EP2603955B1 - Housing for electrical connection between a foil conductor and a conductor - Google Patents

Description

The invention relates to a housing for electrical line connection between a foil conductor and a conductor.

Flexible film conductors, sometimes called flat conductors or ribbon conductors, are widely used in vehicle construction, in particular to allow a mobile, electrical contact in limited space conditions.

Foil conductors usually consist of a tinned copper tape with a thickness of 0.03 mm to 0.1 mm and a width of 2 mm to 16 mm. Copper has been proven for such traces, as it has a good electrical conductivity and a good processability to films and the material costs are low at the same time. Other electrically conductive materials can also be used which can be processed into films. Examples include gold, silver, aluminum or tin.

The tinned copper tape is applied for electrical insulation and stabilization on a substrate made of plastic or laminated on both sides with this. The insulation material is usually made of a 0.025 mm to 0.05 mm thick film based on polyimide. But other plastics or materials with the required insulating properties can be used. A foil conductor band may contain a plurality of electrically insulated, conductive layers.

In the vehicle sector, foil conductors are usually used for contacting electrically functional layers in laminated glass panes. Examples can be found in DE 42 35 063 A1 . DE 20 2004 019 286 U1 or DE 93 13 394 U1 ,

Such laminated glass panes usually consist of at least two rigid individual glass panes which are adhesively bonded to one another by a thermoplastic adhesive layer. The thickness of the adhesive layer is, for example, 0.76 mm. Between the individual glass panes are additionally electrically functional layers such as heating coatings and / or antenna elements, which with connected to a foil conductor. A suitable foil conductor has only a total thickness of 0.3 mm. Such thin film conductors can be embedded without difficulty between the individual glass panes in the thermoplastic adhesive layer.

The use of film conductors for contacting electrically functional layers is not limited to the vehicle sector. How out DE199 60 450 C1 As is known, film conductors are also used in the construction sector. In composite or insulating glass sheets foil conductors are used for electrical contacting of integrated electrical components such as voltage-controlled electrochromic layers, solar cells, heating wires, alarm loops or the like.

As a rule, the disc manufacturer requires a washer with a complete connection element and a plug for tool-free connection to another control electrics. The connection element comprises an approximately 5 cm to 20 cm long foil conductor and at least one round cable with a connector. The connection between the foil conductor and the cable is usually done by soldering and is protected by a housing.

Due to the small thicknesses of the metal foil and the insulating films have foil conductor only a low tear protection and even lower tear strength. In particular, when the foil conductor is directed over corners or sharp edges, tensile forces may concentrate on small areas and locally exceed the tear strength of the foil conductor or one of its layers.

Such tensile loads on the film conductor occur in particular during transport and during installation of the disc. In this case, a defect in the electrical contacting of the foil conductor usually leads to a discarding of the entire disc.

A remedy to fix the transition between the film conductor and cable as close as possible or on the disc, as in EP 593 940 A1 described. In many cases, however, it is desirable to lead the foil conductor around a frame pull or mounting flange, without visually and aesthetically disturbing elements such as connectors or components being on the pane.

In the field of the housing of electrical line connectors for receiving foil conductors, an extensive prior art is known.

US 5,724,730 and EP 1 058 349 A1 reveal electrical cable connectors between foil conductors and round cables by means of soldered connections. The housing around the connection point is in each case designed in two parts. The inlet opening of the housing for the film conductor has on both sides right-angled, sharp entry edges.

DE 199 44 493 A1 . DE 100 06 112 A1 and DE 100 65 354 A1 each describe a connecting element for mechanical fixing and for electrical contacting of foil conductors. In this case, the inlet opening of the film conductor in the housing is funnel-shaped, each configured with a bevel per leading edge.

In practice, damage to a foil conductor occurs in particular at the point of entry into a housing. These arise when the foil conductor is subjected to a tensile load over a sharp edge or the foil conductor is twisted. A corresponding force can then lead in the region of the edge to an at least partial severing of its electrically conductive layer or even to a demolition of the complete foil conductor.

The Japanese patent application JP 10 116659 A shows a housing according to the preamble of claim 1.

The object of the present invention is to provide a housing for electrical conduction connection of a foil conductor to a conductor, which minimizes damage to the foil conductor at the inlet opening under tensile load.

The object of the present invention is achieved by a housing for electrical line connection of a film conductor with a conductor according to claim 1. Preferred embodiments will become apparent from the dependent claims.

The present invention includes a housing having an electrical lead connection between a conductor and a foil conductor. The entrance opening the housing for the film conductor is rounded at its inlet edges at least on one side so that the inlet opening is increasingly extended to the outside. The rounded region of the leading edge preferably runs parallel to the broad side of the foil conductor. That is, the leading edge is parallel to the broad side of the foil conductor and the edge itself is rounded. Preferably, both the upper leading edge and the lower leading edge of the housing are rounded.

An embodiment of the housing according to the invention with only a rounded leading edge is advantageous if the housing is connected to a substrate, for example. A film conductor then experiences no tensile loading in the direction toward the substrate. The rounded leading edge is then advantageously facing away from the substrate leading edge. The leading edge facing the substrate, which is arranged between the foil conductor and the substrate, does not have to be rounded since the foil conductor can not be loaded via this leading edge because of the substrate.

The rounded region of the leading edge preferably extends over an angular segment at an angle of 30 ° to 180 °, preferably 80 ° to 180 °, particularly preferably 135 ° to 180 °. The larger the rounded portion of the leading edge, the further the foil conductor can be bent from its straight extension direction without passing over a sharp edge. The rounded portion of the leading edge preferably begins at the point where the foil conductor emerges from the housing and is no longer firmly connected to the housing.

A rounding should be understood to mean a round shape without edges and corners, that is to say without places with a very small radius of curvature. The rounded region of the leading edge of the housing according to the invention preferably has radii of curvature of at least 0.5 mm. Particularly preferred are the radii of curvature between 0.5 mm and 100 mm, in particular between 0.5 mm and 20 mm. The minimum radius of curvature, over which the film conductor is deflected, is decisive for the maximum tensile stress in the film conductor. With a minimum radius of curvature of 0.5 mm, it is ensured that the foil conductor is not damaged during the stresses usually encountered during the production process, during transport, during installation or during use.

The rounded portion of the leading edge is preferably oval, circular or elliptical. In a circular rounding corresponds to an angular segment of 180 ° of a semicircular leading edge and an angular segment of 90 ° corresponds to a rounding of the leading edge with the shape of a quarter circle.

The housing according to the invention is preferably made of an electrically insulating material. Thermoplastic plastics and elastomers, which are processed by injection molding, are suitable for industrial production. Such injection molding for the production of plastic housings are well known, for example DE 103 53 807 A1 , As thermoplastics and elastomers, for example, polyamide, polyoxymethylene, polybutylene terephthalate or ethylene-propylene-diene rubber is used. Alternatively, potting materials such as acrylate or epoxy resin systems may be used.

If a shield of the electrical line connection is required, the housing can be made of an electrically conductive material with electrically insulating inserts.

The housing according to the invention is preferably produced as a one-part or multi-part element and then equipped with the electrical line connection, including conductor and foil conductor. Alternatively, the housing according to the invention can be cast directly around the electrical line connection between conductor and foil conductor.

The electrical line connection between conductor and foil conductor is preferably carried out by soldering, bonding or welding. During soldering, soldering with a low-melting solder is preferred. Alternatively, the electrically conductive connection by gluing with an electrically conductive adhesive or terminals, for example by means of a metallic clamp, sleeve or connector done.

The housing according to the invention is preferably used for electrical line connection of a foil conductor with a conductor, for example a round cable. Both foil conductor and conductor can be constructed multi-core and connected via several points. The housing according to the invention can serve for the electric line connection of several foil conductors, preferably each one Ingress opening of the foil conductor in the housing has a rounded portion. In a further embodiment, an electrical line connection between a film conductor and a wire or a metallic contact element, for example, to form a plug connection. Furthermore, the electrical line connection between a film conductor and a conductor track, for example, a circuit board with other electronic components take place.

In a further embodiment of the housing according to the invention, the rounded region of the leading edge consists of a separate element. The own element may consist of the same material as the housing or another material, preferably a softer material. A soft material can better conform to the foil conductor and distribute an applied force over a larger area. This leads to a reduction in the tensile stress. As a material for the own element, for example, a circular sealing cord or an O-ring of rubber, perfluoro rubber, polyethylene or polytetrafluoroethylene is used. The own element is preferably inserted into the housing, clamped or glued to the housing. The own element preferably seals off the interior of the housing, for example against moisture.

In the case of a torsion of the film conductor relative to the housing or a force acting in a direction obliquely to its direction of extension, a film conductor experiences high tensile stress peaks. This particularly concerns the edges of the foil conductor, which must absorb a large part of the tension. According to the invention, the leading edge in addition to the rounded portion, a rounding in the direction of extension of the film conductor on. In the case of a torsion or oblique loading of the film conductor is guided along this curve. The applied force is distributed over a larger contact area. The occurring maximum tensile stress in the foil conductor is reduced compared to the maximum tensile stress in a housing with a straight edge.

The invention also encompasses a composite pane with a foil conductor for contacting electrically functional layers in its interior. The film conductor is thereby electrically connected in a housing according to the invention with another conductor.

In the following the invention will be explained in more detail with reference to several drawings. The drawings are purely schematic representations and not to scale. In particular, the layer thicknesses of the film conductor are shown enlarged here for illustrative purposes. The drawings in no way limit the invention.

• Figur 1A ein Gehäuse mit elektrischer Leitungsverbindung zwischen einem Folienleiter und einem Leiter in einer Draufsicht, nach dem Stand der Technik,
• Figur 1B ein erfindungsgemäßes Gehäuse mit einer elektrischen Leitungsverbindung zwischen einem Folienleiter und einem Leiter sowie einer Abrundung in der Erstreckungsrichtung des Folienleiters in einer Draufsicht,
• Figur 2 einen Längsschnitt entlang der Linie I-I aus Figur 1 durch ein Gehäuse mit rechtwinkligen Eintrittskanten nach dem Stand der Technik,
• Figur 3 einen Längsschnitt entlang der Linie I-I aus Figur 1 durch ein Gehäuse mit abgeschrägten Eintrittskanten nach dem Stand der Technik,
• Figur 4 einen Längsschnitt entlang der Linie I-I aus Figur 1 durch ein Ausführungsbeispiel eines erfindungsgemäßen Gehäuses mit halbkreisförmig abgerundeten Eintrittskanten,
• Figur 5 einen Längsschnitt entlang der Linie I-I aus Figur 1 durch ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Gehäuses mit viertelkreisförmig abgerundeten Eintrittskanten,
• Figur 6 einen vergrößerten Ausschnitt des Bereichs der Eintrittsöffnung aus Figur 5,
• Figur 7 einen vergrößerten Ausschnitt der Eintrittsöffnung eines Längsschnitts entlang der Linie I-I aus Figur 1 durch ein erfindungsgemäßes Gehäuse mit abgerundeten Eintrittskanten,
• Figur 8 einen Längsschnitt durch ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Gehäuses mit aufgesetzten kreisförmigen Elementen im Bereich der Eintrittskanten,
• Figur 9 einen Längsschnitt durch ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Gehäuses mit in das Gehäuse eingesetzten kreisförmigen Elementen im Bereich der Eintrittskanten und
• Figur 10 einen Längsschnitt durch ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Gehäuses zur Kontaktierung eines Leiters auf einem Substrat.

Show it:

• Figure 1A a housing with electrical line connection between a foil conductor and a conductor in a plan view, according to the prior art,
• FIG. 1B an inventive housing with an electrical line connection between a film conductor and a conductor and a rounding in the direction of extension of the film conductor in a plan view,
• FIG. 2 a longitudinal section along the line II FIG. 1 by a housing with rectangular entry edges according to the prior art,
• FIG. 3 a longitudinal section along the line II FIG. 1 by a housing with beveled entry edges according to the prior art,
• FIG. 4 a longitudinal section along the line II FIG. 1 by an embodiment of a housing according to the invention with semicircular rounded inlet edges,
• FIG. 5 a longitudinal section along the line II FIG. 1 by a further embodiment of a housing according to the invention with quarter-circle-rounded inlet edges,
• FIG. 6 an enlarged section of the region of the inlet opening FIG. 5 .
• FIG. 7 an enlarged section of the inlet opening of a longitudinal section along the line II FIG. 1 by a housing according to the invention with rounded entry edges,
• FIG. 8 a longitudinal section through a further embodiment of a housing according to the invention with attached circular elements in the region of the leading edges,
• FIG. 9 a longitudinal section through a further embodiment of a housing according to the invention with inserted into the housing circular elements in the region of the leading edges and
• FIG. 10 a longitudinal section through a further embodiment of a housing according to the invention for contacting a conductor on a substrate.

Figure 1A shows a schematic representation of a housing (7) according to the prior art with electrical line connection between a film conductor (1) and a conductor (4) in a plan view. The electrically conductive layer (2) of the film conductor (1) is covered by the electrically insulating layer (3). The electrically conductive region (5) of the conductor (4) is covered by an insulating region (6).

FIG. 1B shows the schematic representation of a housing (7) according to the invention. The housing (7) is rounded in the direction of extension of the film conductor (1) (13). This rounding (13) takes place in combination with a rounding of the entry edges (9, 9 ') and ensures an improved distribution of the tensile stress within the film conductor (1) in the event of torsion or oblique loading of the film conductor (1).

In the case of a deflection or torsion of the film conductor (1) relative to the housing (7) or a force acting in a direction oblique to its extension direction, high tensile stress peaks occur. This particularly concerns the edges (17) of the film conductor (1), which are particularly susceptible to cracks and damage. The particular advantage of this embodiment variant is the avoidance or reduction of tensile loads on the edges (17) of the film conductor (1). By the additional rounding (13) in the direction of extension of the film conductor (1) of the film conductor (1) in a torsion or deflection, ie at a tensile load down or up relative to the extension direction and thus in the plane of FIG. 1B into or out of the drawing plane of FIG. 1B out, over the inner region (18) of the film conductor (1) out. The forces acting on a flat area in the interior (18) of the film conductor (1) and not punctiform on its edge (17). The combination of rounding (13) of the housing (7) in the extension direction and rounding of the entry edges (9,9 '), an optimum force distribution in the film conductor (1) and the maximum tensile stress in the film conductor (1) is many times lower than at Housings according to the prior art. The film conductor (1) can withstand a much higher tensile load without being damaged than in the case of prior art housings. FIG. 2 shows a longitudinal section along the line II FIG. 1 a housing (7, 7 ') with an electrical line connection between a foil conductor (1) and a round cable (4) according to the prior art. The film conductor (1) consists of an electrically conductive layer (2) made of tinned copper, which is laminated with two electrically insulating films (3, 3 ') made of plastic. The total thickness of the film conductor (1) is about 0.3 mm. Inside the housing (7, 7 '), the copper foil (2) freed from insulation is soldered to the electrically conductive area (5) of the round cable (4) (11). The inlet opening (8) of the housing (7, 7 ') for the film conductor (1) is rectangular, with sharp edges (9, 9') configured. For example, if a tensile load of the film conductor (1) orthogonal to its extension direction, ie up or down in FIG. 2 , the film conductor is directed over the sharp leading edge (9 or 9 '). High tensile stresses occur in the film conductor in the region of the edge. If the local tensile stress exceeds the tensile strength of the foil conductor (1), this leads to a tearing or tearing of the foil conductor (1).

FIG. 3 shows a longitudinal section through a further embodiment of a housing (7, 7 ') according to the prior art. Compared to FIG. 2 the entry edges (9, 9 ') of the inlet opening (8) are chamfered and funnel-shaped. Again, in the areas in which the film conductor (1) is guided over sharp edges, increased tensile stresses occur.

In FIG. 4 is a longitudinal section through an inventive housing (7, 7 ') with rounded entry edges (9, 9') shown. The entry edges (9, 9 ') are designed semicircular both at the top of the housing (7) and on its underside (7'). The diameter of the semicircle corresponds in this case the height of a housing part. The angle segment of the rounded area has an angle of α = 180 °. In the case of a tensile load of the film conductor (1) orthogonal to its extension direction, this means up or down in FIG. 4 , the film conductor (1) runs along the rounding of the leading edge (9 or 9 '). The forces occurring for deflecting the foil conductor (1) act on the entire surface on which the foil conductor (1) touches the leading edge (9 or 9 '). The tensile stress in the film conductor (1) is many times lower than in the deflection over sharp edges in housings according to the prior art ( FIG. 2, FIG. 3 ).

In a preferred embodiment of the housing (7, 7 ') according to the invention, the interior (10) is poured out with a plastic or covered with plastic, for example polybutylene terephthalate. This protects the electrical wiring from moisture and corrosion.

FIG. 5 Time a longitudinal section through an inventive housing (7, 7 ') with a quarter-circle rounded inlet edges (9, 9'). In this embodiment, both the leading edge (9) of the upper housing part (7) and the leading edge (9 ') of the lower housing part (7') is rounded off with a quarter circle. The angular segment of the rounded portion of the leading edge (9, 9 ') has an angle of α = 90 °.

In FIG. 6 is an enlarged section of the region of the inlet opening (8) FIG. 5 shown. The curvature of the lower leading edge (9 ') takes place in the form of a quarter circle with radius r over an angle of α = 90 °

FIG. 7 shows an enlarged section of the inlet opening (8) of a longitudinal section along the line II FIG. 1 by an inventive housing (7, 7 '). In contrast to FIG. 6 the curvature of the entry edges (9, 9 ') should not be described by a single circle segment of constant radius. Two curvature circles are shown by way of example: The curvature circle with radius r ₁ describes the curvature at the point (14) of the rounded leading edge (9 '). Point (14) is at the point of greatest curvature, and thus at the point with the smallest radius of curvature of the entire rounded region. A second circle of curvature is applied by way of example at point (15) of the rounded leading edge (9 ') and has a radius of curvature of r ₂ .

In FIG. 8 is a longitudinal section through an inventive housing (7, 7 ') with attached circular elements (12, 12') in the region of the inlet edges (9, 9 ') shown. The elements (12, 12 ') are adhesively bonded to the housing (7, 7'). Circular sealing cords or O-rings of rubber, perfluororubber, polyethylene or polytetrafluoroethylene may be used for the elements (12, 12 ') in a non-limiting manner.

FIG. 9 shows a longitudinal section through an inventive housing (7, 7 ') with in the housing (7, 7') inserted circular elements (12, 12 '). The elements (12, 12 ') are here in a recess in the region of the entry edges (9, 9') fitted.

FIG. 10 shows a longitudinal section through a further embodiment of a housing (7) according to the invention. The housing (7) according to the invention is designed as a half-shell and connected to a substrate (16), for example with a glass pane. The connection between housing (7) and substrate (16) can be done for example by gluing or clamping. The conductor (4) may be, for example, a round cable. Alternatively, the electrically conductive region (5) of the conductor (4) may be a metallic contact surface or a foil conductor, which is preferably connected to the substrate (16). The rounding according to the invention at the leading edge (9) of the film conductor (1) into the housing (7) reduces the maximum tensile stress in the film conductor (1) at a tensile load in the direction away from the substrate (16).

(1)

Folienleiter

(2)

elektrisch leitfähige Schicht von (1)

(3, 3')

elektrisch isolierende Folie von (1)

(4)

Leiter, Rundkabel

(5)

elektrisch leitfähiger Bereich von (4)

(6)

isolierender Bereich von (4)

(7)

Gehäuse, Gehäuse-Oberteil

(7')

Gehäuse, Gehäuse-Unterteil

(8)

Eintrittsöffnung für (1)

(9)

Eintrittskante von (7)

(9')

Eintrittskante von (7')

(10)

Innenraum von (7)

(11)

elektrisch leitfähige Verbindung, Lötkontakt

(12)

Kantenelement, eigenes Element zur Abrundung der Eintrittskante

(13)

Rundung von (7) in Erstreckungsrichtung von (1)

(14)

Punkt der Eintrittskante (7') mit Radius r₁

(15)

Punkt der Eintrittskante (7') mit Radius r₂

(16)

Substrat, Glasscheibe

(17)

Rand von (1)

(18)

innerer Bereich von (1)

α

Winkel des Winkelsegments der Abrundung der Eintrittskante

r, r₁, r₂

Krümmungsradius, Radius des Krümmungskreises

I-I

Schnittebene

Show it:

(1)

foil conductor

(2)

electrically conductive layer of (1)

(3, 3 ')

electrically insulating film of (1)

(4)

Ladder, round cable

(5)

electrically conductive area of (4)

(6)

insulating area of (4)

(7)

Housing, housing upper part

(7 ')

Housing, housing lower part

(8th)

Entrance opening for (1)

(9)

Leading edge of (7)

(9 ')

Leading edge of (7 ')

(10)

Interior of (7)

(11)

electrically conductive connection, solder contact

(12)

Edge element, own element to round off the leading edge

(13)

Rounding of (7) in the spanwise direction of (1)

(14)

Point of the leading edge (7 ') with radius r ₁

(15)

Point of the leading edge (7 ') with radius r ₂

(16)

Substrate, glass pane

(17)

Edge of (1)

(18)

inner area of (1)

α

Angle of the angle segment of the rounding of the leading edge

r, r ₁ , r ₂

Radius of curvature, radius of the circle of curvature

II

cutting plane

Claims (11)

1. Housing (7) with an electrical connection (11) between a conductor (4) and a foil conductor (1), wherein in the entry opening (8) of the housing (7) for the foil conductor (1) at least one entry edge (9, 9') is rounded such that the entry opening (8) is increasingly expanded outward, characterized in that in addition to the rounded region of the entry edge (9, 9'), the entry edge (9, 9') has a rounding (13) in the direction of extension of the foil conductor (1).
2. Housing (7) according to claim 1, wherein the rounded region of the entry edge (9, 9') runs parallel to the wide side of the foil conductor (1).
3. Housing (7) according to one of claims 1 through 2, wherein both entry edges (9, 9') are rounded.
4. Housing (7) according to one of claims 1 through 3, wherein the rounded region of the entry edge (9, 9') is an angular segment with an angle of 30° to 180°, preferably of 80° to 180°, particularly preferably of 135° to 180°.
5. Housing (7) according to one of claims 1 through 4, wherein the rounded region of the entry edge (9, 9') has radii of curvature of at least 0.5 mm, preferably of 0.5 mm to 100 mm, particularly preferably of 0.5 mm to 20 mm.
6. Housing (7) according to one of claims 1 through 5, wherein the housing (7) includes an electrically insulating material, preferably a casting material or thermoplastic material, particularly preferably based on polyamide or an electrically conducting material with electrically insulating inserts.
7. Housing (7) according to one of claims 1 through 6, wherein the housing (7) has a one-part or multi-part element and/or is formed directly around the electrical connection (11) between the conductor (4) and the foil conductor (1).
8. Housing (7) according to one of claims 1 through 7, wherein the electrical connection (11) between the conductor (4) and the foil conductor (1) has a solder, bond, weld, adhesive, or clamp connection.
9. Housing (7) according to one of claims 1 through 8, wherein the electrical connection (11) connects at least one single-wire or multi-wire foil conductor (1) and at least one other foil conductor, a single-wire or multi-wire cable, a wire, a metallic contact element, or a conductor path.
10. Housing (7) according to one of claims 1 through 9, wherein the rounded region of the entry edge (9, 9') has a separate element (12), preferably with a circular shape and is inserted or clamped into the housing (7), or the separate element (12) is adhesively bonded to the housing (7).
11. Composite pane with a foil conductor (1) and a housing (7) according to one of claims 1 through 10 for electrical connection (11) between the foil conductor (1) and another conductor (4).

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