METHOD FOR PRODUCING A FLAT LADDER ARRANGEMENT

Abstract

Method for producing a flat conductor arrangement (7), comprising the steps: - Providing an electrically conductive flat conductor rail (1); - Specifying at least one contact area (3) on the flat conductor surface (2) of the flat conductor rail (1); - Applying a separating layer (4) to a sub-area of ​​the flat conductor surface (2) encompassing at least one contacting area (3), wherein the separating layer (4) has the property of adhering more strongly to a predetermined insulating material of an insulating layer (8) than to the flat conductor surface (2); - Forming the insulating layer (8) containing the insulating material on the flat conductor rail (1) after it has been provided with the separating layer (4); - Removal of a section (9) of the insulating layer (8) together with the underlying separating layer (4) produced at at least one contact area (3) of the flat conductor rail (1).

Description

[0001] The invention relates to a method for manufacturing a flat conductor arrangement.

[0002] The increasing use of different material combinations in vehicle bodies, up to and including complete CFRP bodies (for example, in monocoques), will significantly impair or even render the electrical grounding in motor vehicles in the future. This would necessitate, in some cases, the use of more stranded conductors for grounding, and would likely lead to an increase in the weight of the vehicle's electrical system and wiring harness.

[0003] The electrical return current introduced via so-called ground bolts typically always follows the path of least resistance. Due to the use of different body materials and joining techniques, such as gluing, riveting, welding, and the like, an undefined or undirected electrical return current from electrical components to the vehicle battery is generated. This undirected return current creates an electromagnetic field that can negatively affect vehicle occupants and the vehicle's electronics.

[0004] By using so-called flat conductor rails, especially those made of aluminum, the installation space and conductor weight for electrical grounding can be significantly reduced. These flat conductor rails are often routed along the underbody contour from a rear compartment to the engine compartment of a vehicle. In particular, a multi-layer flat conductor structure as the central electrical supply and grounding system eliminates the formation of an electromagnetic field, regardless of the body materials used. Such flat conductor arrangements in vehicles also result in improved electrical system stability.

[0005] To enable effective mutual cancellation of electromagnetic fields between two adjacent flat conductor rails, the two rails must be positioned as close to each other and with as much surface area as possible. Unlike flat conductor supply lines, which are mainly used in the underbody area and sometimes also in the interior without a second, ground-return rail, and usually with relatively thick PVC insulation exceeding 2.5 mm, these multi-layer flat conductor rails require relatively thin insulation walls.

[0006] To enable particularly easy and cost-effective stripping of aluminum flat conductor cores, i.e., aluminum flat conductor busbars, non-adherent insulating materials are frequently used. However, due to their processing, geometric arrangement, and temperature fluctuations, these insulating materials often exhibit relatively high internal mechanical stresses, which can result in material shrinkage of over 20 mm over a length of 3,000 mm. Mechanical stresses can also occur in the transverse direction, causing the insulating materials to tear during temperature cycling or thermal shock tests. Relative movement between the flat conductor busbars and the insulating plastics used for insulation, especially due to changes in length caused by temperature cycling, can lead to shearing effects and thus to insulation material failure.

[0007] A metallurgical bond between the insulating plastic and the flat conductor rail would eliminate material shrinkage and ensure optimal thermal shock resistance for the entire component, i.e., the flat conductor rail coated with the insulating plastic. However, this would necessitate a significantly more complex and expensive stripping process to remove the optimally bonded insulation from the flat conductor core, i.e., the flat conductor rail. For example, milling the insulating layer from the flat conductor core could cause chip formation. To prevent a short circuit caused by a remaining metal chip, a complex cleaning process would be required. Furthermore, laser-blasting the insulation across a large area can lead to thermal changes in the metal surface, and undefined degradation residues from the insulation can cause undesirable interactions.

[0008] US Patent 3,159,555 A discloses a method for masking busbars. GB Patent 1,086,823 A discloses a ribbon-like cable. US Patent 3,547,718 A discloses a flat and flexible electrical cable. DE Patent 10,2014,004431 A1 discloses a sheathing for profiles with lateral outlets.

[0009] It is therefore the object of the present invention to provide a method for manufacturing a flat conductor arrangement which has at least one electrically conductive flat conductor rail and an insulating layer which at least partially encloses it, by means of which at the same time a particularly stable connection between the insulating layer and the flat conductor rail and a particularly simple local stripping of the insulating layer is made possible.

[0010] This problem is solved by a method for manufacturing a flat conductor arrangement with the features of claim 1. Advantageous embodiments with expedient and non-trivial further developments of the invention are specified in the dependent claims.

[0011] In the inventive method for manufacturing a flat conductor arrangement, an electrically conductive flat conductor rail is provided. This electrically conductive flat conductor rail serves as the flat conductor core of the flat conductor arrangement to be manufactured. At least one contact area is defined on a flat conductor surface of the provided flat conductor rail. When using the flat conductor arrangement, particularly for electrical grounding in motor vehicles, the at least one contact area serves to connect cables or other conductors to the flat conductor rail.

[0012] A flat conductor rail is a strip-shaped rail made of a conductive material. Its dimensions in width and length are large relative to its thickness, i.e., its height. These flat sides extend longitudinally and transversely along the rail and have a significantly larger surface area than the corresponding side faces, which extend longitudinally and vertically. Furthermore, the flat sides also have a significantly larger surface area than the corresponding end faces, which extend transversely and vertically along the rail.

[0013] A separating layer is then applied to a portion of the flat conductor surface encompassing the contact area. This separating layer has the property that a predetermined insulating material adheres more strongly to the separating layer than to the flat conductor surface in the contact area, or at least that adhesion to the flat conductor surface is prevented by the presence of the separating layer. Subsequently, an insulating layer containing the insulating material is produced on the flat conductor rail, i.e., after it has been provided with the separating layer. The production of the insulating layer is preferably carried out in such a way that a connection, particularly preferably a metallurgical bond, is formed between the insulating layer and the flat conductor surface, as well as between the insulating layer and the separating layer.Finally, a section of the insulating layer produced at the contact area of ​​the flat conductor rail, along with the underlying separating layer, is removed.

[0014] The at least one predefined contact area serves to connect a contact element, such as a screw tab, a contact plug, a screw bolt, a cable lug, or the like. Alternatively, an electrical conductor can also be directly connected to the flat conductor rail at the contact area.

[0015] The resulting connection between the insulating material and the flat conductor rail can be either form-fit, force-fit, or material-fit. The first two mechanisms involve a physical bond, achieved through microscopic or macroscopic interlocking of the respective surfaces of the materials—that is, between the flat conductor rail and the insulating material—or through shrinking the insulating layer onto the flat conductor rail. Material-fit, on the other hand, is a chemical bond between the respective materials—that is, between the flat conductor rail and the insulating material. Material-fit connections are defined as all connections in which the bonding partners are held together by atomic or molecular forces. These are also permanent connections that can primarily only be separated by destroying the bonding agents.

[0016] The solution according to the invention therefore consists in selectively applying a separating agent in the form of a separating layer to the flat conductor rail, particularly when using self-adhesive or bonded insulating material. In the areas treated with the separating layer, conventional and simplified stripping can subsequently be carried out. In contrast, in the other areas of the flat conductor rail, an optimal bond between the insulating material and the flat conductor rail is ensured, thus guaranteeing a long-lasting and temperature-resistant insulating layer. Surface areas of the flat conductor rail that are to be exposed again for subsequent contacting are therefore provided with the separating layer, which bonds with the insulating material during the production of the insulating layer. This prevents a metallurgical bond between the insulating material and the flat conductor rail at these points.The separating layer is selectively applied to the areas of the flat conductor rail that will later be stripped. During the production of the insulating layer, the separating layer bonds with it, so that after the insulating layer is removed, a sufficiently machinable surface for contacting is available on the flat conductor surface. Preferably, the insulating layer, along with the separating layer, can be removed from the flat conductor surface without leaving any residue.

[0017] In particular, a uniform and standardized semi-finished product can be produced by applying a release agent regularly, in a timed and recurring manner, and the insulation layer can be stripped individually as required.

[0018] The flat conductor rail, serving as the flat conductor core, can be manufactured, for example, from aluminum. All common extruded materials or rolled strips with a purity of at least 99.5% or higher can be used as the aluminum material. This ensures sufficient electrical conductivity with adjustable material hardness. Such aluminum conductor cores can have thicknesses of, for example, 0.5 to 5.0 mm, preferably 1.0 to 3.0 mm. The aluminum core widths range from 5 to 60 mm, preferably 15 to 60 mm.

[0019] For thin aluminum flat conductor cores, and more generally for thin flat conductor rails, applying the separating layer to the respective flat sides, i.e., all particularly large surface areas, may suffice. However, if the flat conductor rails are somewhat thicker, it may also be necessary to selectively apply the separating layer to the narrow longitudinal sides as well.

[0020] In principle, all thermoplastics or thermoplastic elastomers with sufficient electrical insulation properties and flexibility can be used as insulation material. In particular, polyolefins (PP copolymers, PE, etc.), polyamides (PA 12, etc.), PVC, TPE, or cross-linked PE are suitable.

[0021] Depending on the type of plastic and processing technique, insulation layer thicknesses or wall thicknesses of 0.15 to 3.5 mm, preferably 0.3 to 1.5 mm, are sufficient. A wall thickness of 0.5 to 2.0 mm can preferably be used on the respective narrow longitudinal sides of the flat conductor rails.

[0022] Our own measurements on 60 × 1 mm aluminum strips with only 0.3 mm PP insulation and overhangs on the narrow longitudinal sides of the flat conductor rail show a measured dielectric strength of 16 kV. Therefore, the flat conductor arrangements shown can be used not only in the 12 V and 48 V ranges but also in high-voltage applications.

[0023] The thickness of the insulating layer can also serve to compensate for any curvature of the flat conductor rail perpendicular to the main alignment axis caused by a strip-cutting process, or for burr formation, and to ensure sufficient dielectric strength. Furthermore, an off-center position of the flat conductor rail serving as the core during the manufacturing of the insulating layer can also be accommodated by a sufficiently thick or well-designed insulating layer.

[0024] Due to its lightweight design, aluminum is the preferred core material for the flat conductor rail. However, other common electrically conductive materials or alloys, such as copper or brass, can also be used instead of aluminum. The flat conductor rail can have a wide variety of cross-sectional geometries and profile shapes, with varying width and height ratios. When aluminum is used as the material for the flat conductor rail, it can be made from rolled sheets, strips, extruded profiles, wrought or cast materials, or even foils.

[0025] The inventive method enables the production of a flat conductor arrangement comprising at least one electrically conductive flat conductor rail and an insulating layer that at least partially encloses it. Flat conductor arrangements produced in this way can be used for targeted electrical supply and / or ground return in vehicles with poorly or non-conductive bodies, for example, made of CFRP (carbon fiber reinforced polymer). Using such flat conductor arrangements allows for improved electromagnetic compatibility in the vehicle without additional shielding. Conventional wiring harness installation with flexible supply lines is also possible, particularly without external B+ leads requiring body penetrations and sealing systems. The flat conductor arrangement, serving as an electrical supply and / or ground strap, can be contacted at any point and is therefore multi-drop capable.Especially when aluminum is used as the material for the flat conductor rail, a particularly high degree of lightweight construction can be achieved in the manufactured flat conductor assembly. Such flat conductor assemblies also have a reduced installation height compared to conventional, round supply or ground conductors. Furthermore, flat conductor assemblies manufactured in this way exhibit a higher current-carrying capacity than stranded conductors with the same cross-sectional area. Using such flat conductor assemblies in a multilayer flat conductor structure also results in increased vehicle electrical system stability and the elimination of electromagnetic fields. In addition, a starter-generator battery rail and a vehicle interior power supply rail (also known as terminal 30) can be decoupled from each other. The flat conductor assemblies manufactured in this way can be used in 12 V, 48 V, and high-voltage electrical systems.

[0026] The use of the flat conductor arrangements produced by the method according to the invention is not limited to the automotive sector.

[0027] An advantageous embodiment of the invention provides that, prior to the production of the insulating layer, the flat conductor surface is treated in such a way as to promote a metallurgical bond between the insulating layer and the flat conductor rail. Preferably, the flat conductor surface is treated electrochemically, chemically, or physically for this purpose. Thus, for an optimal metallurgical bond between the insulating material and the flat conductor rail material, the flat conductor surface is preferably treated electrochemically, for example. An electrochemical treatment can be carried out, for example, by anodic oxidation, such as by means of an anodizing process. Particularly when heat is applied during the production of the insulating layer, this can promote a chemical reaction of the insulating material on the flat conductor surface of the flat conductor rail.However, other chemical or physical surface treatments or a favorable material combination with regard to the insulation material used and the flat conductor rail material can also promote a material-bonded connection between the insulation material and the flat conductor rail.

[0028] According to a further advantageous embodiment of the invention, the release layer is applied in the form of a liquid or paste-like release agent. In liquid or paste form, the release agent can be particularly easily dosed and applied as the release layer.

[0029] In a further advantageous embodiment of the invention, the release agent is applied by at least one of the following methods: spray application, whereby an area surrounding the partial region of the flat conductor surface is masked or only locally wetted; pad printing; roller application; screen printing; inkjet printing. Depending on where and how large an area the release layer is to be applied, one of the aforementioned methods can be selected to achieve an optimal result when using a liquid or paste-like release agent.

[0030] According to an alternative advantageous embodiment of the invention, the separating layer is an adhesive tape. Instead of a liquid or paste-like separating agent, an adhesive tape or a self-adhesive strip can also be applied, which likewise provides a locally limited separating effect between the insulating layer and the flat conductor surface. Particularly in small production runs, it can be advantageous to use adhesive tapes or self-adhesive strips as a separating layer. The adhesive tapes or self-adhesive strips used have the property that the respective adhesives remain completely adhered to the tape or self-adhesive strip when removed, thus leaving no residue on the flat conductor surface of the flat conductor rail. This ensures particularly reliable electrical contact at the contact area(s).

[0031] In a further advantageous embodiment of the invention, the separating layer comprises material components that are also present in the insulating material. This ensures a material affinity between the separating layer and the insulating material, which promotes the bond, in particular the material-bonded bond, between the separating layer and the insulating material. This, in turn, simplifies the residue-free local stripping of the insulating layer.

[0032] Another advantageous embodiment of the invention provides that the insulating material is at least partially transparent and the separating layer has a different color than the insulating material and the flat conductor rail. After the insulating layer has been applied, it is therefore particularly easy to identify where the separating layer has been applied. This facilitates the targeted removal of the insulating layer at the points that will then serve as contact areas when the flat conductor arrangement is in use.

[0033] Alternatively or additionally, the contact area located beneath the insulating layer can be marked on the insulating layer itself. Lasers or printers, for example, can be used to mark this contact area, i.e., the area covered with the separating layer. This marking should be synchronized with the respective application process of the separating layer and any masking process used, to ensure that the area covered with the separating layer is accurately targeted when the insulating layer is removed.

[0034] According to a further advantageous embodiment of the invention, the insulating layer is produced by conveying the flat conductor rail, provided with the separating layer, through an extrusion die, by means of which the insulating layer is extruded onto the outside of the flat conductor rail. During the extrusion process, a physical bond or even a chemical reaction occurs between the insulating material and the flat conductor rail due to the application of temperature and pressure, specifically in the areas where the separating layer has not been applied. The separating layer is applied to the flat conductor rail before the extrusion process in such a way that it adheres so strongly that it withstands the shear forces occurring during extrusion, i.e., without the applied separating layer being smeared or otherwise removed from its original position on the flat conductor surface during extrusion.Extrusion allows the insulation layer to be attached to the flat conductor rail particularly easily and quickly, especially if the entire flat conductor rail is to be encased by the insulation layer.

[0035] According to an alternative advantageous embodiment of the invention, the insulating layer is produced by placing the flat conductor rail, provided with the separating layer, into an injection mold and then overmolding the insulating layer onto the outside of the flat conductor rail. Injection molding also makes it possible to completely encase the flat conductor rail with the insulating layer, if necessary. Like extrusion, injection molding is particularly well-suited for producing the insulating layer on the flat conductor rail cost-effectively and reliably, especially in high-volume production. Other alternatives for applying the insulating layer include spray application or coating via an immersion bath.

[0036] Another advantageous embodiment of the invention provides that the application of the separating layer is integrated into a manufacturing process of the flat conductor rail or into a manufacturing process of the insulating layer. This integration of the application of the separating layer, either into the manufacturing process of the flat conductor rail itself or into the manufacturing process of the insulating layer, results in a relatively small to negligible increase in costs, but subsequently significantly simplifies the local stripping of the insulating layer.

[0037] Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings.

[0038] The drawing shows in: Fig. 1 a first embodiment of a process step for applying a separating agent to an electrically conductive flat conductor rail, wherein the separating agent is applied only to opposite flat sides of the flat conductor rail; Fig. 2 a second embodiment of the process step for applying the release agent, wherein the release agent is additionally also applied to the respective narrow longitudinal sides of the now slightly thicker flat conductor rail; Fig. 3 a third embodiment of the process step for applying the release agent, wherein the release agent is applied in the form of transverse strips spaced regularly apart in the main extension direction of the flat conductor rail on the respective flat sides of the flat conductor rail; Fig. 4 a fourth embodiment of the process step for applying the separating agent, wherein the separating agent is again regularly spaced apart in the main extension direction, but is applied to the flat conductor rail in the form of section-wise sheathing; Fig. 5 a fifth embodiment of the process step for applying the separating agent, wherein the separating agent has been applied at regular intervals from each other in the main extension direction to the respective side areas of the flat sides of the flat conductor rail; Fig. 6 a sixth embodiment of the process step for applying the release agent, wherein the flat conductor rail has been clamped with the release agent on its respective narrow longitudinal sides; and in Fig. 7 a perspective view of a flat conductor arrangement which, according to the sixth embodiment, has been treated with the separating agent, wherein an insulating layer has then been applied to the flat conductor rail and subsequently the insulating layer has been stripped again at the areas provided with the separating layers.

[0039] In the figures, identical or functionally equivalent elements are given the same reference symbols.

[0040] A flat conductor rail 1 is shown in a schematic perspective view in Fig. Figure 1 shows the flat conductor rail. The flat conductor rail can be made of aluminum, for example. It serves as a so-called flat conductor core for electrical supply or grounding in motor vehicles. The flat conductor rail 1 also requires an insulating layer (not shown). Contact areas 3 are defined at various points on the flat conductor surface 2 of the flat conductor rail 1. These contact areas 3 serve as points where, for example, cables or other electrical conductors are connected to the flat conductor rail 1. Therefore, it is important that only the bare, electrically conductive metallic material of the flat conductor rail 1 is present at these contact areas 3.As mentioned, the flat conductor rail 1 must be provided with an insulating layer (not shown here) for its use, which usually has to be stripped back at the selected contact areas 3.

[0041] To facilitate particularly easy stripping of the insulating layer (not shown here), a release agent is applied to the respective contact areas 3, forming separating layers 4 on these contact areas. The separating layers 4 can also be applied over a slightly larger area than the actual contact areas 3. These separating layers 4, and thus also the release agent used, have the property that a certain insulating material adheres more strongly to the separating layers 4 than to the flat conductor surface 2.

[0042] The separating layers 4 can be applied, for example, using the stamps 5 shown schematically here or a roller 11. If the separating layers 4 are applied in the form of a liquid or paste-like release agent, the following methods can be used, for example: spray application, whereby the respective surrounding areas of the contact areas 3 are preferably masked or the spray application is locally limited; pad printing; roller application; screen printing; or inkjet printing. The release agent, and thus also the separating layers 4, can be applied sequentially, regularly, irregularly, or selectively to the flat conductor surface 2.

[0043] The in Fig. The embodiment of the flat conductor rail 1 shown in Figure 1 has relatively large, not further specified, flat surfaces on which the separating layers 4 are applied. In the present case, the flat conductor rail 1 is therefore very flat in contrast to its length and width. In this case, it may be sufficient for the separating layers 4 to be applied only to the relatively large flat surfaces.

[0044] In Fig. Figure 2 shows another possible geometric embodiment of the flat conductor rail 1 in a perspective view. As can be seen, the respective narrow longitudinal sides 6 are slightly higher in the embodiment of the flat conductor rail 1 shown here than in the one in Fig. In the embodiment shown in Figure 1, it is advantageous for the separating layers 4 to be applied to the contact areas 3 on both the relatively large flat sides and the somewhat smaller narrow longitudinal sides 6. This facilitates the stripping of the insulating material to be applied subsequently at the contact areas 3. Therefore, in this geometrically comparatively massive embodiment of the flat conductor rail 1 serving as the flat conductor core, the separating agent is applied at least partially around the entire circumference of the flat conductor rail 1.

[0045] In Fig. Figure 3 shows another possible embodiment for applying the separating layers 4 to the respective contact areas 3. In the present case, the flat conductor rail 1 is again designed to be particularly flat, so that the separating layers 4 only need to be applied to the respective flat sides. In this case, the separating layers 4 have been applied in a band-like and regularly repeating pattern.

[0046] In Fig. Figure 4 shows another possible embodiment for attaching the separating layers 4 in a schematic perspective view. In the case shown here, the flat conductor rail 1 is geometrically arranged as in Figure 4. Fig. 2 is formed, so it is somewhat thicker than the ones in the Fig. 1 and Fig. 3 embodiments shown. The separating layers 4 are again applied in a band-like fashion at regular intervals along the longitudinal direction of the flat conductor rail 1. Since the flat conductor rail 1 in the embodiment shown here is again relatively solid, i.e., with a certain material thickness, it is again advantageous to apply the separating layers 4 circumferentially to the flat conductor rail 1, i.e., also to the narrow longitudinal sides 6.

[0047] In Fig. Figure 5 shows another possible embodiment for applying the separating layers 4 to the contact areas 3. The separating layers 4 have again been applied regularly, each being applied in lateral longitudinal areas on the respective flat sides of the flat conductor rail 1.

[0048] In Fig. Figure 6 shows another possible embodiment for arranging the separating layers 4 on the flat conductor rail 1. In the present case, the flat conductor rail 1 is again arranged as in the Fig. 2 and Fig. 4 more massive and not quite as flat as in the designs of the Fig. 1, Fig. 3 and Fig. 5. The separating layers 4 are in turn attached longitudinally one behind the other at regular intervals to the flat conductor rail 1. The separating layers 4 clamp the respective narrow longitudinal sides 6 of the flat conductor rail 1.

[0049] In Fig. Figure 7 shows a schematic perspective view of a flat conductor arrangement 7, which is shown in Fig. 6 shows a flat conductor rail 1, not described in detail here, and an insulating layer 8 surrounding it. As in Fig. 6 where the separating layers 4 have been applied to the contact areas 3, the flat conductor arrangement 7 is stripped by removing respective sections 9 of the previously produced insulating layer 8 from the flat conductor rail 1.

[0050] To facilitate the targeted removal of the sections 9, markings 10 are made on the insulating layer 8 after its production, at the locations where the contact areas 3 are situated, i.e., precisely where the separating layers 4 were previously applied. The markings 10 can, for example, be laser-etched or printed.

[0051] Alternatively or additionally, it is also possible to choose a material for the insulating layer 8 that is at least partially transparent, in which case the separating layers 4 would have a different color than the flat conductor rail 1 and the insulating material 8. This allows the separating layers 4 to show through the at least partially transparent insulating layer 8. Consequently, it is also easy to see where the sections 9 need to be stripped.

[0052] The insulating layer 8 can be produced, for example, by passing the flat conductor rail 1, provided with the separating layers 4, through an extrusion tool (not shown here), by which the insulating layer 8 is extruded onto the outer circumference of the flat conductor rail 1. Alternatively, it is also possible, for example, to place the flat conductor rail 1, provided with the separating layers 4, into an injection mold (also not shown here), by which the insulating layer 8 is then injected.

[0053] These manufacturing methods also apply equally to the other products in the Fig. 1 to 5 shown embodiments of the flat conductor rails provided with the separating layers 4.

[0054] By providing the separating layers 4, it can be ensured that the insulating layer 8 can be removed from the flat conductor rail 1 particularly easily and, in particular, without leaving any residue, at the contact areas 3. The respective separating layers 4 are applied to the flat conductor rail 1 in such a way that they adhere to it, but after the formation of the insulating layer 8, they adhere more strongly to it than to the flat conductor surface 2 of the flat conductor rail 1.

[0055] In the remaining areas of the flat conductor surface 2, i.e., where the separating layers 4 are not applied, the insulating layer 8 can form a metallurgical bond with the flat conductor busbar 1. Preferably, the insulating material of the insulating layer 8 consists of thermoplastics or thermoplastic elastomers with sufficient electrical insulating properties and flexibility. For example, the insulating layer 8 can be made of polyolefins (PP copolymers, PE, etc.), polyamides (PA 12, etc.), PVC, TPE, or cross-linking PE. In particular, the presence of chemically reactive groups in the insulating material of the insulating layer 8, such as maleic anhydride or polyurethane groups, enables a very good metallurgical bond to the flat conductor surface.

[0056] It is particularly advantageous if the flat conductor rail 1 is made of aluminum, for example from rolled sheet, rolled strip, an extruded profile, wrought or cast material, or even from a foil. Besides aluminum, other common electrically conductive materials or alloys, such as copper or brass, can also be used as the current-conducting core material for the flat conductor arrangement 7.

[0057] In addition to the illustrated variants of the flat conductor rail 1, other diverse cross-sectional geometries or profile shapes can also be provided with the separating layers 4 in the described manner and subsequently covered with the insulating layer 8, in order to then remove the sections 9 of the insulating layer 8 in the area of ​​the previously applied separating layers 4. REFERENCE MARK LIST 1 flat conductor rail 2 Flat conductor surface 3 Contact area 4 Separation layer 5 stamps 6 narrow long side 7 Flat conductor arrangement 8 Insulation layer Section 9 10 Mark 11 roll

Claims

[1] Method for producing a flat conductor arrangement (7), comprising the steps: - Providing an electrically conductive flat conductor rail (1); - Specifying at least one contact area (3) on the flat conductor surface (2) of the flat conductor rail (1); - Applying a separating layer (4) to a sub-area of ​​the flat conductor surface (2) encompassing at least one contacting area (3), wherein the separating layer (4) has the property of adhering more strongly to a predetermined insulating material of an insulating layer (8) than to the flat conductor surface (2); - Forming the insulating layer (8) containing the insulating material on the flat conductor rail (1) after it has been provided with the separating layer (4); - Removal of a section (9) of the insulating layer (8) together with the underlying separating layer (4) produced at at least one contact area (3) of the flat conductor rail (1). [2] Method according to claim 1, characterized by , that before the insulating layer (8) is produced the flat conductor surface (2) is treated in such a way as to promote a material-bonded connection between the insulating layer (8) and the flat conductor rail (2). [3] Method according to claim 2, characterized by , that the flat conductor surface (2) is treated electrochemically, chemically or physically. [4] Method according to any one of the preceding claims, characterized by , that the separating layer (4) is applied in the form of a liquid or pasty release agent. [5] Method according to claim 4, characterized by , that the release agent is applied using at least one of the following methods: - Spray application, whereby an area surrounding the sub-area of ​​the flat conductor surface (2) is masked; - localized spray application to partial areas of the flat conductor surface (2) without masking; - Pad printing; - Role assignment; - Screen printing; - Inkjet printing. [6] Method according to any one of claims 1 to 3, characterized by that the separating layer (4) is an adhesive tape or adhesive tape. [7] Method according to any one of the preceding claims, characterized by , that the separating layer (4) includes material components which are also found in the insulating material of the insulating layer (8). [8] Method according to any one of the preceding claims, characterized by , that the insulating material is at least partially transparent and the separating layer (4) has a different color than the insulating material and the flat conductor rail (2). [9] Method according to any one of the preceding claims, characterized by , that at least one contact area (3) arranged below the insulating layer (8) is marked on the insulating layer (8). [10] Method according to any one of the preceding claims, characterized by , that the insulating layer (8) is produced by conveying the flat conductor rail (2) provided with the separating layer (4) through an extrusion tool by means of which the insulating layer (8) is extruded onto the outside of the flat conductor rail (2). [11] Method according to any one of claims 1 to 9, characterized by , that the insulating layer (8) is produced by placing the flat conductor rail (2) provided with the separating layer (4) into an injection molding tool and then injecting the insulating layer (8) onto the outside of the flat conductor rail. [12] Method according to any one of the preceding claims, characterized by, that the application of the separating layer (4) is integrated into a manufacturing process of the flat conductor rail (1) or into a manufacturing process of the insulating layer (8). [13] Method according to any one of the preceding claims, characterized by , that at least one contacting area (3) of the flat conductor rail (1) after removal of the section (9) of the insulating layer (8) a contacting element in the form of a screw tab, a plug-in tongue, a screw bolt or a stranded conductor is attached.

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