Motor vehicle door lock housing and method for its manufacture

Abstract

Motor vehicle door lock housing (1), with a recess (2) in a carrier body (T), wherein the recess (2) accommodates a conductor track structure (3) in its interior, the conductor track structure (3) is composed of several conductor tracks (7), the conductor track structure (3) consists of at least two conductor track substructures (3a, 3b) which are electrically connected to one another by at least one subsequently attached connecting element (8), the first conductor track substructure (3a) is designed as a main conductor track structure (3a) and the second or every second conductor track substructure (3b) is designed as an extension conductor track structure (3b), and the main conductor track structure (3a) is used in all versions of the motor vehicle door lock to be realized, while the extension conductor track structure (3b) is used only if the motor vehicle door lock to be manufactured has optional additional functions.

Description

[0001] The invention relates to a motor vehicle door lock housing with a conductor track structure composed of several conductor tracks.

[0002] Motor vehicle component carriers, and in particular motor vehicle door lock housings with integrated conductor track structures, are typically used when one or more electrical / electronic components are to be accommodated by the motor vehicle component carrier in question and contacted using the conductor track structure. Electrical or electronic components are generally referred to as components that can be used, for example, to query the position of levers located in the lock. This also includes electromechanical components such as microswitches, friction contacts, and / or electric motors.

[0003] The respective automotive component carrier can be inserted into the housing of a motor vehicle door lock, contacted with the described components, and finally encapsulated with an electrically insulating compound. This may be a cast resin. Alternatively or additionally, the automotive component carrier can also be a component of the motor vehicle door lock housing.

[0004] DE 10 2009 002 902 A1 describes a lock housing part with a lead frame inserted into it as a conductor track structure. The conductor tracks are equipped with connecting pins that lead into the interior of the lock housing part. This allows for a lock housing with relatively large design flexibility that can also be manufactured inexpensively.

[0005] In a method for manufacturing a carrier for electrical components according to DE 102 47 567 A1, conductor tracks punched from a sheet metal are overmolded using a plastic injection molding process during the carrier's production and populated with electronic components. The assembly takes place before overmold-forming.

[0006] The teaching according to EP 1 527 967 B1 also concerns a method for producing a carrier body for the lock of a motor vehicle. The conductor tracks of different layers are connected to each other via connecting sections so that they form a single body. Following the attachment of the individual layers of the conductor tracks to an intermediate element, the connecting sections are subjected to a punching operation. This means that the connecting sections ultimately function as mechanical stabilizing webs for the conductor track structure, but must be severed for subsequent function to prevent short circuits, unwanted electrical connections, etc.

[0007] In a method for embedding at least one flexible conductor foil in plastic according to EP 1 231 824 A2, the flexible conductor foil in question is attached to or in a prefabricated stiffening element that secures it against bending. Subsequently, the conductor foil, together with this stiffening element, is overmolded with plastic.

[0008] Finally, document DE 10 2005 049 975 B4, which is still to be considered as prior art, deals with a component carrier with a conductor track structure. The conductor track structure comprises tinplate.

[0009] DE 10 2008 001 915 A1 describes an actuating unit with an adjustably mounted body, with at least one electrically connected component, with an electrical connection for electrically connecting the at least one electrically connected component to an electrical device and with a conductor track connection for electrically connecting the electrically connected component to the electrical connection.

[0010] DE 60 2004 007 216 T2 describes a method for producing a carrier body of the lock of a motor vehicle, comprising the steps of producing an intermediate element consisting of an insulating material, which is provided with conductor tracks in layers and inserting the intermediate element provided with the conductor tracks into a mold for forming the carrier body.

[0011] DE 37 44 603 C1 describes a central electrical system for motor vehicles for the central connection of electrical components, such as fuses, switching devices, cable harnesses, electronic controls for electrical consumers and the like, with a plate-like layered conductor package which has flat printed circuit boards arranged one above the other in different levels and separated from one another by insulating plates.

[0012] Previous approaches to implementing a motor vehicle component carrier with a conductor track structure composed of multiple conductor tracks reach their limits when complex conductor track structures are to be implemented and / or different conductor track structures are required for one and the same type of motor vehicle component carrier or motor vehicle door lock housing in order to realize various expansion / extension levels. In fact, such different configurations have so far only been possible with relatively high effort. This is where the invention comes in.

[0013] The invention is based on the technical problem of further developing such a motor vehicle door lock housing in such a way that the production, in particular of the conductor track structure, is simplified and different versions of the conductor track structure can be implemented without any problem, taking into account different expansion levels.

[0014] The invention is defined by the features of the independent claims.

[0015] To solve this technical problem, a generic motor vehicle door lock housing is characterized within the scope of the invention in that the conductor track structure consists of at least two conductor track substructures that are electrically connected to one another by at least one subsequently attached connecting element.

[0016] This means that, within the scope of the invention, the conductor track structure, which can be more or less complex depending on its functionality and expansion level, is deliberately divided into at least two conductor track substructures. These conductor track substructures generally have a simplified structure. Within the scope of the invention, such a simplified structure means, for example, that the conductor track substructure is composed only of conductor tracks lying in one plane.

[0017] In order to be able to realize complex conductor track structures within the scope of the invention, for example, those that describe two or more levels, the individual conductor track substructures, each spanning only one level, are electrically connected to one another via one or more subsequently attached connecting elements. This means that the subsequently attached connecting elements ensure that even complex three-dimensional designs of the conductor track structure can be produced and do not have to be implemented from the outset in the form of a lead frame.

[0018] A further possibility for simplifying the conductor track structure by means of the at least two conductor track substructures is that, for example, one conductor track substructure has a specific areal extent, whereas the other, second conductor track substructure is equipped with a subsequent areal extent. In this way, the conductor track structure composed of the conductor track substructures can also be adapted to complex geometries of the motor vehicle door lock housing, for example, with different chambers for accommodating the conductor track structure. In this case, the individual conductor track substructures do not necessarily span different planes, but are connected to one another in one plane. However, simplification is achieved by accommodating the respective simplified conductor track substructure in, for example, a separate chamber of the motor vehicle door lock housing and being positioned there.

[0019] In any case, it is clear that, within the scope of the invention, bends on and in a conductor track are generally not required, because extensions of the conductor track structure at different levels are realized according to the invention in such a way that, for example, each level has a conductor track substructure, and these multiple conductor track substructures are only subsequently electrically connected to one another to form the complex conductor track structure using one or more connecting elements. As a result, the individual conductor track substructures usually have a trivial geometry, for example, in the form of a defined flat surface, and can therefore be manufactured simply, quickly, and cost-effectively, for example by punching.

[0020] In addition, the inventive design makes it possible, for example, for a first conductor track structure to be designed as the main conductor track structure, while the second or every second conductor track structure may be designed as an extension conductor track structure. The main conductor track structure is regularly used in all versions of the motor vehicle door lock to be realized. The second or every second conductor track structure or extension conductor track structure, on the other hand, is used only if the door lock to be manufactured has optional additional functions.

[0021] For example, it is conceivable to implement a motor vehicle door lock with a central locking function and, in this context, equip it with a correspondingly designed main conductor track structure. If this motor vehicle door lock is to be additionally equipped with, for example, a "closing" function or the "electrical opening" function, the electrical / electronic components required for these additional functions can be contacted using a respective extension conductor track structure and electrically connected to the main conductor track structure. This provides a cost-effective and flexible production of the motor vehicle door lock housing that can be precisely adapted to the respective conditions. These are the key advantages.

[0022] In order to realize the electrical connection between the two conductor track substructures in detail, the connecting element is advantageously designed as a pin that is connected or connectable to a first conductor track substructure. This pin can then be mechanically coupled to a second conductor track substructure to establish the electrical connection. The pin can be connected to the first conductor track substructure. This (permanent) connection can be realized as a mechanical connection in various ways. Possible options include a welded connection, an insulation displacement connection, a soldered connection, a clamp / crimp connection, a cold-welded connection, or a similar mechanical connection that simultaneously establishes the necessary electrical contact between the respective conductor track and the pin. Alternatively or additionally, the pin can also be designed as a formed part of the respective conductor track.In this case, the pin on the relevant conductor track is designed in such a way that the conductor track is bent or folded at the end, for example.

[0023] In any case, the pin connected to the first conductor track substructure subsequently enters into the described mechanical coupling with the second conductor track substructure to provide the desired electrical connection between the two conductor track substructures. The mechanical coupling between the pin and the second conductor track substructure can again be realized by a welded connection, an insulation displacement connection, a soldered connection, a clamp / crimp connection, a cold-welded connection, or similar connections. In all of these cases, the pin is connected to the first conductor track substructure by the described mechanical connection and / or is an integral part of a conductor track of the first conductor track substructure.The assembly comprising the first conductor track substructure and the one or more pins is then mechanically coupled and subsequently coupled to the second conductor track substructure to establish their electrical connection as described.

[0024] Alternatively or additionally, the pin can also be designed so that it can be connected to the first conductor track substructure. In this case, the connecting element or the pin is mechanically connected to both the first conductor track substructure and the second conductor track substructure when the entire conductor track structure is implemented. This means that the connecting element is designed as a pin that can be connected to both the first and the second conductor track substructure. For this purpose, the pin can be connected to the respective conductor track substructure by a fit, in particular a press fit. The fit or press fit can be implemented in detail such that the respective pin is inserted into a corresponding recess or bore in the respective conductor track up to a stop. This can be done using a press die.

[0025] This allows for the greatest possible flexibility. The connecting element can be firmly attached to the first conductor track substructure and subsequently connected to the second conductor track substructure. It is equally possible to mechanically couple both conductor track substructures to the connecting element at the same time as they are combined to form the conductor track substructure. This allows for the realization of complex conductor track structures with virtually any three-dimensional structure. In this example, this three-dimensional structure is broken down into its various levels and separated into correspondingly simplified conductor track substructures. These conductor track substructures are then electrically combined to form the complex conductor track structure using one or more connecting elements and then further processed.

[0026] The invention generally proceeds in such a way that the complex conductor track structure produced from the conductor track substructures is inserted into a recess of an electrically insulating carrier body and / or a mold for producing the carrier body, populated with electrical / electronic components, and then encapsulated with an electrically insulating compound. In this context, the procedure can be such that the electrically insulating carrier body with the recess has been manufactured in advance and is then equipped with the conductor track structure and the components and encapsulated. However, it is also possible to produce the carrier body together with the encapsulation in a single step. The conductor track structure populated with the electrical / electronic components is then inserted into a mold that simultaneously serves to produce the carrier body and the encapsulation.

[0027] A thermoplastic has proven particularly suitable as an electrically insulating material for the carrier body. This material can preferably be polybutylene terephthalate (PBT) and / or a glass fiber-reinforced plastic. For the electrically insulating compound used during the casting process, the invention recommends a thermoplastic material such as polyethylene (PE).

[0028] In any case, the conductor track structure consists of at least two conductor track substructures, which are electrically connected to one another by at least one subsequently attached connecting element. The complex conductor track structure created in this way is then populated with the electrical / electronic components. Furthermore, the complex conductor track structure and consequently also the one or more connecting elements, together with the electrical / electronic components, are finally encapsulated with the electrically insulating compound. This not only protects the components in question from environmental influences, but also the conductor track substructures and the connecting elements that electrically contact them. This represents the key advantages.

[0029] The invention is explained in more detail below with reference to a drawing which merely represents an exemplary embodiment; in the drawings: Fig. 1 schematically shows a motor vehicle door lock housing according to the invention, Fig. 2 in the motor vehicle door lock housing according to Fig. 1 recorded conductor track structure in a perspective section and Fig. 3A, Fig. 3B and 4A, 4B Details of the electrical contacting of the individual conductor track substructures with each other.

[0030] The figures show a motor vehicle component carrier, which in the exemplary embodiment is a motor vehicle door lock housing 1. The motor vehicle door lock housing 1 is equipped with an indicated recess 2 in a carrier body T, which accommodates a conductor track structure 3 in its interior. The conductor track structure 3 is connected to the Fig. 1 only indicated electrical / electronic components 4. In addition, a connection socket 5 is realized, with the help of which the conductor track structure 3 is or can be electrically connected to, for example, a control unit (not shown) inside a motor vehicle body. Finally, in the Fig. 1 also indicates an electrically insulating mass 6, with the aid of which the conductor track structure 3 is cast together with the electrical / electronic components 4 accommodated thereon or electrically contacted thereon, in order to protect all of the described elements from harmful environmental influences.

[0031] The conductor track structure 3 is composed of several conductor tracks 7, which are shown schematically in the Fig. 1 and enlarged in the detail according to Fig. 2 can be seen. Based on the Fig. 2 additionally shows that the conductor track structure 3 according to the invention consists of at least two conductor track substructures 3a, 3b. Fig. 1 on.

[0032] It can be seen that the two conductor track substructures 3a, 3b are subsequently electrically connected to one another by two connecting elements 8. In this way, the conductor track substructures 3a, 3b can each be designed in a simplified manner compared to the complex conductor track structure 3. In the illustrated example, this simplified design means that the individual conductor track substructures 3a, 3b are arranged at different planes from one another. This means that in the exemplary embodiment, the first conductor track substructure 3a and the second conductor track substructure 3b each span different and spaced-apart planes. Both conductor track structures 3a, 3b each describe a defined flat surface and not, for example, a three-dimensional structure.

[0033] Based on the Fig. 2 to 4, it can be seen that the respective connecting element 8 is a pin 8. The pin 8 can be firmly connected to the first conductor track substructure 3a. In this case, the assembly 3a, 8 comprising the first conductor track substructure 3a and the connecting pin 8 is then mechanically combined with the second conductor track substructure 3b to produce the complex and composite (three-dimensional) conductor track structure 3, respectively, to form the composite conductor track structure 3 or 3a, 8; 3b. This mechanical coupling can be achieved by conventional mechanical joining measures such as a welded joint, soldered joint, etc., as already described.

[0034] The connecting element or the pin 8 can also be firmly connected to the first conductor track substructure 3a or the conductor track 7 therein in such a way that the respective pin 8 is, as it were, integrated into the conductor track 7. This can be achieved by, according to the variant according to the Fig. 3B, the pin 8 is created or formed by bending or reshaping, for example, one end of the conductor track 7 of the first conductor track substructure 3a. In all of these described cases, the connecting element or the pin 8 is thus firmly connected to the respective conductor track 7 of the first conductor track substructure 3a before the structural unit 3a, 8 in question, consisting of the first conductor track substructure 8 and the one or more pins 8, is mechanically and electrically coupled to the second conductor track substructure 3b.

[0035] Alternatively, it is also possible for the two conductor track substructures 3a, 3b to be coupled to each other and to the respective connecting element 8 only during the assembled production of the conductor track structure 3. In this case, the connecting element 8 is designed to be connectable to both the first conductor track structure 3a and the second conductor track structure 3b, and is not already connected to one of the two conductor track structures 3a, 3b from the outset.

[0036] The connectable design of the connecting element or pin 8 with the respective conductor track structure 3a, 3b is usually carried out by a fit, in particular a press fit. Such a fit or press fit is shown in the illustration in the Fig. 3A and Fig. 4A. To achieve such a fit or interference fit, the pin 8 can be equipped with at least one tip 9, which is inserted into a bore or recess 10 to establish the connection. This bore or recess 10 is formed in a conductor track 7.

[0037] To connect the individual conductor track substructures 3a, 3b, the pin 8 with its corresponding tip 9 can now be inserted into the hole or recess 10. This widens the hole or recess 10, so that the desired press fit and thus a strong mechanical connection is available. The pin 8 can be inserted according to the illustration. Fig. 3A, for example, can be firmly connected to the conductor track 7 of the first conductor track substructure 3a at one end. The other end of the pin 8 has the tip 9, so that the desired and described connection to the second conductor track substructure 3b and / or a bridge element 12 for bridging a web S in the housing can be established. However, it is also possible to equip the pin 8 with an associated tip 9 on both sides. In this case, the respective conductor tracks 7 of the associated conductor track substructures 3a, 3b each have the bore or recess 10 (cf. Fig. 3A, Fig. 4A).

[0038] Another variant is in the Fig. 4B. Here, one can see a pin 8 with an insulation displacement terminal 11 into which a conductor track 7 can be inserted to provide the desired mechanical and electrical connection of the pin 8 with the associated conductor track substructure 3a, 3b. - The first conductor track substructure 3a can be a main conductor track structure 3a, which is present in every configuration variant of the Fig. 1. In contrast, the second conductor track substructure 3b is designed as an extension conductor track structure 3b, which is inserted into the recess 2 only as needed and populated with associated components 4. Such an additional function may, for example, be designed as a closing aid, as already described in the introduction.

[0039] During the manufacture of the motor vehicle door lock housing 1, the conductor track substructures 3a, 3b are subsequently electrically coupled to one another by means of the two connecting elements 8, namely to form the complex composite conductor track structure 3 or 3a, 8; 3b or 3a; 8; 3b. Subsequently, this complex composite conductor track structure 3 is populated with the electrical / electronic components 4. Finally, the encapsulation is carried out using the electrically insulating compound 6 as shown in FIG. Fig. 1. First, the conductor track structure 3 is inserted into the recess 2 of the electrically insulating carrier body T. The encapsulation and production of the carrier body T or the component carrier can be performed in one step. For this purpose, the conductor track structure 3, equipped with the components 4, is inserted into a suitably designed injection mold.

[0040] During the encapsulation process, not only are the electrical / electronic components 4 sealed with the help of the electrically insulating compound 6, but this also applies to the one or more connecting elements 8. This provides optimal protection against any environmental influences. - It is understood that the distinction between the first conductor track substructure 3a and the second conductor track substructure 3b in the context of the exemplary embodiment was made solely for reasons of clarity, and both conductor track substructures 3a, 3b can, of course, also exchange their design and functionality.

Claims

[1] Motor vehicle door lock housing (1), with a recess (2) in a carrier body (T), wherein the recess (2) accommodates a conductor track structure (3) in its interior, the conductor track structure (3) is composed of several conductor tracks (7), the conductor track structure (3) consists of at least two conductor track substructures (3a, 3b) which are electrically connected to one another by at least one subsequently attached connecting element (8), the first conductor track substructure (3a) is designed as a main conductor track structure (3a) and the second or every second conductor track substructure (3b) is designed as an extension conductor track structure (3b), and the main conductor track structure (3a) is used in all versions of the motor vehicle door lock to be realized, while the extension conductor track structure (3b) is used only if the motor vehicle door lock to be manufactured has optional additional functions. [2] Motor vehicle door lock housing (1) according to the preceding claim, wherein the connecting element (8) is designed as a pin (8) connected or connectable to a first conductor track substructure (3a), which can then be mechanically coupled to a second conductor track substructure (3b) to establish the electrical connection. [3] Motor vehicle door lock housing (1) according to the preceding claim, wherein the mechanical coupling is realized by a welding, cutting / clamping, soldering, clamping / squeezing, cold welding connection or a similar mechanical connection. [4] Motor vehicle door lock housing (1) according to one of the preceding claims, wherein the connecting element (8) is designed as a pin (8) connectable to both the first conductor track substructure (3a) and the second conductor track substructure (3b). [5] Motor vehicle door lock housing (1) according to one of the preceding claims, wherein the connecting element (8) can be connected to the respective conductor track substructure (3a, 3b) by a fit, in particular a press fit. [6] Motor vehicle door lock housing (1) according to one of the preceding claims, wherein the connecting element (8) is connected to the respective conductor track structure (3a, 3b) by a welding, cutting / clamping, soldering, clamping / squeezing, cold welding connection or a comparable mechanical connection and / or as a formed formed part of the respective conductor track (7). [7] Motor vehicle door lock housing (1) according to one of the preceding claims, wherein the two conductor track substructures (3a, 3b) are arranged on the same plane or on different planes. [8] Method for producing a motor vehicle door lock housing (1), according to which a conductor track structure (3) is inserted into a recess (2) of an electrically insulating carrier body (T), equipped with electrical / electronic components (4) and then encapsulated with an electrically insulating mass (6), wherein the conductor track structure (3) consists of at least two conductor track substructures (3a, 3b) which are electrically connected to one another by at least one subsequently attached connecting element (8), the first conductor track substructure (3a) is designed as a main conductor track structure (3a) and the second or every second conductor track substructure (3b) is designed as an extension conductor track structure (3b), and the main conductor track structure (3a) is used in all versions of the motor vehicle door lock to be realized, while the extension conductor track structure (3b) is used only if the motor vehicle door lock to be manufactured has optional additional functions. [9] Method according to the preceding claim, wherein the connecting element (8) is encapsulated together with the electrical / electronic components (4) with the electrically insulating mass (6).

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