WO2018130550A1

WO2018130550A1 - Vehicle component with foamed electrical conductive structure and manufacturing method for such a component

Info

Publication number: WO2018130550A1
Application number: PCT/EP2018/050525
Authority: WO
Inventors: Klaus Kallee; Leonhard Budjarek
Original assignee: Lisa Dräxlmaier GmbH
Priority date: 2017-01-12
Filing date: 2018-01-10
Publication date: 2018-07-19
Also published as: DE102017100510A1

Abstract

The invention relates to a method for producing a vehicle component (1) having an electrical conductive structure (3) arranged thereon which extends at least between a first electrical contact point (4) for feeding an electric current and a second electrical contact point (5), spaced apart therefrom, for picking off an electric current. According to the invention, the vehicle component (1) is provided. The conductive structure (3) is then formed by applying a foamed, electrically conductive metal material on a surface (2) of the vehicle component (1), specifically in such a manner that the metal material extends consistently between the at least two electrical contact points (4, 5). The invention further relates to a vehicle component (1) having a foamed electrical conductive structure (3).

Description

VEHICLE COMPONENT WITH DUMPED ELECTRIC CONDUCTIVE STRUCTURE AND MANUFACTURING METHOD FOR SUCH A

Technical area

The present invention relates to a method of manufacturing a (power) vehicle component having an electrical guide structure that can be used to replace an electrical line or a vehicle wiring harness. Further, the invention relates to a vehicle component, such as an interior trim part for a door, a vehicle floor, a vehicle roof or the like, with an electrically conductive structure.

State of the art

For example, from DE 10 2007 022 764 B3 it is known that a plurality of electrical lines is laid in motor vehicles, the electrical signals and / or

Transfer working currents between electrical contact points, so for example, signal and / or energy sources with electrical loads or consumers of the vehicle interconnect. The production of vehicle-specific or

Vehicle electrical equipment-specific electrical lines, which may also be combined into cable sets or a wiring harness, takes place on so-called building rebates and designed consuming, since the lines along their longitudinal extent between a start and a target connector (as an example of an electrical contact point) in a variety of Line recordings are hooked to summarize them and eg to be provided with holding parts or other fastening means for attachment to the vehicle.

This process is time-consuming and can currently only be realized manually. The predominantly manual production is particularly due to the necessary

Movements, such. As the threading of lines, the wrapping and In particular branching of cable strands, the striking of contacts and end plugs to the lines, the fixing of strands with cable ties and the

Attachment of holding parts. To date, these movements can only be partially automated, since automation is already made more difficult by the current construction of the construction rescue and the resulting complexity of the movements to be controlled.

DE 101 21 925 A1 discloses a method according to the preamble of claim 1 and proposes for the simplified manufacture and assembly of electrical lines or

Wiring sets in motor vehicles before, electrical wires on a support, e.g. a door operator, to arrange. In this case, individual wires are laid mechanically on the support and fixed by hot glue. Subsequently, the bare wires can be covered with an electrically insulating protective layer. The disadvantage of this is that further wires with a partially difficult to handle longitudinal extension length must be laid so that to be controlled in an automation

Movements are still complex.

DESCRIPTION OF THE INVENTION It is therefore an object of the invention to create an easily produced possibility for connecting two contact points in a vehicle using means that are as simple as possible in terms of construction.

The object is solved by the subject matters of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description and the accompanying figures.

An inventive method for producing a vehicle component provides in principle that no cables, wires or wires are attached to the vehicle component more to connect an electrical connection between two electrical contact points of the vehicle with each other. Instead, an electrical guide structure, for example a current path, a type of large-area conductor track or the like, is provided which extends at least between a first electrical contact point for feeding and a spaced second electrical contact point for tapping an electrical Stroms extends. The contact points correspond in principle to the free ends of a conventional line or a cable to which previously electrical contact elements, such as connectors, cable lugs or the like, are attached. They are too

According to the invention, electrical or electronic components are provided by e.g. Plugging, screwing, soldering, welding, crimping or a similar connection technology.

According to the invention, first the vehicle component, which is preferably an interior trim part, such as a door or trunk trim, a

Door sill trim, a headliner or the like, is provided. It is also possible to provide a guide structure carrier manufactured separately from the vehicle component, which is set up to be subsequently attached to the vehicle component. The vehicle component may e.g. from a plastic, possibly also with fiber or

Natural fiber shares exist and possibly have a surface structuring. At least at the sections to which the lead structure is to be attached, the

Vehicle component have a comparatively rough surface to promote adhesion of the conductive structure. This roughness can be accomplished either by the tool used for the production of the vehicle component or subsequently by a corresponding section-wise roughening. However, the surface can also be made porous, at least in sections, so that the conductive structure can better adhere to the vehicle component by filling the pores. On or on the vehicle component, the conductive structure is then formed in principle by prototyping by placing a foamed, electrically conductive metal material on a surface, e.g. Surface of the vehicle component as

Foam composition is applied or applied. Metal foams are known in the field of materials science and constitute a porous metal material, e.g. may be based on aluminum, copper, nickel or other electrically conductive metal. The foamed metal material is applied so that it extends continuously between the at least two electrical contact points, ie - similar to a conductor track or a cable - an electrically conductive direct connection between the two

Makes contact points. It is possible that the metal material adheres to it by itself or by admixed additives or due to the surface structuring of the vehicle component and is held solely by it. The inventive method brings about several advantages. Thus, by the direct application of the metal material to the vehicle component motion sequences that would be necessary in the production of a wiring set, saved, and thus the wiring harness provision easier to be automated. For example, when using a foam, it eliminates the need to wrap the cables and attach them

Holding parts for attachment to the vehicle component or anywhere on the vehicle. Even the previous installation in the vehicle by laying the line, contact or

Connecting the same with contact points and attaching to the vehicle is simplified, since only the previously required vehicle component mounted and then only the guide structure still has to be electrically coupled. Even a construction kit does not need to be made available, since the lead structure as foam mass directly on the

Vehicle component is applied.

An advantageous development of the invention provides that the metal material bead-shaped and / or linear with a matched to a predetermined current carrying capacity

Cross-sectional size is applied. Depending on whether an electrical load, such as a power window motor or the like, is to be controlled or supplied with a working current via the conductive structure, or whether only one (smaller absolute) control current is to be conducted, the required current-carrying capacity of the conductive structure can vary be. Here, similar to a conventional line, the cross-sectional size of the lead structure may be adjusted by referring to a

Length section more or less foam mass is applied.

In order to achieve electrical insulation of the actual (in the case of cables) current conductor, as in the case of conventional cables or cables, a foamed, electrically insulating plastic can be applied as an electrical insulation on and / or around the conductive structure at least in sections. This can be done successively by first the metal material as a foam mass and then the plastic as

Foam composition is applied. But it is also possible that a tool for

Applying the metal material is set to simultaneously a track with the

Metal material and slightly to the rear offset a shell, apply a coating or the like with the plastic. The foamed metal material may be a composition or a mixture of a metal powder and a preferably powdered blowing agent. The propellant is preferably a metal hydride, such as titanium hydride. Both ingredients present in powder form are first mixed together and then compacted by sintering or extrusion to form a starting material. The starting material is then heated to a temperature above the melting point of the metal, ie about 1085 ° C for copper or about 660.3 ° C for aluminum. In this case, the propellant, eg

Titanium dihydride, gaseous hydrogen free and thus foams up the mixture. A particularly high cost savings through automated production results when the application by a computer-controlled, motor-driven

Foaming device takes place. For example, this can be arranged on a robot arm, which can be driven in particular electrically or hydraulically. This can be controlled by a computer-aided control device, so that the method can be automated or performed by machine.

In order to apply the metal material well, it is advantageous if it is foamed and / or applied with the supply of heat. This can e.g. by the heated metering device, which has, for example, one or more heated nozzles, or the like. The metering device can also be adapted to simultaneously, possibly spatially offset slightly from one another, apply both the metal material and the plastic substantially simultaneously.

The guide structure can be applied to a flat surface of the vehicle component. However, to protect the conductive structure from mechanical damage or to improve the electromagnetic compatibility, it may also be advantageous if the metal material is introduced into a negative contour formed on the vehicle component, such as a recess in the form of a groove, or the like. The line structure can mainly replace previously used line devices. For this purpose, however, it is advantageous if the guiding structure is e.g. can be contacted in order to integrate them in a vehicle electrical system. For this it has proved to be advantageous if a preferably solid electrical contact element provided and with the

Metal material is at least partially foamed. Ideally that is Contact element arranged at a (free) longitudinal end of the guide structure, namely at the contact points. It is conceivable that the contact element is held solely by the foaming with the metal material to the vehicle component. However, it can also be additionally fastened, for example by a fastening means which is connected to the vehicle component, or by a holder which is connected to the vehicle component or formed thereon and holds the contact element.

The invention also relates to a vehicle component, such as an interior trim panel, having an electrical lead structure mounted thereon. According to the invention, the conductive structure as foamed, electrically conductive metal material on at least one surface of the

Vehicle component such applied by prototyping that it extends continuously between a first electrical contact point for feeding and a spaced therefrom, second electrical contact point for tapping an electric current. The contact points are intended to produce an electrical connection to the vehicle electrical system, an electrical energy or signal source and / or an electrical consumer.

The vehicle component can be prefabricated by first being replaced by e.g. Injection molding or another molding method of e.g. a plastic, possibly with fibers, molded and then provided with the foamed metal material. This is a delivery of the vehicle component together with the attached lead structure to a

Vehicle manufacturers possible, the separate attachment of wiring sets deleted. The assembly in the vehicle is therefore also particularly simple, since only (still) the vehicle component (as before) must be mounted. Moreover, only the lead structure at the pads needs to be replaced by e.g. electrical connectors are contacted. It also eliminates on the supplier side, the production of the wiring harness, which must be made mainly manually due to wrapping with wrapping tapes and the attachment of holding parts for attachment to the vehicle. Here, the invention provides a possibility for improved mechanical or automated production.

For a good current carrying capacity, it is advantageous if the metal material is applied bead-shaped or linear on the surface of the vehicle part. So far, electrical cables or cables are surrounded by an insulating jacket. In order to electrically insulate the electrical conductive structure, it can be provided that the conductive structure is at least partially surrounded by a foamed, electrically insulating plastic. Advantageously, the application of the plastic by the same or at least a similar method as the application of the metal material for the lead structure, so that this can be done even substantially simultaneously.

For a simple electrical connection to e.g. the vehicle electrical system, it has proved to be advantageous if at least one of the contact points is formed by a solid electrical contact element, at least in sections of the

Surround metal material, so for example. is foamed, is. The contact element may e.g. be designed for a plug-in, screwing or similar connection, so that e.g. a connector plugged and thereby can be connected to the lead structure. Short description of the figures

Hereinafter, advantageous embodiments of the invention will be explained with reference to the accompanying drawings. FIG. 1 shows a component according to the invention, produced according to the invention

Method and

Figure 2 shows another embodiment of the method according to the invention. The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently provided with the same reference numerals.

Detailed description

FIG. 1 shows a schematic illustration of a vehicle component 1, which may be, for example, an interior trim part for, for example, a vehicle door. In particular, it may be a carrier which is made of a plastic. At or adjacent to the vehicle component 1 is an electric (not shown) Functional element arranged, which may be, for example, a power window motor, a vehicle lighting, a Versteilmotor for vehicle mirrors or the like. The vehicle component 1 is adapted to be attached to the vehicle. In the prior art, such a functional element has hitherto been controlled or supplied with electric current via one or more electrical lines. For this purpose, the line was integrated into a vehicle (power) electrical system, that is, for example, electrically connected to an energy source.

The vehicle component 1 has a surface 2, which is embodied here as an example as a flat surface, but may also have positive and negative contours. The surface 2 of the vehicle component 1 has a surface structuring which makes it possible to carry an electrical guide structure 3 with a current carrying capacity for conducting a control or load current. The conductive structure 3 adhesively adheres to the surface 2 and is therefore in this

Embodiment not further attached. That is, the vehicle component 1 and the

Guide structure 3 are adhesively bonded together by adhesion. The conductive structure 3 extends in the finished state throughout the area 2 between electrical contact points 4 and 5, one of which serves to connect the conductive structure 3 to the vehicle (power) electrical system and the other of the connection to the functional element. Both contact points 4, 5 are solid, e.g. formed from a sheet material formed contact elements. The contact points 4, 5 correspond functionally so

conventional contact elements which are attached to free ends of electrical lines. The contact elements are e.g. designed as plug contacts, so that the lead structure 3 can be connected by simply plugging to the vehicle electrical system. It is indicated here by dashed lines that the respective contact point 4, 5 forming contact element is foamed on one side, that is surrounded by the metal foam of the guide structure 3.

The conductive structure 3 is formed by a foamed copper-based metal material which extends in a bead shape and continuously across the surface 2, to reproduce a wiring harness with one or more flexible electric lines, as used in the prior art. The cross-sectional size of the bead is sized according to the current carrying capacity required for the application, and is even dimensioned here to carry a working current. The metal foam for the conductive structure 3 consists essentially of a metal powder, which is exemplified here copper due to its good electrical conductivity, and also a powdered metal hydride, which is here for example titanium hydride. These two

Ingredients are mixed together and compacted by sintering or extrusion to a starting material. The starting material is then heated to a temperature above the melting point of the metal, whereby the metal hydride releases gaseous hydrogen and the mixture foams.

The conductive structure 3 is surrounded or encased by an electrical insulation 6, which is indicated here in sections. The insulation 6 is formed by an electrically insulating, foamed plastic, so a polymer foam, which is applied to and / or around the guide structure 3 around. The polymer foam also adheres to the surface 2 of the vehicle component 1, but may also be secured by additional fastening means.

FIG. 1 also shows a method for producing the conductive structure 3 on the surface 2 of the vehicle component 1. It can be seen that a computer-aided controlled

Foaming device 7 is used, which has a first metering 7.1 and a second metering 7.2. Both metering nozzles 7.1, 7.2 are arranged on a (not shown) robot arm and also heated, so that the metal foam easily emerge from the foaming device 7 and can be distributed on the surface 2. The

Dosing nozzle 7.1 is set up to distribute the metal foam for the guide structure 3. Via the metering nozzle 7.2, the polymer foam for the electrical insulation 6 can be distributed on the surface 2.

In the exemplary embodiment according to FIG. 1, the vehicle component 1 is thus initially provided and then, by means of the metering nozzle 7.1 of the foaming device 7, first the metal foam for the guide structure 3 is applied by foaming and controlled guiding of the robot arm carrying the metering nozzle 7.1. Then, by means of the metering nozzle 7.2, which is guided by the same or a further robot arm, the polymer foam for the insulation 6 is applied to the metal foam of the guide structure 3. For this drives the

Robotic arm the route of the lead structure 3 from. The exemplary embodiment according to FIG. 2 differs from the exemplary embodiment shown in FIG. 1 in that the metering nozzles 7.1, 7.2 of the foaming device 7 are now held on a common carrier, such as the robot arm. As a result, here both dosing nozzles 7.1, 7.2 are guided together, ie simultaneously, over the surface 2 of the vehicle component 1. Ideally, the metering nozzle 7.1 is arranged for the metal foam of the guide structure 3 in the guide direction immediately before the metering nozzle 7.2, so that first the metal foam and only then the polymer foam for the iso-6 is applied. This also causes a short cycle time, since for applying the lead structure 3 and for isolating the corresponding route must be traversed only once.

After applying the conductive structure 3 and possibly the insulation 6, the vehicle component 1 is mounted in the vehicle, the contact points 4, 5 are connected to the vehicle electrical system.

LIST OF REFERENCE NUMBERS

1 vehicle component (for example, interior trim part)

2 area (e.g., surface)

3 Electrical conductive structure (e.g., metal foam)

4 electrical contact point (e.g., electrical contact element)

5 electrical contact point (e.g., electrical contact element)

6 insulation (e.g., insulating foam)

7 foaming device

7.1 Dosing nozzle

7.2 Dosing nozzle

Claims

Method for producing a vehicle component (1) with an electrical guide structure (3) arranged thereon, which extends at least between a first electrical contact point (4) for feeding in and a second electrical contact point (5) spaced apart for picking up an electric current through the steps:

Providing the vehicle component (1),

- Prototyping the conductive structure (3) by applying a foamed, electrically conductive metal material on a surface (2) of the vehicle component (1) such that the metal material extends continuously between the at least two electrical contact points (4, 5).

A method according to claim 1, characterized in that the metal material is bead-shaped with a matched to a predetermined current carrying capacity

Cross-sectional size is applied.

A method according to claim 1 or 2, characterized in that on and / or around the guide structure (3) around at least partially a foamed, electrically insulating plastic as electrical insulation (6) is applied.

Method according to one of the preceding claims, characterized in that a composition of a metal powder and a metal hydride is used as the blowing agent as the metal material.

Method according to one of the preceding claims, characterized in that the application by a computer-controlled, motor-driven

Foaming device (7) takes place.

A method according to claim 5, characterized in that the metal material is foamed and supplied with the supply of heat.

7. The method according to any one of the preceding claims, characterized in that the metal material in a formed on the vehicle component (1)

Negative contour is introduced.

8. The method according to any one of the preceding claims, characterized in that a solid electrical contact element provided and with the

Metal material is at least partially foamed.

9. Vehicle component (1) with an electrical conductive structure (3), characterized in that the conductive structure (3) as a foamed, electrically conductive metal material on at least one surface (2) of the vehicle component (1) is urgeformt such that they are continuous between a first electrical contact point (4) for feeding and a spaced second electrical contact point (5) for tapping an electric current extends.

10. Vehicle component (1) according to claim 9, characterized in that the

Metal material is applied bead-shaped or linear.

1 1. Vehicle component (1) according to claim 9 or 10, characterized in that the guide structure (3) is at least partially surrounded by a foamed, electrically insulating plastic.

12. Vehicle component (1) according to one of claims 9 to 1 1, characterized in that at least one of the contact points (4, 5) is formed by a solid electrical contact element, at least in sections of the

Metal material is surrounded.