EP3584806B1 - A cable and method for producing - Google Patents

A cable and method for producing Download PDF

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Publication number
EP3584806B1
EP3584806B1 EP19168097.4A EP19168097A EP3584806B1 EP 3584806 B1 EP3584806 B1 EP 3584806B1 EP 19168097 A EP19168097 A EP 19168097A EP 3584806 B1 EP3584806 B1 EP 3584806B1
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European Patent Office
Prior art keywords
coating
cable
flat cable
flat
metal material
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EP19168097.4A
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German (de)
French (fr)
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EP3584806A1 (en
Inventor
Richard REEPEN
Kai Moldenhauer
Markus Rösch
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Auto Kabel Management GmbH
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Auto Kabel Management GmbH
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/009—Cables with built-in connecting points or with predetermined areas for making deviations
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/08—Flat or ribbon cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables

Definitions

  • the subject matter relates to a method for producing a cable and a cable, in particular for automotive applications.
  • Flat cables in particular have a rectangular cross section. Because of their advantageous ratio between weight and surface area, flat cables are used in particular for battery cables for starter-generator cables. High currents flow on the flat cables, so that the flat cables have large cable cross-sections. In addition, flat cables have the advantage that they can implement large cable cross-sections in narrow, inaccessible areas and at the same time enable a high current-carrying capacity for battery cables.
  • connection cables In the course of the increasing electrification of a wide variety of consumers in a motor vehicle, outlets along a battery string at various points within the vehicle are necessary.
  • the flat cable is connected to the vehicle peripherals, for example power distributors, external start support points, convenience consumers and the like, via connecting cables.
  • the connecting cables can be both round cables and again flat cables.
  • the connection lines must be connected to the central battery line. So far, this has mostly been done using connection bolts, e.g. threaded bolts, with standardized connection geometry.
  • connecting bolts to flat cables are, however, disadvantageous in two respects.
  • the connecting bolts require sufficient installation space and make it more difficult to lay the line during assembly; on the other hand, the connecting bolts must be attached to the Flat cables are welded on and must therefore be rotationally symmetrical. This is not always possible, especially in complicated laying geometries.
  • the U.S. 6,863,753 Bl discloses a manufacturing process for flat cables with one or more wire (s) made of metal, which can be completely coated with another metal such as tin, aluminum, etc.
  • the method comprises the two steps of continuously providing the coated cable, for example by means of rollers, and continuously applying an insulating tape to both sides of the core (s).
  • the DE 10 2016 124601 B3 discloses a type of connection between a metal electrical flat conductor and at least one electrical stranded conductor and a method for producing this connection.
  • the flat conductor comprises a first metal material and is coated with a second metal. The coating can be partially applied to the flat conductor.
  • the WO 2017/076535 A1 discloses a type of cable made of flat cables running parallel to one another and made of conductive solid material, for example copper or aluminum, for the automotive sector.
  • the lines are each separated by an insulation layer, preferably all lines are surrounded by insulation and can each be shielded by a metal shield for better electromagnetic compatibility, which must not be connected to the conductor for the shielding effect.
  • the US 2011/048768 A1 discloses a type of cable which comprises a metal conductor, for example a stranded conductor made of tin-coated copper conductors, which is at least partially encased by a first and a second sheath which influence the manner in which the conductor is bent.
  • a metal conductor for example a stranded conductor made of tin-coated copper conductors, which is at least partially encased by a first and a second sheath which influence the manner in which the conductor is bent.
  • the CN 103 000 265 A discloses a miniaturized flat copper electrical cable and a method for its manufacture.
  • the conductor is coated with a layer of silver, which can be mixed with aluminum or nickel, and a second layer Layer of aluminum.
  • the coated conductor is covered with an insulation layer, for example by means of extrusion.
  • the JP 2008 177085 A discloses a multi-core flat cable which is partially surrounded by insulation and a method for its manufacture. In the area of one end of the cable, the insulation has been removed so that, viewed from the end, a narrow insulated area is followed by a cable section with exposed cable cores and followed again by the insulated cable. To fasten the cable end, holes are drilled through the wires in the narrow insulated area. The wires can be coated.
  • the US 2014/290977 A1 discloses a method for continuously manufacturing an insulated flat cable, and the flat cable is made by this method.
  • the conductor or conductors is / are made from a conductive material, preferably from a metal foil.
  • the conductor (s) is / are provided, for example from a roll and processed into an insulated flat conductor in a continuous surface treatment process.
  • the finished cable can be rolled up again.
  • the method thus comprises the two steps of providing one or more conductive conductors / conductors and applying an insulation strip in each case from two sides of the conductor / conductors.
  • connection could be screwed directly onto the flat cable, but this is particularly disadvantageous when using base metal materials for the flat cable, for example aluminum materials.
  • base metal materials for the flat cable for example aluminum materials.
  • aluminum is ductile, so that it can flow along the screw connection, on the other hand, the less noble metal tends to contact corrosion.
  • the object of the object was to provide a flat cable which is suitable for direct contact with outlets.
  • a cable is manufactured in a continuous process.
  • a flat cable made of a first metal is first provided.
  • a flat cable from an extruder or a coil can be made available as an almost endless material.
  • the flat cable is preferably provided with a constant advance and coated directly during the advance.
  • the coating takes place with a second metal different from the first metal.
  • the coating takes place partially on the flat cable, in particular through friction under pressure.
  • the first coated flat cable is coated with an insulation layer. It is thus possible to apply the insulation layer to the coated flat conductor in an extrusion process with a constant advance.
  • the provision, coating and application take place in a continuous process in which the flat cable is provided in one piece at the same feed rate and is fed to the coating and application.
  • the cable provided is preferably initially uncoiled from a coil. This makes it possible to carry out the continuous process on an almost endless material, since several 100 meters of cable can be provided on a coil, which can be completely coated and insulated in the continuous process.
  • the coating takes place by means of roll cladding, friction coating or powder coating.
  • the coating process is particularly environmentally friendly.
  • the coating is applied in sections to the flat part, with a section without a coating lying between two sections with a coating.
  • an individual coating can be applied to the flat cable in a cost-effective manner.
  • the coating can take place in the areas required for this.
  • the first metal material is a copper material and that the second metal material is an aluminum material or that the first metal material is an aluminum material and that the second metal material is a copper material.
  • the choice of the second metal material is usually made according to the connection of the cable to a connector.
  • the metal material of the coating is selected depending on the type and material of the connecting part, in particular the bolt to be screwed.
  • a metal material is selected here which ensures that metals of the same type or similar as possible are in direct contact with one another at the connection between the cable and the connection part.
  • the flat cable is supplied as an endless strip, in particular the flat cable is unwound from a coil.
  • the flat cable be formed from a solid material in order to ensure a particularly good current-carrying capacity.
  • a cable cross-section of at least 15 mm 2 preferably between 15 mm 2 and 250 mm 2, makes sense for the application in question.
  • Another aspect is a device for performing the method according to claim 9.
  • Fig. 1 shows a feed device 2, for example a coil, from which a flat cable 4 is unwound.
  • the flat cable 4 is continuously fed along a feed direction 6 with a preferably constant feed to a coating unit 8.
  • the coating unit 8 can, for example, be a device for roll cladding or for friction welding, with which a coating material is applied to the flat cable.
  • the coating unit 8 applies, for example, a thin metal sheet or a metal foil 10 as a coating material to the flat cable 4 in a continuous process.
  • the advance of the flat cable 4 along the coating unit 8 can be constant.
  • the coating material can be applied by the coating unit 8 to at least one surface, preferably a broad side of the flat cable 4, but also to more than one surface of the flat cable 4.
  • the coating material is applied to the flat cable 4 with interruptions. Areas with a coating 10 can follow areas without a coating 10. An area without a coating 10 lies between two areas with a coating 10. The distances between the areas with a coating 10 can be freely adjustable. The distances between two areas with coating 10 can also be different from one another.
  • the material of the flat cable 4 differs from the material of the coating 10.
  • the flat cable can for example be made of an aluminum material and the coating 10 of a copper material.
  • the coated flat cable 4 is fed to an insulation device 12.
  • the isolation device 12 can, for example, be an extruder.
  • an insulating material 14 is applied to the coated flat cable 4 and the coated flat cable 4 is coated circumferentially with the insulator 14.
  • the cable 16 now obtained has a flat cable 4 with a coating 10 as its core and is completely sheathed with the insulator 14.
  • the cable 16 is then prefabricated, for example, by cutting it or rewinding it onto a coil.
  • Fig. 2 shows a cable 16 stripped from its end face, which is not part of the claimed invention. It can be seen that the end face of the insulator 14 is stripped. It can also be seen that a coating 10 has been applied to the flat cable 4. The coating 10 is applied along the entire wide surface of the flat cable 4.
  • FIG Fig. 3 A sectional coating according to the invention is shown in FIG Fig. 3 shown.
  • the Fig. 3 shows the flat cable 4 with coatings 10 which were applied in sections.
  • the distances between the areas with coating 10 and the areas without coating 10 can be variable.
  • the width of the sections with coating 10 can also be variable.
  • the flat conductor 4 coated in sections in this way is coated with the insulator 14 in the insulation device 12.
  • the cable 16 can then be cut to length in such a way that the coating 10 is present in the areas in which outlets are applied to the cable 16.
  • These can be bolts that are screwed into the coating 10, for example.
  • a suitable choice of the material of the coating 10 can, for example, ensure a single-type screw connection with a bolt.
  • the intermetallic transition between the coating 10 and the flat cable 4 remains fully protected by the insulation 14, so that no ambient moisture can penetrate into the metallic transition, which makes contact corrosion more difficult.

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  • Insulated Conductors (AREA)

Description

Der Gegenstand betrifft ein Verfahren zur Herstellung eines Kabels sowie ein Kabel, insbesondere für automotive Anwendungen.The subject matter relates to a method for producing a cable and a cable, in particular for automotive applications.

Die Automobilindustrie nutzt statt Rundleitungen immer häufiger profilierte, massive Flachleitungen. Flachleitungen haben dabei insbesondere einen rechteckigen Querschnitt. Aufgrund ihres vorteilhaften Verhältnisses zwischen Gewicht und Oberfläche sind Flachleitungen insbesondere für Batterieleitungen für Starter-Generator-Leitungen im Einsatz. Auf den Flachleitungen fließen hohe Ströme, so dass die Flachleitungen große Leitungsquerschnitte aufweisen. Darüber hinaus haben Flachleitungen den Vorteil, dass sie in engen, unzugänglichen Bereichen große Leitungsquerschnitte realisieren können und gleichzeitig eine hohe Stromtragfähigkeit für Batterieleitungen ermöglichen.The automotive industry is increasingly using profiled, solid flat cables instead of round cables. Flat cables in particular have a rectangular cross section. Because of their advantageous ratio between weight and surface area, flat cables are used in particular for battery cables for starter-generator cables. High currents flow on the flat cables, so that the flat cables have large cable cross-sections. In addition, flat cables have the advantage that they can implement large cable cross-sections in narrow, inaccessible areas and at the same time enable a high current-carrying capacity for battery cables.

Im Zuge der zunehmenden Elektrifizierung verschiedenartigster Verbraucher in einem Kraftfahrzeug sind Abgänge entlang eines Batteriestrangs an verschiedenen Punkten innerhalb des Fahrzeugs notwendig. Die Flachleitung wird über Verbindungsleitungen mit der Fahrzeugperipherie, beispielsweise Stromverteilern, Fremdstartstützpunkten, Komfortverbrauchern und dergleichen verbunden. Die Verbindungsleitungen können dabei sowohl Rundleitungen als auch erneut Flachleitungen sein. Die Verbindungsleitungen müssen mit der zentralen Batterieleitung verbunden werden. Dies erfolgt bisher meist über Anschlussbolzen, z.B. Gewindebolzen, mit standardisierter Anschlussgeometrie.In the course of the increasing electrification of a wide variety of consumers in a motor vehicle, outlets along a battery string at various points within the vehicle are necessary. The flat cable is connected to the vehicle peripherals, for example power distributors, external start support points, convenience consumers and the like, via connecting cables. The connecting cables can be both round cables and again flat cables. The connection lines must be connected to the central battery line. So far, this has mostly been done using connection bolts, e.g. threaded bolts, with standardized connection geometry.

Das Aufbringen von Anschlussbolzen auf Flachleitungen ist jedoch in zweierlei Hinsicht nachteilig. Einerseits benötigen die Anschlussbolzen einen ausreichenden Bauraum und erschweren das Verlegen der Leitung bei der Montage, andererseits müssen die Anschlussbolzen beispielsweise mittels Rotationsreibschweißen an die Flachleitung angeschweißt werden und müssen daher rotationssymmetrisch sein. Dies ist nicht immer möglich, insbesondere in komplizierten Verlegegeometrien.The application of connecting bolts to flat cables is, however, disadvantageous in two respects. On the one hand, the connecting bolts require sufficient installation space and make it more difficult to lay the line during assembly; on the other hand, the connecting bolts must be attached to the Flat cables are welded on and must therefore be rotationally symmetrical. This is not always possible, especially in complicated laying geometries.

Die US 6 863 753 Bloffenbart ein Herstellungsverfahren von Flachkabeln mit einer oder mehreren Ader(-n) aus Metall, die mit einem weiteren Metall wie Zinn, Aluminium, etc. vollständig beschichtet sein können. Das Verfahren umfasst die zwei Schritte eines kontinuierlichen Bereitstellens des beschichteten Kabels, beispielsweise über Rollen, und eines kontinuierlichem Aufbringens jeweils eines Isolationsbandes auf beiden Seiten der Ader(-n).the U.S. 6,863,753 Bl discloses a manufacturing process for flat cables with one or more wire (s) made of metal, which can be completely coated with another metal such as tin, aluminum, etc. The method comprises the two steps of continuously providing the coated cable, for example by means of rollers, and continuously applying an insulating tape to both sides of the core (s).

Die DE 10 2016 124601 B3 offenbart eine Verbindungsart zwischen einem metallenen elektrischen Flachleiter und zumindest einem elektrischen Litzenleiter sowie ein Verfahren zur Herstellung dieser Verbindung. Der Flachleiter umfasst einen ersten Metallwerkstoff und wird mit einem zweiten Metall beschichtet. Die Beschichtung kann teilweise auf dem Flachleiter aufgebracht sein.the DE 10 2016 124601 B3 discloses a type of connection between a metal electrical flat conductor and at least one electrical stranded conductor and a method for producing this connection. The flat conductor comprises a first metal material and is coated with a second metal. The coating can be partially applied to the flat conductor.

Die WO 2017/076535 Aloffenbart eine Kabelbauart aus zueinander parallel verlaufenden Flachleitungen aus leifähigem Vollmaterial, beispielsweise Kupfer oder Aluminium, für den Automobilbereich. Die Leitungen sind jeweils durch eine Isolationsschicht getrennt, bevorzugt sind alle Leitungen von einer Isolation umgeben und können jeweils für eine bessere elektromagnetische Verträglichkeit von einer Metallschirmung abgeschirmt sein, die für die Schirmungswirkung nicht mit dem Leiter verbunden sein darf.the WO 2017/076535 A1 discloses a type of cable made of flat cables running parallel to one another and made of conductive solid material, for example copper or aluminum, for the automotive sector. The lines are each separated by an insulation layer, preferably all lines are surrounded by insulation and can each be shielded by a metal shield for better electromagnetic compatibility, which must not be connected to the conductor for the shielding effect.

Die US 2011/048768 Aloffenbart eine Kabelbauart, die einen Metalleiter, beispielsweise einen Litzenleiter aus zinnbeschichteten Kupferleitungen, umfasst, der von einer ersten und einer zweiten Ummantelung zumindest teilweise umhüllt ist, die die Verbiegungsweise des Leiters beeinflussen.the US 2011/048768 A1 discloses a type of cable which comprises a metal conductor, for example a stranded conductor made of tin-coated copper conductors, which is at least partially encased by a first and a second sheath which influence the manner in which the conductor is bent.

Die CN 103 000 265 A offenbart ein miniaturisiertes elektrisches Flachleiter-Kabel aus Kupfer und eine Methode zu dessen Herstellung. Der Leiter ist beschichtet mit einer Silberschicht, welche mit Aluminium oder Nickel gemischt sein kann, und einer zweiten Schicht aus Aluminium. Der beschichtete Leiter wird mit einer Isolationsschicht, beispielsweise mittels Extrusion, umhüllt.the CN 103 000 265 A discloses a miniaturized flat copper electrical cable and a method for its manufacture. The conductor is coated with a layer of silver, which can be mixed with aluminum or nickel, and a second layer Layer of aluminum. The coated conductor is covered with an insulation layer, for example by means of extrusion.

Die JP 2008 177085 A offenbart ein mehradriges Flachkabel, das teilweise von einer Isolation umgeben ist und ein Verfahren zu dessen Herstellung. Im Bereich eines Endes des Kabels ist die Isolation entfernt, sodass vom Ende aus gesehen ein schmaler isolierter Bereich gefolgt wird von einem Kabelabschnitt mit entblößten Kabeladern und wieder gefolgt vom Isolierten Kabel. Zur Befestigung des Kabelendes werden im Bereich des schmalen isolierten Bereichs Löcher durch die Adern gebohrt. Die Adern können beschichtet sein.the JP 2008 177085 A discloses a multi-core flat cable which is partially surrounded by insulation and a method for its manufacture. In the area of one end of the cable, the insulation has been removed so that, viewed from the end, a narrow insulated area is followed by a cable section with exposed cable cores and followed again by the insulated cable. To fasten the cable end, holes are drilled through the wires in the narrow insulated area. The wires can be coated.

Die US 2014/290977 Aloffenbart ein Verfahren zum kontinuierlichen Herstellen eines isolierten Flachkabels und das Flachkabel hergestellt nach diesem Verfahren. Der oder die Leiter ist/ sind aus einem leitfähigem Material, vorzugsweise aus einer Metallfolie, gefertigt. In der Herstellung wird/ werden der/ die Leiter bereitgestellt, beispielsweise von einer Rolle und in einem kontinuierlichen Oberflächenbearbeitungsverfahren zu einem isolierten Flachleiter verarbeitet das fertige Kabel kann wieder aufgerollt werden. Das Verfahren umfasst also die zwei Schritte Bereitstellen eines/ mehrerer leitfähigen/ leitfähiger Leiters/ Leiter und Aufbringen jeweils eines Isolationsstreifens von zwei Seiten des Leiters/ der Leiter.the US 2014/290977 A1 discloses a method for continuously manufacturing an insulated flat cable, and the flat cable is made by this method. The conductor or conductors is / are made from a conductive material, preferably from a metal foil. During production, the conductor (s) is / are provided, for example from a roll and processed into an insulated flat conductor in a continuous surface treatment process. The finished cable can be rolled up again. The method thus comprises the two steps of providing one or more conductive conductors / conductors and applying an insulation strip in each case from two sides of the conductor / conductors.

Es wäre von Vorteil, wenn auf die Flachleitung unmittelbar eine Verbindung aufgeschraubt werden könnte, dies ist jedoch insbesondere bei der Verwendung von unedlen Metallwerkstoffen für die Flachleitung, beispielsweise Aluminiumwerkstoffen, nachteilig. Einerseits ist Aluminium duktil, so dass es zum Fließen entlang der Verschraubung kommen kann, andererseits neigt das unedlere Metall zu Kontaktkorrosion.It would be advantageous if a connection could be screwed directly onto the flat cable, but this is particularly disadvantageous when using base metal materials for the flat cable, for example aluminum materials. On the one hand, aluminum is ductile, so that it can flow along the screw connection, on the other hand, the less noble metal tends to contact corrosion.

Aus diesem Grunde lag dem Gegenstand die Aufgabe zugrunde, eine Flachleitung zur Verfügung zu stellen, welche sich zur unmittelbaren Kontaktierung mit Abgängen eignet.For this reason, the object of the object was to provide a flat cable which is suitable for direct contact with outlets.

Diese Aufgabe wird gegenständlich durch ein Verfahren nach Anspruch 1 gelöst. Hierbei wird ein Kabel in einem kontinuierlichen Prozess hergestellt. Dazu wird zunächst eine Flachleitung aus einem ersten Metall bereitgestellt. Insbesondere kann eine Flachleitung von einem Extruder oder einem Coil als nahezu Endlosmaterial zur Verfügung gestellt werden.This object is objectively achieved by a method according to claim 1. Here, a cable is manufactured in a continuous process. For this purpose, a flat cable made of a first metal is first provided. In particular, a flat cable from an extruder or a coil can be made available as an almost endless material.

Die Flachleitung wird dabei bevorzugt mit einem konstanten Vortrieb bereitgestellt und während des Vortriebs unmittelbar beschichtet. Die Beschichtung erfolgt dabei mit einem zweiten, von dem ersten Metall verschiedenen Metall. Die Beschichtung erfolgt dabei partiell auf der Flachleitung, insbesondere durch Reibung unter Druck.The flat cable is preferably provided with a constant advance and coated directly during the advance. The coating takes place with a second metal different from the first metal. The coating takes place partially on the flat cable, in particular through friction under pressure.

Mit dem gleichen Vortrieb wird die so zunächst beschichtete Flachleitung mit einer Isolationsschicht beschichtet. Somit ist es möglich, mit einem konstanten Vorschub auf den beschichteten Flachleiter in einem Extrusionsprozess die Isolationsschicht aufzubringen.With the same advance, the first coated flat cable is coated with an insulation layer. It is thus possible to apply the insulation layer to the coated flat conductor in an extrusion process with a constant advance.

Bei dem gegenständlichen Verfahren erfolgt das Bereitstellen, Beschichten und Aufbringen in einem kontinuierlichen Prozess, bei dem die Flachleitung mit einer gleichen Vorschubgeschwindigkeit in einem Stück bereitgestellt wird und der Beschichtung und dem Aufbringen zugeführt wird.In the case of the method at issue, the provision, coating and application take place in a continuous process in which the flat cable is provided in one piece at the same feed rate and is fed to the coating and application.

Gemäß einem Ausführungsbeispiel wird vorgeschlagen, dass die Schritte Bereitstellen, Beschichten und Aufbringen unmittelbar aufeinander folgen. Hierdurch ist es möglich, in einer kompakten Anlage ein komplett vorkonfektioniertes Kabel zur Verfügung zu stellen, welches sich zum unmittelbaren Verschrauben mit Anschlussbolzen eignet.According to one exemplary embodiment, it is proposed that the steps of providing, coating and applying follow one another directly. This makes it possible to provide a completely pre-assembled cable in a compact system, which is suitable for direct screwing with connection bolts.

Das bereitgestellte Kabel ist bevorzugt zunächst von einem Coil abgecoilt. Dadurch ist es möglich, den kontinuierlichen Prozess an einem nahezu Endlosmaterial durchzuführen, da auf einem Coil mehrere 100 Meter Kabel bereitgestellt werden können, die in dem kontinuierlichen Prozess vollständig beschichtet und isoliert werden können.The cable provided is preferably initially uncoiled from a coil. This makes it possible to carry out the continuous process on an almost endless material, since several 100 meters of cable can be provided on a coil, which can be completely coated and insulated in the continuous process.

Gegenständlich erfolgt das Beschichten mittels Walzplattieren, Reibbeschichten oder Pulverbeschichten. Durch das Entfallen einer Galvanik ist der Beschichtungsprozess besonders umweltschonend. Wie bereits erwähnt, wird bevorzugt, wenn das Aufbringen mittels Extrudieren erfolgt. Da in der Regel die Kontaktierung mit einem Abgang nur auf einer Oberfläche des Flachteils erfolgt, wird vorgeschlagen, dass die Beschichtung auf nur einer breiten Oberfläche des Flachteils erfolgt. Somit wird weniger Beschichtungsmaterial verwendet und insbesondere kann das mechanische Beschichtungsverfahren auf nur auf eine Oberfläche des Flachteils beschränkt werden.In the present case, the coating takes place by means of roll cladding, friction coating or powder coating. As there is no need for electroplating, the coating process is particularly environmentally friendly. As already mentioned, it is preferred if the application takes place by means of extrusion. Since, as a rule, the contact with an outlet takes place only on one surface of the flat part, it is proposed that the coating take place on only one wide surface of the flat part. Thus, less coating material is used and, in particular, the mechanical coating process can be limited to only one surface of the flat part.

Gegenständlich wird die Beschichtung abschnittsweise auf das Flachteil aufgebracht, wobei zwischen zwei Abschnitten mit einer Beschichtung ein Abschnitt ohne eine Beschichtung liegt. Hierdurch kann kostengünstig eine individuelle Beschichtung auf die Flachleitung aufgebracht werden. Je nach Anwendung des Kabels kann die Beschichtung in den jeweils hierfür notwendigen Bereichen erfolgen.In the present case, the coating is applied in sections to the flat part, with a section without a coating lying between two sections with a coating. In this way, an individual coating can be applied to the flat cable in a cost-effective manner. Depending on the application of the cable, the coating can take place in the areas required for this.

Gemäß einem Ausführungsbeispiel wird vorgeschlagen, dass der erste Metallwerkstoff ein Kupferwerkstoff ist und dass der zweite Metallwerkstoff ein Aluminiumwerkstoff ist oder dass der erste Metallwerkstoff ein Aluminiumwerkstoff ist und dass der zweite Metallwerkstoff ein Kupferwerkstoff ist. Die Wahl des zweiten Metallwerkstoffs erfolgt in der Regel entsprechend der Anbindung des Kabels an ein Anschlussteil. Je nach Art und Material des Anschlussteils, insbesondere des zu verschraubenden Bolzens, wird das Metallwerkstoff der Beschichtung gewählt. Hier wird insbesondere ein Metallwerkstoff gewählt, welcher sicherstellt, dass möglichst sortenreine oder ähnliche Metalle an der Verbindung zwischen Kabel und Anschlussteil unmittelbar aneinander anliegen.According to one embodiment it is proposed that the first metal material is a copper material and that the second metal material is an aluminum material or that the first metal material is an aluminum material and that the second metal material is a copper material. The choice of the second metal material is usually made according to the connection of the cable to a connector. The metal material of the coating is selected depending on the type and material of the connecting part, in particular the bolt to be screwed. In particular, a metal material is selected here which ensures that metals of the same type or similar as possible are in direct contact with one another at the connection between the cable and the connection part.

Die Flachleitung wird gemäß einem Ausführungsbeispiel als Endlosband zugeführt, insbesondere wird die Flachleitung von einem Coil abgewickelt.According to one exemplary embodiment, the flat cable is supplied as an endless strip, in particular the flat cable is unwound from a coil.

Wie bereits erläutert, wird das gegenständliche Kabel als Energieleitung in automotiven Anwendungen eingesetzt. Aus diesem Grunde wird vorgeschlagen, dass die Flachleitung aus einem Vollmaterial gebildet ist, um eine besonders gute Stromtragfähigkeit zu gewährleisten. Darüber hinaus ist ein Kabelquerschnitt von zumindest 15 mm2, bevorzugt zwischen 15 mm2 und 250 mm2 sinnvoll für die gegenständliche Anwendung.As already explained, the cable in question is used as a power line in automotive applications. For this reason, it is proposed that the flat cable be formed from a solid material in order to ensure a particularly good current-carrying capacity. In addition, a cable cross-section of at least 15 mm 2 , preferably between 15 mm 2 and 250 mm 2, makes sense for the application in question.

Ein weiterer Aspekt ist eine Vorrichtung zur Durchführung des Verfahrens nach Anspruch 9.Another aspect is a device for performing the method according to claim 9.

Nachfolgend wird der Gegenstand anhand einer Ausführungsbeispiele zeigenden Zeichnung näher erläutert. In der Zeichnung zeigen:

  • Fig. 1 eine Vorrichtung zur Durchführung des gegenständlichen Verfahren zur Herstellung eines Kabels nach Figur 3;
  • Fig. 2 eine Ansicht eines Kabels hergestellt nach einem nicht beanspruchten Verfahren;
  • Fig. 3 eine Ansicht eines Kabels hergestellt nach dem gegenständlichen Verfahren;
The subject matter is explained in more detail below with the aid of a drawing showing exemplary embodiments. In the drawing show:
  • Fig. 1 a device for carrying out the subject method for producing a cable according to Figure 3 ;
  • Fig. 2 a view of a cable made by a method not claimed;
  • Fig. 3 a view of a cable produced by the method in question;

Fig. 1 zeigt eine Zuführeinrichtung 2, beispielsweise ein Coil, von der eine Flachleitung 4 abgewickelt wird. Die Flachleitung 4 wird entlang einer Vorschubrichtung 6 kontinuierlich mit einem bevorzugt konstanten Vorschub einer Beschichtungseinheit 8 zugeführt. Die Beschichtungseinheit 8 kann beispielsweise eine Einrichtung zur Walzplattierung oder zum Reibschweißen sein, mit der ein Beschichtungswerkstoff auf die Flachleitung aufgebracht wird. Die Beschichtungseinheit 8 bringt als Beschichtungswerkstoff z.B. ein dünnes Metallblech oder eine Metallfolie 10 auf die Flachleitung 4 in einem kontinuierlichen Prozess auf. Dabei kann der Vorschub der Flachleitung 4 entlang der Beschichtungseinheit 8 konstant sein. Der Beschichtungswerkstoff kann durch die Beschichtungseinheit 8 auf zumindest eine Oberfläche, bevorzugt eine breite Seite der Flachleitung 4, aber auch auf mehr als eine Oberfläche der Flachleitung 4 aufgebracht werden. Fig. 1 shows a feed device 2, for example a coil, from which a flat cable 4 is unwound. The flat cable 4 is continuously fed along a feed direction 6 with a preferably constant feed to a coating unit 8. The coating unit 8 can, for example, be a device for roll cladding or for friction welding, with which a coating material is applied to the flat cable. The coating unit 8 applies, for example, a thin metal sheet or a metal foil 10 as a coating material to the flat cable 4 in a continuous process. The advance of the flat cable 4 along the coating unit 8 can be constant. The coating material can be applied by the coating unit 8 to at least one surface, preferably a broad side of the flat cable 4, but also to more than one surface of the flat cable 4.

Der Beschichtungswerkstoff wird mit Unterbrechungen auf die Flachleitung 4 aufgebracht. Dabei können Bereiche mit einer Beschichtung 10 auf Bereiche ohne Beschichtung 10 folgen. Zwischen zwei Bereichen mit einer Beschichtung 10 liegt ein Bereich ohne eine Beschichtung 10. Die Abstände zwischen den Bereich mit Beschichtung 10 kann dabei frei einstellbar sein. Auch können die Abstände zwischen zwei Bereichen mit Beschichtung 10 voneinander verschieden sein.The coating material is applied to the flat cable 4 with interruptions. Areas with a coating 10 can follow areas without a coating 10. An area without a coating 10 lies between two areas with a coating 10. The distances between the areas with a coating 10 can be freely adjustable. The distances between two areas with coating 10 can also be different from one another.

Das Material der Flachleitung 4 unterscheidet sich von dem Material der Beschichtung 10. Die Flachleitung kann beispielsweise aus einem Aluminiumwerkstoff sein und die Beschichtung 10 aus einem Kupferwerkstoff.The material of the flat cable 4 differs from the material of the coating 10. The flat cable can for example be made of an aluminum material and the coating 10 of a copper material.

Die beschichtete Flachleitung 4 wird einer Isolationseinrichtung 12 zugeführt. Die Isolationseinrichtung 12 kann beispielsweise ein Extruder sein. In der Isolationseinrichtung 12 wird ein isolierendes Material 14 auf die beschichtete Flachleitung 4 aufgebracht und die beschichtete Flachleitung 4 wird umfänglich mit dem Isolator 14 beschichtet.The coated flat cable 4 is fed to an insulation device 12. The isolation device 12 can, for example, be an extruder. In the insulation device 12, an insulating material 14 is applied to the coated flat cable 4 and the coated flat cable 4 is coated circumferentially with the insulator 14.

Das nun erhaltene Kabel 16 weist als Seele eine Flachleitung 4 mit einer Beschichtung 10 auf und ist vollumfänglich mit dem Isolator 14 ummantelt. Das Kabel 16 wird anschließend beispielsweise vorkonfektioniert, indem es geschnitten wird oder erneut auf ein Coil aufgewickelt.The cable 16 now obtained has a flat cable 4 with a coating 10 as its core and is completely sheathed with the insulator 14. The cable 16 is then prefabricated, for example, by cutting it or rewinding it onto a coil.

Fig. 2 zeigt ein stirnseitig abisoliertes Kabel 16, das nicht Teil der beanspruchten Erfindung ist. Zu erkennen ist, dass der Isolator 14 stirnseitig abisoliert ist. Ferner ist zu erkennen, dass auf die Flachleitung 4 eine Beschichtung 10 aufgebracht ist. Die Beschichtung 10 ist entlang der gesamten breiten Oberfläche der Flachleitung 4 aufgebracht. Fig. 2 shows a cable 16 stripped from its end face, which is not part of the claimed invention. It can be seen that the end face of the insulator 14 is stripped. It can also be seen that a coating 10 has been applied to the flat cable 4. The coating 10 is applied along the entire wide surface of the flat cable 4.

Eine erfindungsgemäße abschnittsweise Beschichtung ist in der Fig. 3 gezeigt.A sectional coating according to the invention is shown in FIG Fig. 3 shown.

Die Fig. 3 zeigt die Flachleitung 4 mit Beschichtungen 10 die abschnittsweise aufgebracht wurden. Die Abstände zwischen den Bereichen mit Beschichtung 10 und den Bereichen ohne Beschichtung 10 können variabel sein. Auch kann die Breite der Abschnitte mit Beschichtung 10 variabel sein. Der so abschnittsweise beschichtete Flachleiter 4 wird in der Isolationseinrichtung 12 mit dem Isolator 14 beschichtet. Bei der anschließenden Konfektionierung kann das Kabel 16 dann so abgelängt werden, dass die Beschichtung 10 in den Bereichen vorhanden ist, in denen Abgänge auf das Kabel 16 aufgebracht werden. Dies können beispielsweise Bolzen sein, die in die Beschichtung 10 eingeschraubt werden.the Fig. 3 shows the flat cable 4 with coatings 10 which were applied in sections. The distances between the areas with coating 10 and the areas without coating 10 can be variable. The width of the sections with coating 10 can also be variable. The flat conductor 4 coated in sections in this way is coated with the insulator 14 in the insulation device 12. During the subsequent assembly, the cable 16 can then be cut to length in such a way that the coating 10 is present in the areas in which outlets are applied to the cable 16. These can be bolts that are screwed into the coating 10, for example.

Durch eine geeignete Wahl des Werkstoffs der Beschichtung 10 kann beispielsweise eine sortenreine Verschraubung mit einem Bolzen gewährleistet werden. Der intermetallische Übergang zwischen der Beschichtung 10 und der Flachleitung 4 bleibt dabei durch die Isolation 14 vollumfänglich geschützt, so dass keine Umgebungsfeuchte in den metallischen Übergang eindringen kann, was Kontaktkorrosion erschwert.A suitable choice of the material of the coating 10 can, for example, ensure a single-type screw connection with a bolt. The intermetallic transition between the coating 10 and the flat cable 4 remains fully protected by the insulation 14, so that no ambient moisture can penetrate into the metallic transition, which makes contact corrosion more difficult.

Claims (12)

  1. Method of manufacturing a cable comprising the steps of
    - providing a flat cable (4) made of a first metal material,
    - coating, in sections, the flat cable (4) with a second metal material (10) different from the first metal material, wherein between two sections with a coating there is a section without a coating, and
    - applying an insulating layer (14) to the flat cable (4) together with the coating (10) wherein
    - the flat cable (4) is fed in a continuous process to the steps of providing, coating and applying,
    characterized in that.
    - the coating is made by roll cladding, friction coating or powder coating,
  2. Method according to claim 1,
    characterized in
    - that during the continuous process the steps of providing, coating and applying follow one another directly.
  3. Method according to claim 1 or 2,
    characterized in
    - that the cable (16) is not coiled until after applying.
  4. Process according to one of the preceding claims,
    characterized in
    - that applying is carried out by means of extrusion.
  5. Method according to one of the preceding claims,
    characterized in
    - that the coating is carried out on only one wide surface of the flat cable (4).
  6. Method according to one of the preceding claims,
    characterized in
    - that the first metal material is a copper material and that the second metal material is an aluminium material or that the first metal material is an aluminium material and that the second metal material is a copper material.
  7. Method according to any one of the preceding claims,
    characterised in that
    - in that the flat cable (4) is fed as an endless strip, in particular in that the flat cable (4) is unwound from a coil.
  8. Method according to one of the preceding claims,
    characterised in that
    - in that the flat cable (4) is formed from a solid material and in particular has a cable cross-section of at least 15mm2, preferably between 15mm2 and 250mm2.
  9. Device for carrying out a method according to one of the preceding claims comprising,
    - a feeding device (2) for continuously feeding a flat cable (4),
    - a coating device (8) for coating in sections the flat cable (4) continuously fed from the feeding device by means of roll cladding, friction coating or powder coating, wherein between two sections with a coating there is a section without a coating, and
    - an insulation device (12) for continuously applying insulation (14) to the coated flat cable (4) continuously fed from the coating device (8).
  10. Device according to claim 9,
    characterized in
    - in that the coating device (8) and the insulation device (12) are arranged on a common tool table.
  11. Device according to claim 9 or 10,
    characterized in
    - that a removal unit is arranged for receiving the coated cable (16) from the insulation device (12) and for feeding the cable (16) to a coil.
  12. Decive according to any one of the preceding claims,
    characterized in
    - that the insulation device (12) is an extruder.
EP19168097.4A 2018-06-19 2019-04-09 A cable and method for producing Active EP3584806B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102018114627.2A DE102018114627B4 (en) 2018-06-19 2018-06-19 Method and device for producing a cable

Publications (2)

Publication Number Publication Date
EP3584806A1 EP3584806A1 (en) 2019-12-25
EP3584806B1 true EP3584806B1 (en) 2021-09-29

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EP (1) EP3584806B1 (en)
DE (1) DE102018114627B4 (en)
ES (1) ES2895638T3 (en)

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3555926B2 (en) * 1999-01-29 2004-08-18 ソニーケミカル株式会社 Flat cable manufacturing apparatus and manufacturing method
JP2008177085A (en) * 2007-01-19 2008-07-31 Sumitomo Electric Ind Ltd Flat cable, and its manufacturing method
GB2459658A (en) * 2008-04-29 2009-11-04 Tyco Electronics Ltd Uk Power Cable
JP5181876B2 (en) 2008-06-30 2013-04-10 住友電気工業株式会社 Flat cable manufacturing method
JP5609064B2 (en) 2009-11-02 2014-10-22 住友電気工業株式会社 Shielded flat cable and manufacturing method thereof
FR2975864A1 (en) * 2011-05-27 2012-11-30 Eads Europ Aeronautic Defence SEMI-PRODUCT IN THE FORM OF A CONDUCTIVE BAND INTEGRABLE IN A COMPOSITE MATERIAL AND METHOD OF MANUFACTURING SUCH A BAND
CN103000265B (en) * 2012-11-22 2016-06-01 芜湖航天特种缆业股份有限公司 A kind of miniature hookup wire and manufacture method thereof
CN103117114B (en) 2013-02-21 2016-07-06 罗志昭 A kind of copper and aluminium alloy are with the use of method
DE102014004430A1 (en) 2014-03-27 2015-10-01 Alanod Gmbh & Co. Kg Self-adhesive plastic for the insulation of metal surfaces
DE102014017886A1 (en) 2014-12-04 2016-06-09 Auto-Kabel Management Gmbh Method for producing an electrical connection part
DE102015118921A1 (en) * 2015-11-04 2017-05-04 Auto-Kabel Management Gmbh Multiple voltage onboard power supply system as well as voltage levels - comprehensive multilayer cable
DE102016124601B3 (en) * 2016-12-16 2018-03-01 Auto-Kabel Management Gmbh Connection of an electrical flat conductor with electrical stranded conductors

Also Published As

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ES2895638T3 (en) 2022-02-22
DE102018114627B4 (en) 2024-02-15
DE102018114627A1 (en) 2019-12-19
EP3584806A1 (en) 2019-12-25

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