and the conductor tracks are preferably formed in a common multi-stage injection device in a short time sequence. The spray device may be ausgestaltest that immediately after the formation of the tracks and any intervening cooling phase, the envelope is also sprayed directly into the spray device. In a preferred embodiment of the invention, however, it is provided that the carrier webs carrying carrier part is stored as a preform. After a storage period of several hours, several days or even several months can then be sprayed on demand in a simple injection molding machine, the enclosure. This has the significant advantage that the geometric shape of the plastic component, which is determined by the geometric shape of the envelope, can be adjusted as needed, i. for plastic components of the type mentioned, which have different geometric shapes and configurations, always the same inner support member can be used with sprayed tracks, whereby the production of the plastic component is simple and inexpensive. It is only necessary to maintain a corresponding large number of prefabricated carrier parts with applied printed conductors and then to spray, if necessary, an envelope with the desired geometric shape.

To connect the conductor to a further electrical line or an electrical power source, the conductor is provided with prefabricated connection elements, in particular in the form of plugs or sockets. The connection elements can be positioned in the injection mold prior to the injection of the metallic material of the conductor track and then embedded in the metallic material. Alternatively, however, it is also possible to subsequently mount the connection elements, which can be done, for example, by pressing prefabricated connection elements into the metallic material of the conductor track.

In device-technical terms, the above object is achieved by a plastic component having the features of claim 15. The plastic component has at least one electrical conductor made of a metallic material which is arranged on a carrier part made of plastic. In this case, the carrier part made of plastic by means of an injection molding process and the at least one electrical conductor track by means of a metal casting or metal injection method are produced successively, wherein the last-formed component is molded onto the previously formed component. In addition, a sprayed enclosure of an electrically insulating material is provided, which preferably completely encapsulates the carrier part and the conductor tracks.

According to the invention, a plurality of carrier parts are provided, of which at least some carrier parts and in particular all carrier parts each have at least one conductor track. The carrier parts are arranged in a predetermined relative position to each other and fixed by the enclosure and enclosed or encapsulated.

In one possible embodiment of the invention can be provided that the carrier parts are stacked or stacked.

Preferably, the carrier parts are connected to each other via connecting elements which form joints. The connecting elements may be integrally formed webs or hinges.

In a preferred embodiment of the invention it is provided that the carrier part has at least on one side and in particular on opposite sides at least one channel-like groove in which the conductor track is arranged. After the support member is formed with the channel-shaped groove or the grooves, the liquid metal can be introduced directly into the channel-shaped groove or grooves, being guided by the Nutwandungen. The liquid metal flows through the channel-shaped grooves and fills them completely, whereby the conductor track is formed. The introduction of the liquid metal into the channel-shaped groove or grooves can be done by direct pouring or preferably by direct injection of the molten metal into the groove.

In order to reliably hold the strip conductors in the groove, it can be held in a form-fitting manner in the groove or on the carrier part, at least in some areas. For this purpose, it may be provided that undercuts are formed in or on the groove, in which the conductor track engages at least partially. When the liquid metal is introduced into the groove, it flows behind the undercuts, so that it is securely and permanently held in the groove in the solidified state.

The existing plastic cover may be positively and / or cohesively connected to the support member.

The carrier part may be, for example, a flat, a spatially curved or a spatially graduated plate.

Further device-related features of the plastic component have already been discussed above in connection with the method according to the invention, which should be referred to in order to avoid repetition.

Further details and features of the invention will become apparent from the following description of embodiments with reference to the drawings.

• 1 Eine perspektivische Explosionsdarstellung der Teile eines erfindungsgemäßen Kunststoff-Bauteils,
• 2 eine perspektivische Ansicht eines erfindungsgemäßen Kunststoff-Bauteils,
• 3 eine perspektivische Ansicht der Unterseite des Kunststoff-Bauteils gemäß 2, wobei das eingekapselte Trägerteil gestrichelt dargestellt ist,
• 4 eine perspektivische Ansicht mehrerer nebeneinander angeordneter Trägerteile,
• 5 die Trägerteile gemäß 4 bei der Ausbildung eines Trägerteil-Stapels,
• 6 einen aus den Trägerteilen gemäß 4 gebildeten Trägerteil-Stapel,
• 7 den Trägerteil-Stapel gemäß 6 mit aufgebrachter Umhüllung,
• 8 eine perspektivische Explosionsdarstellung der Teile eines erfindungsgemäßen Kunststoff-Bauteils gemäß einer weiteren Ausführungsform,
• 9 eine perspektivische Darstellung des Trägerteils gemäß 8 mit Leiterbahnen und Anschlusselementen und
• 10 das Kunststoff-Bauteil mit aufgebrachter Umhüllung.

Show it:

• 1 An exploded perspective view of the parts of a plastic component according to the invention,
• 2 a perspective view of a plastic component according to the invention,
• 3 a perspective view of the underside of the plastic component according to 2 wherein the encapsulated carrier part is shown in dashed lines,
• 4 a perspective view of a plurality of juxtaposed carrier parts,
• 5 the carrier parts according to 4 in the formation of a carrier stack,
• 6 one of the support parts according to 4 formed carrier stack,
• 7 the carrier part stack according to 6 with applied wrap,
• 8th an exploded perspective view of the parts of a plastic component according to the invention according to a further embodiment,
• 9 a perspective view of the carrier part according to 8th with interconnects and connection elements and
• 10 the plastic component with applied wrap.

1 shows the components of a plastic component according to the invention 10 in an exploded, perspective exploded view.

The plastic component 10 has a support part 11 on, which is formed in the example shown as a spatially curved plate, so that for the surface of the support member 11, a three-dimensional geometry is reached. The carrier part 11 It is made of plastic and has several channel-like grooves on its upper side 13 , the respective opposite end portions of the support member 11 connect with each other. Also on the underside of the carrier part 11 is at least a groove 13 trained by the in 1 only the left-side end is shown on the left end side of the support member 11.

On the top and bottom of the carrier part 11 are knob-like projections 15 molded, which serve as a spacer for a subsequent machining process.

In the carrier part 11 is a pocket-like recess 14 formed, in which a prefabricated electronic component, such as a chip 19 can be used.

The carrier part 11 is produced in a first process step in an injection molding device made of plastic. Once the carrier part 11 has sufficient strength, is in the grooves 13 a liquid metal injected or poured. The liquid metal fills the grooves 13 completely off and forms traces 12 , in the 1 are shown outlined. The electronic component 19 can either be retrofitted in the pocket-like recess 14 mounted or already pre-positioned.

The carrier part 11 with the tracks 12 and optionally the electronic component 19 is then preferably placed in heap and stored. If necessary, it is positioned in a conventional injection molding machine, with the knob-like projections 15 make sure the carrier part 11 is held in the injection molding machine at a distance in the local cavity and can be encapsulated with a plastic material. The plastic material forms an electrically insulating sheath 16 that the support part 11 completely encapsulated and preferably made of the same plastic material as the carrier part 11 exists, so that between the cladding 16 and the carrier part 11 a solid preferably cohesive connection is given. As 2 indicates exists on the outside of the plastic component 10 only connection elements 20 in the form of plugs or sockets that allow electrical connection between the track and a continuity line.

3 shows the plastic component according to 2 in turned by 180 °, turned upside down, where dashed the inside of the enclosure 16 arranged carrier part 11 is shown, that of the cladding 16 is completely enclosed.

The 4 to 7 show the production of an alternative plastic component 10 , which consists of three support parts 11 is constructed. In a first process step, the three carrier parts 11 injected together in juxtaposed alignment of a plastic material, wherein adjacent support members 11 in each case via a web-like or hinge-like connecting element 17 are hinged together. The carrier parts 11 each have on at least one side and preferably on opposite sides in each case the grooves 13 auf, in a subsequent process step with a metal material to form the tracks 12 be filled. In the illustrated embodiment has the according to 4 middle carrier part 11 a pocket-like recess 14 for receiving an electronic component 19 ,

After production of the carrier parts 11 and the tracks 12 as well as the assembly of the electronic component 19 become the carrier parts 11 around their fasteners 17 relative to the adjacent support part 11 pivoted and thus stacked and stacked. As 5 shows, the according to 4 right support part about the hinge-like connecting element 17 pivoted in the direction of the arrow P ₁ and thus on the top of the central support member 11 placed. The left carrier part 11 becomes its hinged connecting element 17 pivoted in the direction of the arrow P ₂ and on the underside of the central support member 11 placed. It is thus an in 6 illustrated carrier part stack 18 is formed, whereby a spatial conductor track architecture is made possible, in which the tracks of superimposed carrier parts 11 can come into contact with each other.

Connection elements in the form of plugs or sockets can be formed in a manner not shown on the interconnects by prefabricated connection elements either in training the interconnects 12 poured into these and embedded or subsequently in the tracks 12 be introduced.

The carrier part stack 18 is in a subsequent process step with the enclosure 16 splashed in 7 only shown by dashed lines. The serving 16 encloses the carrier part stack 18 completely and make sure the support parts 11 be kept in their predetermined relative position.

The 8th to 10 show a plastic component according to the invention in the manner of a cable. As a carrier part 11 a strip-like plastic profile with a cross or + - cross section is used (see detail B), so that four in the longitudinal direction of the support part 11 running channel-like grooves 13 are formed, which are arranged distributed over the circumference of the support member 11. The grooves 13 are filled in a subsequent process step with a liquid metal material, which in the grooves 13 is injected, so that in the longitudinal direction of the support member 11 running tracks 12 are formed (see detail A). Prefabricated pin-like connecting elements 20 are either in the metal material of the tracks 12 poured or subsequently introduced into this. There are thus four distributed over the circumference, mutually separate interconnects 12 educated. The carrier part 11 with the tracks 12 and the connection elements 20 is in 9 shown. In a subsequent process step, the carrier part 11 and the tracks 12 with the serving 16 molded plastic, so that the carrier part 11 and the tracks 12 are completely encapsulated and only the connection elements 20 on the top of the plastic component 10 stand out as it is in 10 is shown.

Claims (21)

A method for producing a plastic component (10), wherein a plurality of carrier parts (11) are made of plastic, of which at least some carrier parts (11) each have at least one conductor track (12), wherein the carrier parts (11) by means of an injection molding process and the Conductor tracks (12) are produced successively by means of a metal casting or metal injection method, wherein the later formed component is molded onto the previously formed component and wherein the support members (11) are so encapsulated in a subsequent step with an electrically insulating sheath (16) made of plastic in that connection elements (20) of the conductor track (12) are accessible from the outside of the plastic component (10), characterized in that the carrier parts (11) are stacked on one another in a predetermined relative position before application of the sheath (16) and then with the carrier Enclosure (16) fixed and wrapped. Method according to Claim 1 , characterized in that the carrier parts (11) are connected to each other via connecting elements (17) which form joints. Method according to Claim 2 , characterized in that the connecting elements (17) are formed by integrally formed webs or hinges. Method according to one of Claims 1 to 3 , characterized in that first the carrier parts (11) made of plastic and the electrical conductor tracks (12) are then molded onto the carrier parts (11). Method according to one of Claims 1 to 3 , characterized in that first the electrical conductor tracks (12) produced and the carrier parts (11) made of plastic are subsequently molded onto the conductor tracks (12). Method according to one of Claims 1 to 5 , characterized in that in at least one of the carrier parts (11) on at least one side at least one groove (13) is formed, which is filled with a metallic material forming the conductor track (12). Method according to Claim 6 , characterized in that the carrier part (11) has on opposite sides in each case at least one groove (13). Method according to one of Claims 1 to 7 , characterized in that the carrier part (11) is formed as a flat or spatially curved or spatially stepped plate. Method according to one of Claims 1 to 8th , characterized in that the subsequently formed component is positively secured to the previously formed component. Method according to one of Claims 1 to 9 , characterized in that the two successively produced components adhere to each other superficially. Method according to one of Claims 1 to 10 , characterized in that the sheath (16) consists of the same plastic as the carrier parts (11). Method according to one of Claims 1 to 11 , characterized in that the sheath (16) with the carrier parts (12) is positively connected and / or materially connected. Method according to one of Claims 1 to 2 , characterized in that the carrier webs (11) carrying the printed conductors (12) are stored intermediately prior to the application of the coating (16). Method according to one of Claims 1 to 3 , characterized in that prefabricated electrical connection elements (20) are connected to the conductor tracks (12). Plastic component with a plurality of carrier parts (11) made of plastic, of which at least some carrier parts (11) each have at least one conductor track (12) made of a metallic material, wherein the carrier part (11) made of plastic by means of an injection molding process and the at least one electrical conductor track (12) are produced successively by means of a metal casting or metal injection process, wherein the last formed component is injection-molded onto the previously formed component, and with a sprayed-on envelope (16) of an electrically insulating material, characterized in that the carrier parts (11) in a predetermined relative position stacked and fixed by the sheath (16) and enclosed. Plastic component after Claim 15 , characterized in that the carrier parts (11) via connecting elements (17) are interconnected, forming the joints. Plastic component after Claim 16 , characterized in that the connecting elements (17) are formed by integrally formed webs or hinges. Plastic component according to one of the Claims 15 to 17 , characterized in that at least one of the carrier parts (11) has at least on one of its sides a channel-like groove (13) in which the conductor track (12) is arranged. Plastic component after Claim 18 , characterized in that the conductor track (11) in the groove (13) is held positively at least in partial areas. Plastic component after Claim 18 or 19 , characterized in that the sheath (16) consists of plastic and is connected to the carrier parts (11) positively and / or cohesively. Plastic component according to one of the Claims 15 to 20 , characterized in that the carrier parts (11) are formed as a flat or spatially curved or spatially stepped plate.

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