LU101059B1

LU101059B1 - Flexible Multilayer Encapsulation of Electrical Connections

Info

Publication number: LU101059B1
Application number: LU101059A
Authority: LU
Inventors: Matthias Massing; Günter Gödert; Raphael Bennes; Harald Schon; Steffen Schuler; Klaus-Peter Schmitz
Original assignee: Iee Sa
Priority date: 2018-12-17
Filing date: 2018-12-17
Publication date: 2020-06-17

Abstract

An electrical connection encapsulation device (12; 12') for electrically connecting a flexible flat cable (14) to discrete electrical wires (46, 48) is presented. The electrical connection encapsulation device (12') comprises a flexible flat cable (14) with a dielectric, planar, flexible carrier (16) and at least one electrically conductive line (22, 24, 26, 28) attached to at least one surface (20), a first flat, soft and pliable material layer (50) and a second flat, soft and pliable material layer (52), attached to the first surface (18) and the second surface (20) of the flexible carrier (16), respectively, by adhesive bonds, at least one electrical connector member (32, 34, 36, 38) that is electrically connectable to a discrete electrical wire (46, 48) at one end and to the a least one electrically conductive line (22, 24, 26, 28) with the other end at least in an operational state. The first (50) and second flat, soft and pliable material layers (52) are arranged to at least partially overlap the at least one electrically conductive line (22, 24, 26, 28) in the connecting end region (40) in the perpendicular direction (44), and to extend beyond the end of the at least one electrical connector member (32, 34, 36, 38) that is facing away from the connecting end region (40).

Description

Flexible Multilayer Encapsulation of Electrical Connections Technical field

[0001] The invention relates to an electrical connection encapsulation device for electrically connecting a flexible flat cable to discrete electrical wires, a flexible flat cable-to-electrical wire encapsulated connector device comprising such electrical connection encapsulation device, and a method for producing such flexible flat cable-to-electrical wire encapsulated connector devices. Background of the Invention

[0002] Electric heating devices are widely used in the automotive industry, for instance for providing passenger comfort by heating a vehicle compartment in general, and/or passenger seats, and/or arm rests, and/or panels, or as a part of a battery temperature management system. Electric heating devices having flexible and/or stretchable heater members are known to be employed in vehicle steering wheels for heating right after start-up of a vehicle engine at cold ambient conditions.

[0003] In addition to providing comfort by a fast warming up it is considered as a requirement for such electric heating devices that they should be unnoticeable to the vehicle user if not put into operation.

[0004] In the field of automotive vehicle sensor application it is known to employ capacitive sensors for providing input to Automatic Driver Assistance Systems (ADAS), for instance for the purpose of a seat belt reminder (SBR) system or an activation control for an auxiliary restraint system (ARS), based on seat occupation detection and/or classification devices. Sensed signals can serve as a basis for making decisions by an ADAS, for instance for a decision to deploy an air bag system to a specific vehicle seat or not.

[0005] Capacitive occupant sensing systems have been proposed in great variety, e.g. for controlling the deployment of one or more airbags, such as e.g. a driver airbag, a passenger airbag and/or a side airbag.

[0006] Another automotive capacitive sensor application is hands-off detection. WO 2016/096815 A1 proposes a planar flexible carrier for use in steering wheel heating and/or sensing. The planar carrier, which can be employed for mountingon a rim of a steering wheel without wrinkles, comprises a portion of planar flexible foil of roughly rectangular shape having two longitudinal sides and two lateral sides. A length B of the lateral sides is 0.96 to 1.00 times the perimeter of the rim. A number of N cut-outs per unit length are provided on each of the longitudinal sides, wherein the cut-outs of one side are located in a staggered fashion relative to opposing cut-out portions on the opposite side. The determining of an optimum shape and size of the cut-outs is described. Further described is a heat carrier, a heating and/or sensing device and methods for their production.

[0007] Therefore, it has been proposed in the art to use foil and/or textile as carrier materials for sensor members of sensing devices or for heating members of heating devices in many automotive applications in order to meet available space requirements or to enhance a user comfort. Foil and/or textile-based sensor members and foil and/or textile-based heating members have the appearance of a thin flexible foil or film.

[0008] Space and/or user comfort requirements for the sensor member and/or the heater member also hold for the necessary electrical connections to and from the sensor member and/or the heater member. Conventional electrical connections such as crimp connections, clinch connections and riveted connections are often encapsulated, for instance by a hot melt cast process or by a plastic housing with snap fit, which in principle is not adapted to thin flexible foil or film sensor members or heater members. Moreover, hot melt cast processes are time- consuming and require complex manufacturing equipment. Object of the invention

[0009] It is therefore an object of the invention to provide an electrical connector for foil and/or textile-based sensor members and heating members that is adapted to the compactness of foil and/or textile-based sensor members and heating members, that provides appropriate mechanical protection against external influences and that allows for using a simple and robust manufacturing process.

General Description of the Invention

[0010] In one aspect of the present invention, the object is achieved by an electrical connection encapsulation device for electrically connecting a flexible flat cable to discrete electrical wires.

[0011] The electrical connection encapsulation device comprises a flexible flat cable, a first flat, soft and pliable material layer, a second flat, soft and pliable material layer and at least one electrical connector member.

[0012] It is noted herewith that the terms “first”, “second”, etc. are used in the present application for distinction purposes only, and are not meant to indicate or anticipate a sequence or a priority in any way.

[0013] The flexible flat cable has a connecting end region and includes at least one dielectric, planar, flexible carrier having a first surface and an opposite second surface arranged in parallel to the first surface. At least one out of the first surface and the second surface is equipped with at least one electrically conductive line that is attached to the respective surface and extends at least within the connecting end region.

[0014] The first flat, soft and pliable material layer is attached to the first surface of the flexible carrier at the connecting end region by an adhesive bond. The second flat, soft and pliable material layer is attached to the second surface of the flexible carrier at the connecting end region by an adhesive bond.

[0015] The at least one electrical connector member is electrically connectable to a discrete electrical wire with one end that is facing away from the connecting end region. The other end of the at least one electrical connector member is facing towards the connecting end region and is arranged to partially overlap the at least one electrically conductive line in a direction that is perpendicular to the surfaces of the flexible carrier for providing an electrical contact to the at least one electrically conductive line at least in an operational state.

[0016] The first flat, soft and pliable material layer and the second flat, soft and pliable material layer are arranged to at least partially overlap the at least one electrically conductive line in the connecting end region in the perpendicular direction, and to extend beyond the end of the at least one electrical connector member that is facing away from the connecting end region.

[0017] The proposed multi-layer electrical connection encapsulation device can provide a flat, compact design, sufficient reinforcement and mechanical protection against external influences, tightness against liquids and can allow for a use of simple and robust manufacturing techniques. A mechanical reinforcement of electrical connections between conductive lines of a flexible flat cable and discrete electric wires against tensile forces and/or bending loads can readily be established. A mechanical flexibility of encapsulation can be adjusted by a number of layers, respective thickness and type of material.

[0018] In principle, the invention is beneficially applicable to any flexible flat cable that needs to be electrically connected to discrete electrical wires or cables. In particular, the invention is applicable with advantage in the automotive sector. The term “automotive”, as used in the present application, shall particularly be understood as being suitable for use in vehicles including passenger cars, trucks, semi-trailer trucks and buses.

[0019] Preferably, the electrical connection encapsulation device comprises a protection layer that is arranged to cover and to be in direct contact with a portion of the at least one electrically conductive line in the connecting end region, wherein the protection layer extends beyond the flat, soft and pliable flat material layers in a direction away from the connecting end region. In this way, a further mechanical protection can be provided to the at least one electrically conductive line in an end region of the flat, soft and pliable flat material layers.

[0020] In preferred embodiments, the electric connection encapsulation device further comprises at least a first flat, stiff material layer that is attached by an adhesive bond to the first flat, soft and pliable material layer or to the second flat, soft and pliable material layer, to a surface facing away from the flexible carrier. The term “stiff, as used in the present application, shall in particular be understood such that the stiff material has a bending strength that is at least three times larger, more preferable at least ten times larger, and, most preferable, at least twenty times larger than the bending strength of the flat, soft and pliable material layers. By that, enhanced mechanical protection against external influences can be provided towards at least one side of the electrical connection encapsulation device.

[0021] Preferably, the electrical connection encapsulation device additionally includes at least a second flat, stiff material layer that is attached by an adhesive bond to an open surface of the first flat, soft and pliable material layer or the second flat, soft and pliable material layer that is facing away from the flexible carrier. In this way, the first flat, stiff material layer and the second flat, stiff material layer can act together form a protective shell with particularly strong protection properties against mechanical external influences.

[0022] Preferably, the first flat, stiff material layer and/or the second flat, stiff material layer are/is made at least for a most part from a material that is selected from a group of materials formed by polyethylene terephthalate (PET), polyimide (PI), polyetherimide (PEI), polyethylene naphthalate (PEN), polyoxymethylene (POM), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polyether ether ketone (PEEK), metal foil and selected combinations of at least two of these materials.

[0023] A mechanical flexibility of encapsulation can be adjusted by a number of layers, respective thickness and type of material.

[0024] In preferred embodiments, at least one of the adhesive bonds is provided by a layer of adhesive material. By that, a particularly compact design of the electrical connection encapsulation device can be accomplished.

[0025] Preferably, at least one of the adhesive bonds is provided by a double- sided adhesive tape. In this way, the adhesive bond can be prepared in advance, allowing to create a stock, and a fast manufacturing process can be achieved.

[0026] In preferred embodiments, an adhesive material of at least one of the adhesive bonds is formed by a pressure-sensitive adhesive. This can allow for a particularly fast manufacturing process.

[0027] In preferred embodiments of the electrical connection encapsulation device the flat, soft and pliable material layer, which has a surface that is facing towards the surface of the planar, flexible carrier that is equipped with the at least one electrically conductive line, comprises at least one aperture that is configured for taking up, in an operational state, at least a portion of the at least one electrically conductive line or at least a portion of the at least one electrical connector member.

[0028] The phrase “being configured to”, as used in the present application, shall in particular be understood as being specifically laid out, furnished or arranged. The at least one aperture can provide access to the at least one electrically conductive line or to the at least one electrical connector member and can provide installation space for installing bulk electrical components such as resistors and/or capacitors that are electrically connected to the at least one electrically conductive line or to the at least one electrical connector member.

[0029] The at least one aperture is adjustable to different flexible flat cables, connecting end regions and electrical connector member geometries and can thus provide a large freedom of design with regard to size, shape and number of apertures for a variety of applications.

[0030] Preferably, at least one of the flat, soft and pliable material layers is made at least for a most part from a soft polymeric foam, a synthetic textile or a combination of both.

[0031] These materials are available in a large variability, and vast experience exists regarding mechanical properties and production methods. Thus, appropriate materials can be selected from a large pool in order to meet existing application requirements.

[0032] For the purposes of the present invention, the term “synthetic textile” shall particularly be understood to encompass any flexible material consisting of a network of synthetic fibers, e.g. yarns or threads. Yarn may be produced by spinning synthetic fibers to produce long strands. Synthetic textiles may be produced by weaving, knitting, crocheting, knotting, felting, or braiding. Woven textiles are to be understood in particular as a flat fabric comprising at least two interlaced thread systems arranged essentially perpendicular to one another (for instance warp and weft). In this context, a knitted textile or knitted fabric is to be understood in particular to mean a textile produced by interlooping of yarns. The term “synthetic textile” shall also include non-woven fabrics made from intermingled or bonded-together fibers and shall encompass felt, which is neither woven nor knitted.

[0033] Non-limiting examples for the soft polymeric foam are expanded polyolefin foams such as expanded polyethylene foam (EPE foam), flexible polyurethane (PUR) foams, or a combination of at least two of these foams.

[0034] Preferably, the at least one dielectric, planar, flexible carrier is made at least for a most part from a material that is selected from a group of materials formed by polyethylene terephthalate (PET), polyimide (PI), polyetherimide (PEI), polyethylene naphthalate (PEN), polyether ether ketone (PEEK) and selected combinations of at least two of these materials.

[0035] In another aspect of the invention, a flexible flat cable-to-electrical wire encapsulated connector device is provided. The flexible flat cable-to-electrical wire encapsulated connector comprises an electrical connection encapsulation device as disclosed herein, wherein the flexible flat cable comprises a plurality of electrically conductive lines. The flexible flat cable-to-electrical wire encapsulated connector device further includes a plurality of discrete electrical wires. Each of the discrete electrical wires is electrically connected to at least one of the electrical connector members.

[0036] The benefits described in context with the electrical connection encapsulation device apply to the flexible flat cable-to-electrical wire encapsulated connector device to the full extent.

[0037] In yet another aspect of the invention, a method for producing a flexible flat cable-to-electrical wire encapsulated connector device as disclosed herein is provided. The method comprises at least the following steps: - preparing a first subassembly unit that comprises the flexible flat cable and the plurality of discrete electrical wires being electrically connected to the plurality of electrical connector members, - preparing a second subassembly unit comprising at least the first flat, soft and pliable material layer and a layer of adhesive material or the double- sided adhesive tape, - preparing a third subassembly unit comprising at least the second flat, soft and pliable material layer and a layer of adhesive material or the double- sided adhesive tape, - arranging the subassembly unit on a conveyor unit,

- by operating the conveyor unit, transporting the first subassembly unit to a first laminating station, - pressing the first subassembly unit and the second subassembly unit against each other, with the layer of adhesive material or the double-sided adhesive tape facing the plurality of discrete electrical wires, for establishing an adhesive bond, - by operating the conveyor unit, transporting the bonded-together first subassembly unit and second subassembly unit to a second laminating station, and - pressing the bonded-together first subassembly unit and second subassembly unit and the third subassembly unit against each other, with the layer of adhesive material or the double-sided adhesive tape of the third subassembly unit facing the surface of the planar, flexible carrier opposite of the surface with the plurality of discrete electrical wires, for establishing an adhesive bond.

[0038] The proposed method can enable a fast, reliable and cost-efficient production of flexible flat cable-to-electrical wire encapsulated connector devices.

The method can further provide high flexibility with regard to a bill of materials, and a number of layers can be changed without a need for modification of the manufacturing equipment.

[0039] In suitable embodiments, the first, second and third subassembly units can be prepared and held in stock.

[0040] Preferably, the conveyor unit comprises a conveyor belt, and in particular a linear conveyor belt. This can allow for a short and hardware-and cost-efficient production line.

[0041] In preferred embodiments of the method, the conveyor unit comprises means to provide sufficient reaction force during execution of the steps of pressing. By that, setup times during production of the flexible flat cable-to- electrical wire encapsulated connector devices can be avoided.

[0042] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.

[0043] It shall be pointed out that the features and measures detailed individually in the preceding description can be combined with one another in any technically meaningful manner and show further embodiments of the invention. The description characterizes and specifies the invention in particular in connection with the figures.

Brief Description of the Drawings

[0044] Further details and advantages of the present invention will be apparent from the following detailed description of not limiting embodiments with reference to the attached drawing, wherein: Fig. 1 schematically illustrates a flexible flat cable-to-electrical wire encapsulated connector device in an operational state, comprising an electrical connection encapsulation device in accordance with the invention, in a perspective view; Fig. 2 schematically illustrates another embodiment of an electrical connection encapsulation device in accordance with the invention, in a sectional side view, Fig. 3 schematically shows a setup for executing the method pursuant to Fig. 3; and Fig. 4 is a flow chart of a method for producing the flexible flat cable-to-electrical wire encapsulated connector device pursuant to Fig. 2.

Description of Preferred Embodiments

[0045] Fig. 1 schematically illustrates a flexible flat cable-to-electrical wire encapsulated connector device 10 in an operational state, comprising an electrical connection encapsulation device 12 in accordance with the invention, in a perspective view.

[0046] The electrical connection encapsulation device 12 includes a flexible flat cable 14. The flexible flat cable 14 comprises a dielectric, planar, flexible carrier 16 that has a first surface 18, which is facing upwards in the illustration of Fig. 1, and an opposite second surface 20, which is facing downwards in the illustration of Fig. 1, and is arranged in parallel to the first surface 18.

[0047] In this specific embodiment, the dielectric, planar, flexible carrier 16 is completely made from polyetherimide (PE!) and has a thickness of about 75 um. In other embodiments, the dielectric, planar, flexible carrier may be made at least for a most part from a material that is selected from a group of materials formed by polyethylene terephthalate (PET), polyimide (PI), polyethylene naphthalate (PEN), polyether ether ketone (PEEK) and selected combinations of at least two of these materials. In other embodiments, a thickness of the dielectric, planar, flexible carrier may be selected in a range between 75 um and 0.35 mm.

[0048] The second surface 20 of the flexible flat cable 14 is equipped with a plurality of four electrically conductive lines 22, 24, 26, 28. The four electrically conductive lines 22, 24, 26, 28 are attached to the second surface 20 in a spaced manner and run parallel to a direction of extension 42 of the dielectric, planar, flexible carrier 16. The four electrically conductive lines 22, 24, 26, 28 may be attached to the second surface 20 by applying electrically conductive ink comprising silver or copper in a screen printing or ink jet printing process in combination with a curing process, or, alternatively, by laminating copper foil onto the second surface 20, or by any other method that appears to be suitable to those skilled in the art. A thickness of the four electrically conductive lines 22, 24, 26, 28 in a direction 44 that is perpendicular to the surfaces 18, 20 of the flexible carrier 16 (in the following also referred to as “perpendicular direction 44”) may range between 10 um and 30 um and in this specific embodiment is selected to be about 20 um.

[0049] The flexible flat cable 14 comprises a connecting end region 40. The four electrically conductive lines 22, 24, 26, 28 extend to an outer end of the connecting end region 40, where each one of the four electrically conductive lines 22, 24, 26, 28 is ending in a terminal pad 30. The electrical connection encapsulation device 12 further includes a plurality of four electrical connector members 32, 34, 36, 38, which in this specific embodiment are designed as crimp connectors, arranged to partially overlap the electrically conductive lines 22, 24, 26, 28 in the perpendicular direction 44.

[0050] The flexible flat cable-to-electrical wire encapsulated connector device 10 further includes a plurality of two discrete electrical wires 46, 48 made from copper. Each of the two discrete electrical wires 46, 48 is electrically connected bycrimping to an end of one of the electrical connector members 32, 38 that is facing away from the connecting end region 40. The other ends of the electrical connector members 32, 38 that are facing away from the electrical wires 46, 48 match to the terminal pads and partially overlap the respective electrically conductive line 22, 28 in the perpendicular direction 44. Each of these other ends provide an electrical contact between one of the discrete electrical wires 46, 48 and one of the electrical conductive lines 22, 28 that are arranged close to outer edges of the flexible flat cable 14.

[0051] The electrical connection encapsulation device 12 further includes a first flat, soft and pliable material layer 50 of rectangular shape that is attached to the first surface 18 of the flexible carrier 16 at the connecting end region 40 by an adhesive bond. The first flat, soft and pliable material layer 50 is arranged to partially overlap the four electrically conductive lines 22, 24, 26, 28 in the connecting end region 40 in the perpendicular direction 44 and to extend beyond the ends of the four electrical connector members 32, 34, 36, 38 that are facing away from the connecting end region 40, covering a portion of the two discrete electrical wires 46, 48. In this specific embodiment, the adhesive bond is provided by a double-sided adhesive tape. In other embodiments, the adhesive bond may be provided by a layer of adhesive material. In both cases, the adhesive may be formed by a pressure-sensitive adhesive. A thickness of the adhesive bond may range between 50 um and 1.0 mm. Adhesive bonds provided by a double-sided adhesive tape may tend to be closer to the upper limit, whereas adhesive bonds provided by a layer of adhesive material may tend to be closer to the lower limit.

[0052] The electrical connection encapsulation device 12 further comprises a second flat, soft and pliable material layer 52 of rectangular shape that is attached to the second surface 20 of the flexible carrier 16 at the connecting end region 40 by an adhesive bond. The second flat, soft and pliable material layer 52 is arranged to partially overlap the four electrically conductive lines 22, 24, 26, 28 in the connecting end region 40 in the perpendicular direction 44 and to extend beyond the ends of the four electrical connector members 32, 34, 36, 38 that are facing away from the connecting end region 40, covering a portion of the two discrete electrical copper wires 46, 48. In this specific embodiment, the adhesive bond is provided by a double-sided adhesive tape. In other embodiments, theadhesive bond may be provided by a layer of adhesive material. In both cases, the adhesive may be formed by a pressure-sensitive adhesive.

[0053] The first 50 and the second flat, soft and pliable material layer 52 have same outer dimensions and are arranged to completely overlap each other in the perpendicular direction 44. In this specific embodiment, they are completely made from a soft polymeric foam, namely expanded polyethylene foam (EPE foam), which is readily commercially available. In other embodiments, though, they may be made, at least for a most part, also from a synthetic textile or from a combination of a soft polymeric foam and a synthetic textile. A thickness of the first flat, soft and pliable material layer 50 and the second flat, soft and pliable material layer 52 in the perpendicular direction 44 may be selected in a range between

0.1 mm and 5.0 mm. The thickness of the first flat, soft and pliable material layer 50 and the thickness of the second flat, soft and pliable material layer 52 may be chosen to be equal, but they may as well be chosen to be different, depending on the specific application.

[0054] The second flat, soft and pliable material layer 52, which has a surface that is facing towards the surface 20 of the planar, flexible carrier 16 that is equipped with the plurality of four electrically conductive lines 22, 24, 26, 28, comprises an aperture 54 (or through-hole) that in this specific embodiment is square-shaped, and that is configured for taking up, in the operational state, an end portion of two 34, 36 of the plurality of four electrical connector members 32, 34, 36, 38, which are electrically connected to electrically conductive lines 24, 26 that are arranged in a middle region of a width of the flexible flat cable 14. During a manufacturing process, the aperture 54 provides access to the two 34, 36 of the plurality of four electrical connector members 32, 34, 36, 38 and further provides installation space for installing bulk electrical components such as a resistor 56, as indicated in Fig. 1, which is electrically connected between the two electrical connector members 34, 36 that, in turn, are electrically connected to the electrically conductive lines 24, 26 that are arranged in the middle region of the width of the flexible flat cable 14.

[0055] Fig. 2 schematically illustrates an alternative embodiment of an electrical connection encapsulation device 12' in accordance with the invention, in a sectional side view. In order to avoid unnecessary repetitions, only differences withrespect to the first embodiment pursuant to Fig. 1 will be described. For features in Fig. 2 that are not described in context with the alternative embodiment, reference is made to the description of the first embodiment.

[0056] In comparison to the embodiment shown in Fig. 1, the electrical connection encapsulation device 12' pursuant to Fig. 2 further comprises a first flat, stiff material layer 58 that is attached by an adhesive bond to a surface of the first flat, soft and pliable material layer 50 that is facing away from the flexible carrier 16. The electrical connection encapsulation device 12' also includes a second flat, stiff material layer 60 that is attached by an adhesive bond to an open surface of the second flat, soft and pliable material layer 52 that is facing away from the flexible carrier 16.

[0057] In this specific embodiment, the first flat, stiff material layer 58 and the second flat, stiff material layer 60 are completely made from polyethylene terephthalate (PET). In other embodiments, the first flat, stiff material layer and the second flat, stiff material layer may be made, at least for a most part, from a material that is selected from a group of materials formed by polyimide (PI), polyetherimide (PEI), polyethylene naphthalate (PEN), polyoxymethylene (POM), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polyether ether ketone (PEEK), metal foil and selected combinations of at least two of these materials.

[0058] A thickness of the first flat, stiff material layer 58 and the second flat, stiff material layer 60 in the perpendicular direction 44 may be selected in a range between 10 um and 3.0 mm. The thickness of the first flat, stiff material layer 58 and the thickness of the second flat, stiff material layer 60 may be chosen to be equal, but they may as well be chosen to be different, as indicated in Fig. 2, depending on the specific application.

[0059] The electrical connection encapsulation device 12' comprises a dielectric protection layer 62 that is arranged to cover and to be in direct contact with a portion of the plurality of four electrically conductive lines 22, 24, 26, 28 in the connecting end region 40. The dielectric protection layer 62 extends beyond the first flat, soft and pliable material layer 50 and the second flat, soft and pliable material layer 52 in a direction away from the connecting end region 40. The dielectric protection layer 62 may be made for a most part or completely from polyurethane or any other material that appears to be suitable to those skilled inthe art. A thickness of the dielectric protection layer 62 in the perpendicular direction 44 may be selected in a range between 10 um and 80 um.

[0060] The aperture 54 in the second flat, soft and pliable material layer 52 in this specific embodiment is arranged for taking up, in the operational state, end portions of the plurality of four electrically conductive lines 22, 24, 26, 28.

[0061] In the following, a method for producing a flexible flat cable-to-electrical wire encapsulated connector device with the electrical connection encapsulation device 12' pursuant to Fig. 2 will be described with reference to Figs. 2, 3 and 4, which schematically show a production setup in Fig. 3 for executing the method as show in a flow chart in Fig. 4.

[0062] The production setup includes a conveyor unit 72 comprising a linear conveyor belt 74 and a controllable electric drive (not shown) for driving the conveyor belt 74. The setup further comprises a pick and place station 76, a first laminating station 78 and a second laminating station 80. The linear conveyor belt 74 is configured to move items to at least these three stations 76, 78, 80 along one conveying direction 82. At the first laminating station 78 and at the second laminating station 80 the production setup further comprises a pressure stamp (not shown) for applying a mechanical load from above or from below, respectively, and also a sufficiently rigid platform (not shown) that is extendable during stops of the linear conveyor belt 74 to provide sufficient reaction force against a mechanical load applied by the respective pressure stamp.

[0063] A first subassembly unit 84 that comprises the flexible flat cabie 14 and the plurality of two discrete electrical copper wires 46, 48 that are electrically connected to the plurality of two electrical connector members 32, 38 is prepared in a preparatory step 90. As an alternative step 90’, a plurality of first subassembly units 84 can also be prepared in advance, held in stock and procured for production.

[0064] As a second subassembly unit 86, a sandwiched assembly of the second flat, stiff material layer 60, a double-sided adhesive tape 70, the second flat, soft and pliable material layer 52, and another double-sided adhesive tape 68 is prepared in a preparatory step 92. As an alternative step 92', a plurality of secondsubassembly units 86 can also be prepared in advance, held in stock and procured for production.

[0065] As a third subassembly unit 88, a sandwiched assembly of a double-sided adhesive tape 66, the first flat, soft and pliable material layer 50, another double- sided adhesive tape 64 and the first flat, stiff material layer 58 is prepared in a preparatory step 94. As an alternative step 94', a plurality of third subassembly units 88 can also be prepared in advance, held in stock and procured for production.

[0066] In a next step 96 of the method, the first subassembly unit 84 is arranged at the pick and place station 76. By operating the conveyor unit 72, the first subassembly unit 84 is transported to the first laminating station 78 in another step 98. There, the first subassembly unit 84 and the second subassembly unit 86 are pressed against each other in a next step 100, with the double-sided adhesive tape 68 facing the plurality of discrete electrical wires 46, 48, for establishing an adhesive bond by operating the pressure stamp to apply a predetermined mechanical load from above and by extending a sufficiently rigid platform from below.

[0067] By operating the conveyor unit 72 in a next step 102, the bonded-together first 84 and second subassembly unit 86 are transported to the second laminating station 80. There, the bonded-together first 84 and second subassembly unit 86 and the third subassembly unit 88 are pressed against each other in a next step 104, with the double-sided adhesive tape 66 of the third subassembly unit 88 facing the surface 18 of the planar, flexible carrier 16 opposite of the surface 20 with the plurality of discrete electrical wires 46, 48, for establishing an adhesive bond by operating the pressure stamp to apply a predetermined mechanical load from below and by extending a sufficiently rigid platform from above.

[0068] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments.

[0069] Other variations to be disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a studyof the drawings, the disclosure, and the appended claims.

In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article

“a” or “an” does not exclude a plurality, which is meant to express a quantity of atleast two.

The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannotbe used to advantage.

Any reference signs in the claims should not be construedas limiting scope.

List of Reference Symbols flexible flat cable-to-electrical 50 first flat, soft and pliable material wire encapsulated connector layer device 52 second flat, soft and pliable 12 electrical connection material layer encapsulation device 54 aperture 14 flexible flat cable 56 resistor 16 dielectric, planar, flexible carrier 58 first flat, stiff material layer 18 first surface 60 second flat, stiff material layer second surface 62 dielectric protection layer 22 electrically conductive line 64 double-sided adhesive tape 24 electrically conductive line 66 double-sided adhesive tape 26 electrically conductive line 68 double-sided adhesive tape 28 electrically conductive line 70 double-sided adhesive tape terminal pad 72 conveyor unit 32 electrical connector member 74 linear conveyor belt 34 electrical connector member 76 pick and place station 36 electrical connector member 78 first laminating station 38 electrical connector member 80 second laminating station 40 connecting end region 82 conveying direction 42 direction of extension 84 first subassembly unit 44 perpendicular direction 86 second subassembly unit 46 discrete electrical wire 88 third subassembly unit 48 discrete electrical wire Method steps: 90 prepare first subassembly unit 92 prepare second subassembly unit 94 prepare third subassembly unit 96 arrange first subassembly unit at pick and place station 98 transport first subassembly unit to first laminating station 100 press first subassembly unit and second subassembly unit against each other

Claims

1. An electrical connection encapsulation device (12; 12") for electrically connecting a flexible flat cable (14) to discrete electrical wires (46, 48), comprising - a flexible flat cable (14) having a connecting end region (40) and including at least one dielectric, planar, flexible carrier (16) having a first surface (18) and an opposite second surface (20) arranged in parallel to the first surface (18), wherein at least one out of the first surface (18) and the second surface (20) is equipped with at least one electrically conductive line (22, 24, 26, 28), being attached to the respective surface (20) and extending at least within the connecting end region (40), - a first flat, soft and pliable material layer (50) that is attached to the first surface (18) of the flexible carrier (16) at the connecting end region (40) by an adhesive bond (66), - a second flat, soft and pliable material layer (52) that is attached to the second surface (20) of the flexible carrier (16) at the connecting end region (40) by an adhesive bond (68), - at least one electrical connector member (32, 34, 36, 38) that is electrically connectable to a discrete electrical wire (46, 48) with one end facing away from the connecting end region (40), and whose other end is facing towards the connecting end region (40) and is arranged to partially overlap the at least one electrically conductive line (22, 24, 26, 28) in a direction (44) that is perpendicular to the surfaces (18, 20) of the flexible carrier (16) for providing an electrical contact to the at least one electrically conductive line (22, 24, 26, 28) at least in an operational state, wherein the first flat, soft and pliable material layer (50) and the second flat, soft and pliable material layer (52) are arranged to at least partially overlap the at least one electrically conductive line (22, 24, 26, 28) in the connecting end region (40) in the perpendicular direction (44), and to extend beyond the end of the at least one electrical connector member (32, 34, 36, 38) that is facing away from the connecting end region (40).

2. The electrical connection encapsulation device (12') as claimed in claim 1, further comprising at least a first flat, stiff material layer (58) that is attached byan adhesive bond (64) to the first flat, soft and pliable material layer (50) or to the second flat, soft and pliable material layer (52), to a surface facing away from the flexible carrier (16).

3. The electrical connection encapsulation device (12') as claimed in claim 2, further comprising at least a second flat, stiff material layer (60) that is attached by an adhesive bond (70) to an open surface of the first flat, soft and pliable material layer (50) or the second flat, soft and pliable material layer (52) that is facing away from the flexible carrier (16).

4. The electrical connection encapsulation device (12; 12") as claimed in any one of the preceding claims, wherein at least one of the adhesive bonds is provided by a layer of adhesive material.

5. The electrical connection encapsulation device (12; 12") as claimed in any one of the preceding claims, wherein at least one of the adhesive bonds is provided by a double-sided adhesive tape (64, 66, 68, 70).

6. The electrical connection encapsulation device (12; 12') as claimed in any one of the preceding claims, wherein an adhesive material of at least one of the adhesive bonds (64, 66, 68, 70) is formed by a pressure-sensitive adhesive.

7. The electrical connection encapsulation device (12; 12') as claimed in any one of the preceding claims, wherein the second flat, soft and pliable material layer (52), which has a surface that is facing towards the surface (20) of the planar, flexible carrier (16) that is equipped with the at least one electrically conductive line (22, 24, 26, 28), comprises at least one aperture (54; 54") that is configured for taking up, in an operational state, at least a portion of the at least one electrically conductive line (22, 24, 26, 28) or at least a portion of the at least one electrical connector member (32, 34, 36, 38).

8. The electrical connection encapsulation device (12') as claimed in any one of the preceding claims, wherein at least one of the flat, soft and pliable material layers (50, 52) is made at least for a most part from a soft polymeric foam, a synthetic textile or a combination of both.

9. The electrical connection encapsulation device (12; 12") as claimed in any one of the preceding claims, wherein the at least one dielectric, planar, flexible carrier (16) is made at least for a most part from a material that is selectedfrom a group of materials formed by polyethylene terephthalate, polyimide, polyetherimide, polyethylene naphthalate, polyether ether ketone and selected combinations of at least two of these materials.

10. A flexible flat cable-to-electrical wire encapsulated connector device (10), comprising an electrical connection encapsulation device (12; 12') as claimed in any one of claims, the flexible flat cable (14) having a plurality of electrically conductive lines (22, 24, 26, 28), the flexible flat cable-to-electrical wire encapsulated connector device (10) further including a plurality of discrete electrical wires (46, 48), wherein each of the discrete electrical wires (46, 48) is electrically connected to at least one of the electrical connector members (32, 38).

11. A method for producing a flexible flat cable-to-electrical wire encapsulated connector device (10) as claimed in claim 10, the method comprising at least the following steps: - preparing (90) a first subassembly unit (84) that comprises the flexible flat cable (14) and the plurality of discrete electrical wires (46, 48) being electrically connected to the plurality of electrical connector members (32, 38), - preparing (92) a second subassembly unit (86) comprising at least the second flat, soft and pliable material layer (52) and a layer of adhesive material or the double-sided adhesive tape (68), - preparing (94) a third subassembly unit (88) comprising at least the first flat, soft and pliable material layer (50) and a layer of adhesive material or the double-sided adhesive tape (66), | 25 - arranging (96) the first subassembly unit on a conveyor unit (72), - by operating the conveyor unit (72), transporting (98) the first subassembly unit (84) to a first laminating station (78), - pressing (100) the first subassembly unit (84) and the second subassembly unit (86) against each other, with the layer of adhesive material or the double-sided adhesive tape (68) facing the plurality of discrete electrical wires (46, 48), for establishing an adhesive bond,

- by operating the conveyor unit (72), transporting (102) the bonded-together first subassembly unit (84) and second subassembly unit (86) to a second laminating station (80), and - pressing (104) the bonded-together first subassembly unit (84) and second subassembly unit (86) and the third subassembly unit (88) against each other, with the layer of adhesive material or the double-sided adhesive tape (66) of the third subassembly unit (88) facing the surface of the planar, flexible carrier (18) opposite of the surface (20) with the plurality of discrete electrical wires (46, 48), for establishing an adhesive bond.

12. The method as claimed in claim 11, wherein the conveyor unit (72) comprises means to provide sufficient reaction force during execution of the steps of pressing (100, 104).