Plastic laminate and method of manufacture

Abstract

A plastic laminate (100) comprises: at least one plastic layer (200), the plastic layer (200) having at least one through hole (210); at least one heating conductor (300) connected to the at least one plastic layer (200), the heating conductor (300) comprising a heating section (310) and at least two contact sections (320); at least one electrical contact assembly (400); and at least one connecting part (500) which passes through the at least one through-hole (210) of the plastic layer (200) at least in sections and is fixed to the plastic layer (200), the at least one connecting part (500) establishing a low-resistance electrical connection between at least one of the contact sections (320) of the heating conductor (300) and the electrical contact arrangement (400).

Description

Technical Field

[0001] The present invention relates to a plastic laminate and a manufacturing method thereof. Background Art

[0002] Advances in the field of connection technology are described, especially in the field of motor vehicles. Summary of the Invention

[0003] One aspect of this specification relates to the following subject matter: A plastic laminate, comprising: at least one plastic layer having at least one through-hole; at least one heating conductor connected to the at least one plastic layer, the heating conductor including a heating section and at least two contact sections; at least one electrical contact assembly; and at least one connecting member that at least partially passes through the at least one through-hole of the plastic layer and is fixed to the plastic layer, wherein the at least one connecting member establishes a low-resistance electrical connection between at least one of the contact sections of the heating conductor and the electrical contact assembly.

[0004] By establishing such a low-resistance electrical connection between the contact section and the electrical contact assembly, on the one hand, a durable electrical connection is ensured, and on the other hand, a high heat input in the area of the connecting member is prevented. Therefore, the service life of the plastic laminate is extended. Therefore, the soldering process in the area of the plastic laminate is blocked or at least reduced.

[0005] Advantageously, the provided plastic laminate can be used as a cover plate for sensors in the field of motor vehicles. The low-resistance contact of the heating wire enables efficient and contact-proof energy supply, allowing for the desired heat input in the sensor-related area of the cover plate.

[0006] A feature of an advantageous example is that the at least one connecting member makes electrical and mechanical contact with at least one contact section of the heating conductor on a first side of the at least one plastic layer, and the at least one connecting member makes electrical and mechanical contact with the at least one electrical contact assembly on a second side of the at least one plastic layer opposite to the first side.

[0007] Advantageously, the arrangement and implementation of the contact of the heating conductor with the electrical contact assembly are structurally decoupled.

[0008] Advantageously, the arrangement and execution of the contact of the heating conductor with the electrical contact assembly are structurally decoupled.

[0009] A feature of an advantageous example is that the contact section of the heating conductor, the at least one plastic layer in sections, and the clamping section of the electrical contact assembly are clamped between a first section of the at least one connecting member and a second section of the at least one connecting member.

[0010] Advantageously, a low-resistance electrical connection is established in a simple manner.

[0011] A characteristic of an advantageous example is that the contact surface of the contact section of at least one connecting component facing the heating conductor has contact protrusions.

[0012] Through the contact protrusions, the contact of the contact section is improved in such a way that, for example, the paint layer of the heating conductor can be broken. Even without a coating, the contact protrusions increase the surface that is important for mechanical contact between the contact section and the connecting component. Therefore, the contact tends to become lower in resistance.

[0013] A characteristic of an advantageous example is that at least one connecting component is implemented as a rivet connection.

[0014] Advantageously, the rivet connection is durable because it is insensitive to thermal fluctuations and mechanical loads.

[0015] A characteristic of an advantageous example is that at least one other plastic layer is arranged on the side of at least one plastic layer facing away from the electrical contact assembly, and this other plastic layer segmentally surrounds the connecting component.

[0016] Advantageously, the connection assembly on this opposite side is thus electrically insulated. Therefore, degrees of freedom are created in the structural arrangement of the electrical contact of the heating conductor.

[0017] A characteristic of an advantageous example is that the contact section of the heating conductor is clamped between the contact surface of at least one connecting component facing at least one plastic layer and a conductive contact disk arranged between at least one plastic layer and the contact surface.

[0018] Advantageously, the electrical conductivity between the connecting component and the heating conductor can be further increased thereby.

[0019] A characteristic of an advantageous example is that the contact disk is arranged on the side of at least one plastic layer opposite to the side having the electrical contact assembly, wherein the contact disk protrudes beyond the adjacent section of the connecting component with a protrusion, wherein the contact section of at least one heating conductor is connected to the protrusion of the contact disk in a form-fitting manner, and wherein the contact disk has a through-hole through which at least one connecting component passes at least segmentally.

[0020] Advantageously, the contact is serially guided through the contact disk. Therefore, the contact of the heating conductor is implemented separately from the guidance to the opposite side electrically connected to the electrical contact assembly.

[0021] A characteristic of an advantageous example is that the contact surface of at least one contact disk facing away from at least one plastic layer has contact protrusions.

[0022] The contact protrusions of the contact disk enable further increasing and / or ensuring the electrical conductivity.

[0023] A favorable example is characterized in that the electrical contact component is a flexible or rigid printed circuit board.

[0024] Advantageously, contact sections are arranged on the printed circuit board. Electrical components can also be arranged on the printed circuit board.

[0025] A favorable example is characterized in that the printed conductors of the printed circuit board are electrically and mechanically contacted by means of connecting components.

[0026] A favorable example is characterized in that the heating section of the heating conductor passes through the sensor-related section of the plastic laminate.

[0027] Thus, advantageously, the sections of the plastic laminate used as the cover plate that are important for the sensor and its signal detection are heated.

[0028] A favorable example is characterized in that the plastic laminate includes: a light coupling-in region for coupling in light of a light source, a light coupling-out region for coupling out light, and a light conduction region for conducting the light coupled in through the light coupling-in region to the light coupling-out region.

[0029] Advantageously, backlighting of the plastic laminate used as the cover plate can thus be carried out.

[0030] A favorable example is characterized in that the light coupling-in region is located outside the sensor-related section of the plastic laminate, and the light coupling-out region is located inside the sensor-related section of the plastic laminate.

[0031] Advantageously, light can also be emitted in the sensor-related section, thereby creating design freedom, especially in the front region of the vehicle.

[0032] One aspect of this specification relates to a device for a motor vehicle, which includes: a housing; a radar transmitter and / or radar receiver arranged in the housing for transmitting and / or receiving radar signals; and a plastic laminate according to this specification, wherein the plastic laminate in the form of a cover plate at least partially closes an opening of the housing.

[0033] Another aspect of this specification relates to a method for manufacturing a plastic laminate, the method including: printing at least one side of at least one plastic layer; removing at least a part of the printed layer; and connecting at least one connecting component to at least one plastic layer. Description of the Drawings

[0034] In the drawings: Figures 1 to 4 A plastic laminate with connecting components is shown in cross section respectively; Figure 5Shows a device for a motor vehicle; Figure 6 Shows a motor vehicle; Figure 7 Shows a schematic flow chart for manufacturing a plastic laminate; Figures 8 to 10 Shows different examples of plastic laminates. Detailed Description

[0035] Figure 1 Shows a plastic laminate 100. The plastic laminate 100 includes: at least one plastic layer 200 having at least one through hole 210; at least one heating conductor 300 connected to the at least one plastic layer 200, the heating conductor 300 including a heating section 310 and at least two contact sections 320; at least one electrical contact assembly 400; and at least one connecting member 500 that at least partially passes through the at least one through hole 210 of the plastic layer 200 and is fixed to the plastic layer 200, wherein the at least one connecting member 500 establishes a low-resistance electrical connection between at least one of the contact sections 320 of the heating conductor 300 and the electrical contact assembly 400.

[0036] The heating conductor 300 is inserted into the plastic laminate 100 as a heating component and has a diameter in the range of, for example, 10 µm - 200 µm. The heating conductor 300 is, for example, coated with white paint or black UV paint. Of course, another paint can also at least partially cover the heating conductor 300. In another example, the heating conductor 300 is not painted.

[0037] The heating conductor 300 is arranged on the at least one plastic layer 200. In the example shown, the heating conductor 300 is located on a side of the at least one plastic layer facing away from the at least one contact assembly 400.

[0038] In the foregoing case, the connecting member 500 is implemented in a conductive manner and can thus be referred to as an electromechanical connecting member 500.

[0039] The contact assembly 400 is formed, for example, such that it is inserted into an injection mold together with the at least one plastic layer 200. When the mold is closed, scraping is performed outside the vertical or angled contact assembly 400 to keep the plastic melt away from the contact assembly 400.

[0040] Here, it is conceivable that the contact assembly 400 is inserted into the mold and connected to the film by injection overmolding. After this process, the rivet contacts must be closed after the component is completed.

[0041] At least one connecting component 500 makes electrical and mechanical contact with at least one contact section 320 of the heating conductor 300 on a first side of at least one plastic layer 200. At least one connecting component 500 makes electrical and mechanical contact with at least one electrical contact assembly 400 on a second side of at least one plastic layer 200 opposite the first side.

[0042] In the example, the contact section 320 of the heating conductor 300, the at least one plastic layer 200 in sections, and the clamping section 410 of the electrical contact assembly 400 are clamped between a first section 510 of at least one connecting component 500 and a second section 520 of at least one connecting component 500.

[0043] The first and second sections 510 and 520 of the connecting component 500 are connected to each other by means of a connecting section 530.

[0044] The contact surface 522 of at least one connecting component 500 facing the contact section 320 of the heating conductor 300 has contact protrusions in terms of surface roughness.

[0045] Alternatively, the contact section 320 of the heating conductor 300 can be inserted between wedge locking discs. Alternatively, only one wedge locking disc is used.

[0046] According to one example, at least one contact section 320 is laid multiple times, i.e., in a coil shape and / or in a meandering shape, on the contact surface 522 to increase the electrically effective contact surface.

[0047] The contact surface 512 of the first section 510 abuts against the clamping section 410 of the electrical contact assembly 400 and thus establishes an electrical connection between the contact section 320 of the heating conductor 300 and the contact section 420 of the electrical contact assembly 400.

[0048] The contact section 420 protrudes obliquely from the clamping section 410 and thus provides a flat plug or a pin plug in the sense of a plug contact, which can be electrically and mechanically contacted by means of a socket. Alternatively, the socket can also be part of the electrical contact assembly 400. With the proposed design, a high degree of freedom is brought to the extrusion molding of the contact section 420, and thus various geometries of the plug connection can be envisaged here.

[0049] The clamping section 410 includes a recess 412 through which the connecting component passes in sections.

[0050] In one example, at least one connecting component 500 is implemented as a rivet connection. The rivet, which is part of the connecting component 500, is configured, for example, as a solid rivet or a hollow rivet. The connecting component 500 uses a rivet made of a conductive material, such as copper, aluminum, or a copper alloy. The rivet is constructed such that it creates a surface with a minimum contact resistance between the components to be connected during installation. The rivet is made of a core material with high electrical conductivity and is optionally provided with a corrosion-resistant coating. The rivet connection has improved electrical conductivity, high reliability and durability, as well as a simple and cost-effective installation method compared to conventional mechanical connections.

[0051] In one example not shown in the figures, the connecting component 500 includes a screw with an external thread that engages into an internal thread of a mating component. Alternatively, a self-tapping screw or a self-drilling screw can also be used to engage into the mating component. Here, at least the screw or the mating component is guided through the through-hole 210.

[0052] One example provides that at least one further plastic layer 600 is arranged on the side of at least one plastic layer 200 facing away from the electrical contact assembly 400, and the further plastic layer 600 surrounds the connecting component 500 in sections.

[0053] For example, the surface 610 of at least the further plastic layer 600 forms the outer end of the plastic laminate 100 or is additionally provided with a surface coating.

[0054] In an alternative example of the plastic laminate 100, the further plastic layer 600 can be at least partially omitted.

[0055] Figure 2 Another example of the plastic laminate 100 is shown. This example provides that the contact section 320 of the heating conductor 300 is clamped between the contact surface 522 of at least one connecting component 500 facing at least one plastic layer 200 and a conductive contact disk 600 arranged between at least one plastic layer 200 and the contact surface 522.

[0056] The contact disk 600 includes a through-hole through which at least one connecting component 500 passes.

[0057] Figure 3 Another example of the plastic laminate 100 is shown. This example provides that the contact disk 600 is arranged on the side of at least one plastic layer 200 opposite to the side with the electrical contact assembly 400, wherein the contact disk 600 protrudes beyond the adjacent section 520 of the connecting component 500 with a protrusion 620, and wherein the contact section 320 of at least one heating conductor 300 is connected to the protrusion 620 of the contact disk 600 in a material-locking manner, and wherein the contact disk 600 has a through-hole through which at least one connecting component 500 passes at least in sections.

[0058] For example, the material-fit connection 624 between the contact pad 600 and the contact section 320 is a welded connection.

[0059] It is provided that the contact surface 622 of at least one contact pad 600 facing away from at least one plastic layer 200 has contact protrusions in terms of roughness.

[0060] In contrast to Figure 1 which is different, Figure 4 it is shown that the electrical contact assembly 400 is a flexible or rigid printed circuit board, wherein the printed conductors 422 of the printed circuit board are electrically and mechanically contacted by means of the connecting component 500.

[0061] For example, the contact section 420 is located on the printed circuit board, and the contact section 420 is connected to the connecting component 500 via the printed conductor 422. In addition, in this example, electronic components 490, such as resistors, capacitors, coils or integrated circuits, are located on the printed circuit board.

[0062] A printed circuit board according to Figure 4 can be used to replace the electrical contacts of the contact assembly 400 according to Figures 1 to 3 in.

[0063] Figure 5 The device 800 is shown, which is exemplary configured as a motor vehicle headlight, wherein the plastic laminate 100 serves as a cover disk. However, the application of the plastic laminate 100 is not limited to use in motor vehicle headlights. More precisely, the plastic laminate serves as a cover disk for radar components or cameras.

[0064] The device 800 for a motor vehicle includes: a housing 810; a radar transmitter and / or radar receiver 820 arranged in the housing 810 for transmitting and / or receiving radar signals; and a plastic laminate 100, wherein the plastic laminate 100 in the form of a cover disk at least partially closes an opening of the housing 810.

[0065] The radar component 820 transmits and receives radar signals through the sensor-related area 110 of the plastic laminate according to the double arrow 822. The radar component is operated by a control device 890.

[0066] It is provided that the heating section 310 of the heating conductor 300 passes through the sensor-related section 110 of the plastic laminate 100.

[0067] In this example, it is further provided that the plastic laminate 100 includes: a light-coupling-in area 150 for coupling in light of a light source 830, a light-coupling-out area for coupling out light, and a light-conducting area for conducting the light coupled in through the light-coupling-in area 150 to the light-coupling-out area.

[0068] Another example provides that the optocoupler input region is located outside the sensor-related section 110 of the plastic laminate 100, while the optocoupler output region is located inside the sensor-related section 110 of the plastic laminate 100.

[0069] In Figure 5 the example shown, the plastic laminate 100 is part of a device 800 that, in addition to a radar transmitter and / or radar receiver 820, also includes lighting components of a motor vehicle headlight. Of course, the device 800 can also be provided without these lighting components. Thus, Figure 6 a motor vehicle 900 is shown that includes the device 800 oriented in the travel direction x.

[0070] In another example, the device is part of a taillight or represents a taillight. Of course, the device 800 can also be part of a panel or grille assembly.

[0071] Figure 7 A schematic flow chart is shown. A method for manufacturing the plastic laminate 100 of the foregoing figures is described. First, the plastic film is delivered in the form of a roll or web and, if necessary, pre-cut in step 1010.

[0072] After step 1010, at least one side of at least one plastic layer is printed 1020. Step 1020 includes, for example, a screen printing process, applying a transfer base coat, and priming.

[0073] After the printing 1020, at least a part of the printed layer is removed 1030. The removal 1030 is performed, for example, by means of laser hatching to change the surface structure of the material. By the removal 1030, for example, backlighting of a logo or other contour can be made possible.

[0074] Preferably, after the removal 1030, the preform made of at least one plastic layer is trimmed 1040.

[0075] Preferably, at least one connecting component 500 is connected 1050 to at least one plastic layer before thermoforming 1060.

[0076] After the connection 1050, at least one plastic layer is thermoformed 1060.

[0077] The final shape of the plastic laminate as a cover plate is achieved by stamping 1070.

[0078] Compared with Figure 1 Figure 8 ​Shows an example of a plastic laminate 100, in which a heating conductor 300 is arranged on the same side of at least one plastic layer 200 as an electrical contact assembly 400. Accordingly, at least one contact section 320 of the heating conductor 300 is arranged between a clamping section 410 of the contact assembly 400 and at least one plastic layer 200.

[0079] An advantage of this arrangement of the heating conductor 300 is that an additional rivet assembly can be dispensed with. Here, it is advantageous that there is no mechanical lock on the plastic laminate, so that the plastic laminate or film can move easily during the spraying process. Thereby, formation of wrinkles and stresses in the plastic laminate and in particular in the heating assembly can be avoided during the spraying process.

[0080] Of course, Figure 8 the arrangement of the heating conductor 800 shown can also be transferred to all other embodiments shown in this specification according to Figures 1 to 4 the present specification.

[0081] Figure 9 Shows another example of a plastic laminate 100, in which another plastic layer 600 different from at least one plastic layer 200 leads to the other side of at least one plastic layer 100 through a through-hole 210. First and second sections 510, 520 of a connecting member 500, which partly represent the connecting member 500, fix at least one plastic layer 200, a contact section 320 of the heating conductor 300, and a clamping section 410 of the electrical contact assembly 400 to one another.

[0082] To establish the aforementioned connection, for example, a protrusion is retained during the injection molding process for manufacturing another plastic layer 600, which protrusion extends through the through-hole 210 from a side of at least one plastic layer 200 oriented in the x-direction and protrudes on a side of the contact assembly 400. An overhang of the protrusion of another plastic layer 600 is transformed into a section 510 by a thermal caulking process. The section 510 ensures a form-fitting fixation of at least one plastic layer 200, a contact section 320 of the heating conductor 300, and a clamping section 410 of the electrical contact assembly 400 along the x-axis.

[0083] As an alternative to the thermal caulking process, a sleeve can be slipped over the overhang of the protrusion in a form not shown, which sleeve engages by means of a hook into the overhang of the plastic pin / protrusion and thus ensures contact of the electrical contact assembly 400 with the heating conductor 300.

[0084] Figure 10 Shows another example of a plastic laminate 100, in which it is provided that the connecting member 500 extends into another plastic layer 600, and the connecting assembly 500 is fixed in a recess 630 of another plastic layer 600.

[0085] The protrusion 640 is part of another plastic layer 600 and extends at least into the through-hole 210 of at least one plastic layer 200. The recess 630 passes through the protrusion 640.

[0086] In an example not shown, the other plastic layer forms a spiral dome, and the recess 630 is arranged in the spiral dome.

[0087] In examples with or without a spiral dome, the recess 630 is provided for receiving a connection assembly 500 configured as a screw. Thus, the electrical contact assembly 400 is screwed into the plastic laminate 100 by means of a screw connection. Advantageously, in this case, the attachment of the connection assembly 500 can be decoupled in terms of time and manufacturing from the formation of the plastic laminate.

[0088] In the case of a screw connection, cost advantages are achieved and a low-resistance range and a secure electrical connection of the plug contact or the electrical contact assembly 400 are ensured.

[0089] Alternatively, open rivets can be used and pressed in, so that the electrical contact assembly 400 is connected to the heating conductor 300.

Claims

1. A plastic laminate (100), comprising: at least one plastic layer (200), the plastic layer (200) having at least one through hole (210); at least one heating conductor (300) connected to the at least one plastic layer (200), the heating conductor (300) comprising a heating section (310) and at least two contact sections (320); at least one electrical contact assembly (400); as well as At least one connecting component (500) is at least partially passed through the at least one through hole (210) of the plastic layer (200) and fixed to the plastic layer (200), wherein the at least one connecting component (500) establishes a low-resistance electrical connection between at least one of the contact sections (320) of the heating conductor (300) and the electrical contact assembly (400).

2. The plastic laminate (100) according to claim 1, wherein: The at least one connecting component (500) is in electrical and mechanical contact with at least one contact section (320) of the heating conductor (300) on a first side of the at least one plastic layer (200), and the at least one connecting component (100) is in electrical and mechanical contact with the at least one electrical contact component (400) on a second side of the at least one plastic layer (200) opposite to the first side.

3. The plastic laminate (100) according to claim 1 or 2, wherein: The contact section (320) of the heating conductor (300), the at least one plastic layer (200) in sections, and the clamping section (410) of the electrical contact assembly (400) are clamped between a first section (510) of the at least one connecting component (500) and a second section (520) of the at least one connecting component (500).

4. The plastic laminate (100) according to any one of the preceding claims, wherein A contact surface (522) of the at least one connecting component (500) facing the contact section (320) of the heating conductor (300) has a contact protrusion.

5. The plastic laminate (100) according to any one of the preceding claims, wherein The at least one connecting component (500) is implemented as a rivet connection.

6. The plastic laminate (100) according to any one of the preceding claims, wherein At least one further plastic layer (600) is arranged on a side of the at least one plastic layer (200) facing away from the electrical contact component (400), the further plastic layer (600) surrounding the connecting element (500) in sections.

7. The plastic laminate (100) according to any one of the preceding claims, wherein The contact section (320) of the heating conductor (300) is clamped between the contact surface (522) of the at least one connecting component (500) facing the at least one plastic layer (200) and an electrically conductive contact disk (600) arranged between the at least one plastic layer (200) and the contact surface (522).

8. The plastic laminate (100) according to any one of claims 1 to 6, wherein: The contact disc (600) is arranged on a side of the at least one plastic layer (200) opposite to a side having the electrical contact component (400), wherein the contact disc (600) protrudes with a protrusion (620) beyond an adjacent section (520) of the connecting component (500), and wherein the contact section (320) of the at least one heating conductor (300) is connected to the protrusion (620) of the contact disc (600) in a material-fitting manner, and wherein the contact disc (600) has a through-hole through which the at least one connecting component (500) passes at least in sections.

9. The plastic laminate (100) according to claim 7 or 8, wherein: A contact surface (622) of the at least one contact disk (600) facing away from the at least one plastic layer (200) has a contact protrusion.

10. The plastic laminate (100) according to any one of the preceding claims, wherein The electrical contact assembly (400) is a flexible or rigid printed circuit board.

11. The plastic laminate (100) according to any one of the preceding claims, wherein Conductor tracks (422) of the printed circuit board are electrically and mechanically contacted by means of the connecting element (500).

12. The plastic laminate (100) according to any one of the preceding claims, wherein The heating section (610) of the heating conductor (600) passes through a sensor-related section (110) of the plastic laminate (100).

13. The plastic laminate (100) according to any one of the preceding claims, wherein The plastic laminate (100) comprises: a light coupling-in region (150) for coupling-in light of a light source (830), a light outcoupling region for outcoupling light, and a light conducting region for conducting light coupled in through the light coupling-in region (150) to the light outcoupling region.

14. Plastic laminate (100) according to any one of the two preceding claims, wherein The light incoupling region is located outside the sensor-related section (110) of the plastic laminate (100), and wherein the light outcoupling region is located inside the sensor-related section (110) of the plastic laminate (100).

15. The plastic laminate (100) according to any one of the preceding claims, wherein The at least one contact section (320) of the heating conductor (300) is arranged between the clamping section (410) and the at least one plastic layer (200).

16. The plastic laminate (100) according to any one of the preceding claims, wherein Another plastic layer (600) different from the at least one plastic layer (200) leads to the other side of the at least one plastic layer (100) through the through hole (210), and the first and second sections (510, 520) of the connecting component (500) partially representing the at least one plastic layer (200), the contact section (320) of the heating conductor (300) and the clamping section (410) of the electrical contact component (400) are fixed to each other.

17. The plastic laminate (100) according to any one of the preceding claims, wherein The connecting component (500) extends into the further plastic layer (600), and the connecting component (500) is fixed in a recess (630) of the further plastic layer (600).

18. Plastic laminate (100) according to the preceding claim, wherein The protrusion (640) as part of the further plastic layer (600) extends at least into the through hole (210) of the at least one plastic layer (200), and wherein the recess (630) passes through the protrusion (640).

19. A device (800) for a motor vehicle (900), comprising: Housing (810); A radar transmitter and / or a radar receiver (820) arranged in the housing (810) for transmitting and / or receiving radar signals; as well as The plastic laminate (100) according to any one of the preceding claims, wherein the plastic laminate (100) in the form of a cover disk closes an opening of the housing (810) at least in sections.

20. A method for producing a plastic laminate (100) according to any one of claims 1 to 18, the method comprising: Printing at least one side of the at least one plastic layer (1020); removing at least a portion of the printed layer (1030); as well as The at least one connecting component (500) is connected to the at least one plastic layer (1050).

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