Contacting sheet for a composite component, textile semi-finished product with contacting sheet, composite component for a motor vehicle and manufacturing method

Abstract

Contacting plate (10) which is designed to be connected to a sensor wire (24) and to be pressed into a fiber composite material (12), wherein the contacting plate (10) has a plate-like base body (14), characterized in that the contacting plate (10) has an embossed recess (20) which is provided in an edge region (18) of the contacting plate (10), so that a trough-like recess (20) is formed which is open on one side and which is designed to receive a material-locking connection (22) with the sensor wire (24).

Description

[0001] The invention relates to a contact plate configured to be connected to a sensor wire and pressed into a fiber composite material, wherein the contact plate has a plate-like base body. The invention further relates to a textile semi-finished product with such a contact plate, a manufacturing method for a composite component, a composite component, and a motor vehicle with such a composite component.

[0002] Various approaches to electrical contact creation in composite components are known from the prior art. Examples include DE 10 2014 205 015 A1, DE 10 2006 027 213 A1, DE 10 2012 213 917 A1, DE 10 2014 018 979 A1, and DE 10 2011 109 474 A1. For the technological background of soldering connections outside of composite materials, reference is made to DE 20 08 735 A and the use of so-called solder lugs.

[0003] In the production of fiber-reinforced composite components, such as underbody protection elements for motor vehicles, it is necessary to be able to electrically connect or contact a sensor wire located within the composite component so that corresponding signals can be accessed by a control unit or similar device. For this purpose, contact plates can be used that are connected to one end of the sensor wire and can then be electrically connected from the outside, for example by means of a screw or bolt or similar, even if the contact plate is integrally integrated into the composite component.

[0004] The object underlying the invention is seen as being to provide a contact plate which enables a reliable and stable connection with the sensor wire, particularly taking into account further processing in a mold.

[0005] This problem is solved by a contact plate, a semi-finished product, a manufacturing process, a composite component, and a motor vehicle, each with the features of its respective independent patent claim. Advantageous embodiments with expedient further developments are specified in the dependent patent claims.

[0006] A contact plate is proposed, designed to be connected to a sensor wire and pressed into a fiber composite material. The contact plate has a plate-like base. It features a embossed recess designed to accommodate a bonded connection, particularly a soldered joint, with the sensor wire. This ensures that the soldered sensor wire and the applied solder material cannot be detached from the contact plate during subsequent pressing in a mold. In particular, this also prevents the sensor wire from shearing off.

[0007] The contact plate has a recess in one of its edges. This creates a kind of trough-like or basin-like depression in the edge area, which is open on one side. The sensor wire can be guided to the contact plate through the open edge, and the solder material can be applied in the recess.

[0008] The contact plate can have at least one through-opening arranged such that an imaginary connecting line between the recess and the through-opening runs essentially parallel to an edge of the contact plate where no recess is provided. Such a through-opening can be used, in particular, to temporarily attach the contact plate to a textile semi-finished product, especially a fiberglass-reinforced fabric or nonwoven, using embroidery techniques. Furthermore, such a through-opening facilitates the subsequent fixing of the contact plate in a pressed composite component because heated plastic passes through the through-opening, so that after the plastic cools and solidifies, a positive-locking connection is formed between the contact plate and the plastic.

[0009] In addition to at least one through-hole, the contact plate may have groove-like or hole-like connecting sections designed to form a positive-locking connection with a plastic compound. Such connecting sections improve the final connection between the contact plate and the molded composite component.

[0010] The contact plate can have a predefined contact area located outside the recess, particularly in a central area of ​​the plate-like base body. Since the position of the contact plate in a finished composite component is essentially known, but can also be subsequently determined by appropriate analytical methods, it is possible to establish an electrical connection between the contact plate embedded in the composite component and the sensor wire by means of a screw, bolt, or the like, which is attached to the composite component in the area of ​​the contact zone.

[0011] Furthermore, a textile semi-finished product is proposed, in particular a glass fiber-containing fabric or nonwoven, with at least one contact plate described above and a sensor wire which is materially connected to the contact plate in the area of ​​the recess, wherein the contact plate and the sensor wire are fixed to the textile semi-finished product by means of embroidery.

[0012] In the textile semi-finished product, the contact plate is fixed to the semi-finished product in such a way that the recess of the contact plate faces away from the semi-finished product. In other words, the trough-like or basin-like recess is designed so that its more convex outer surface faces the semi-finished product and its more concave inner surface faces away from it. This allows the recess of the contact plate to serve as protection for the sensor wire, which is bonded or soldered to the material, particularly from a mold in which the semi-finished product is held and formed and pressed under pressure to produce a composite component.

[0013] In the textile semi-finished product, the contact plate can be stitched to the semi-finished product in the area of ​​its at least one through-hole. This at least one through-hole enables a simple and reliable connection between the contact plate and a fixing thread that is attached to the textile semi-finished product.

[0014] A method for manufacturing a composite component, in particular an underbody protection element for a motor vehicle, is also proposed, comprising the following steps: Providing a first textile semi-finished product with integrated sensor wire; providing a contact plate described above; Preliminary fixing of the contact plate to the semi-finished product; material-locking connection of the sensor wire to the contact plate in the area of ​​the recess formed on the contact plate; provision of a second textile semi-finished product; Arranging the first textile semi-finished product and the second textile semi-finished product in a mold such that a cavity is formed between the two semi-finished products, wherein the first textile semi-finished product is arranged in the mold such that the material-locking connection faces the cavity; Filling the cavity with a plastic molding compound and pressing the two semi-finished products together with the plastic molding compound to form the composite component.

[0015] In this process, the contact plate can be temporarily fixed to the semi-finished product by means of an embroidery connection.

[0016] In this process, the material-bonded connection between the sensor wire and the contact plate can be achieved by soldering.

[0017] A multi-layered composite component, in particular an underbody protection element for a motor vehicle, is also proposed, with a first fiber composite layer; a second fiber composite layer; a plastic layer arranged between the fiber composite layers, wherein the fiber composite layers and the plastic layer are pressed together, the first fiber composite layer comprising at least one sensor wire. It is provided that at least one contact plate, described above and materially bonded to a corresponding sensor wire, is arranged in the first fiber composite layer.

[0018] A motor vehicle, in particular an electrically powered motor vehicle, may be equipped with such an underbody protection element.

[0019] Further advantages and details of the invention will become apparent from the following description of embodiments with reference to the figures. These show: Fig. 1 a simplified and schematic top view of a contact plate arranged on a textile semi-finished product; Fig. 2 a simplified and schematic sectional view corresponding to section line II-II of the Fig. 1; Fig. Figure 3 in sub-figures A) to C) shows simplified and schematic process steps for manufacturing a composite component with a contact plate.

[0020] In Fig. Figure 1 shows a simplified and schematic top view of a contact plate 10. The contact plate 10 is shown here by way of example on a textile semi-finished product 12, in particular a glass fiber-containing fabric or nonwoven.

[0021] The contact plate 10 has a substantially rectangular shape with a plate-like base body 14, two longer sides or edges 16, and two shorter sides or edges 18. At the point in the Fig. 1. On the left edge 18, the contact plate 10 has an embossed recess 20. The recess 20 is designed to accommodate a material-locking connection 22, in particular a soldered connection with a sensor wire 24.

[0022] The sensor wire 24, shown here only as a short segment, is connected to the semi-finished product 12 using textile techniques. In particular, the sensor wire 24 serves to detect deformations and / or damage to a finished composite component due to changes in the electrical resistance of the sensor wire 24. Such a sensor wire 24 can, for example, be arranged in a meandering pattern on a textile semi-finished product 12.

[0023] In the example shown, the contact plate 10 has two through-openings 26. The number of through-openings 26 is not limited to two; there may be only one through-opening 26 or there may be more than two such through-openings 26.

[0024] The contact plate 10 is temporarily connected to the textile semi-finished product 12 by means of an embroidery thread 28, in particular by means of suitable embroidery fixing, which is simplified by the cross 30. It should be noted that the sensor wire 24 can also be attached to the semi-finished product 12 by means of the embroidery thread 28. Furthermore, it is also conceivable that the sensor wire 24, together with the embroidery thread 28, is guided from the connection point 22 to the through-opening 26.

[0025] In Fig. A contact area 32 is indicated by a dashed rectangle, which is shown here on the base body 14 of the contact plate 10. The contact area 32 serves in particular to establish an electrically conductive connection between the contact plate 10 and an external component, such as a control unit or the like, for example by using a screw, a bolt end or the like, the tip of which is in contact with the contact area.

[0026] From the Fig. 1 It is further evident that an imaginary connecting line between the recess 20 and the through-opening 26 runs essentially parallel to an edge 16 of the contacting plate, where no recess 20 is provided.

[0027] Fig. Figure 2 shows a simplified and schematic sectional view corresponding to section line II-II of the Fig. 1 the contact plate 10 and the semi-finished product 12.

[0028] This illustration again shows the embossed recess 20 in the contact plate 10. The sensor wire 24 is electrically connected to the contact plate 10 in the trough- or basin-shaped recess 20 by means of a solder joint 22.

[0029] From the sectional view 22 it can also be seen that the embroidery thread 28 is guided through the through-openings 26 and is connected to the semi-finished product 12 in an embroidery technique, so that the contact plate 10 is fixed at least temporarily to the semi-finished product 12, in particular for further processing of the semi-finished product 12 together with the contact plate 10.

[0030] Fig. Figure 3 shows, in sub-figures A) to C), a method 500 for manufacturing a composite component, in particular an underbody protection element for a motor vehicle. The method 500 comprises the following steps: In step S501, a first textile semi-finished product 12 with integrated sensor wire is provided.

[0031] According to step S502, a contact plate 10 is provided.

[0032] In step S503, the contact plate 10 is provisionally fixed to the semi-finished product 12. The provisional fixing of the contact plate 10 to the semi-finished product 12 can be done by means of an embroidery connection.

[0033] According to step S504, the sensor wire 24 is connected to the contact plate 10 in the area of ​​the recess 20 formed on the contact plate 10. The material-locking connection between the sensor wire 24 and the contact plate 10 can be made in particular by soldering.

[0034] The state of the semi-finished product 12, with the contact plate provisionally fixed to it, as achieved up to this point according to method 500, is from the Fig. 3A visible.

[0035] According to a further step S505, a second textile semi-finished product 12a is provided.

[0036] According to step S506, the first textile semi-finished product 12 and the second textile semi-finished product 12a are arranged in a mold such that a cavity 40 is formed between the two semi-finished products 12, 12a, wherein the first textile semi-finished product 12 is arranged in the mold such that the material-locking connection 22 faces the cavity 40. In the Fig. 3A is the forming tool schematically indicated by the arrows 42.

[0037] According to step S507, the cavity 40 is filled with a plastic molding compound 44, and subsequently, according to step S508, the two semi-finished products 12, 12a are pressed together with the plastic molding compound 44 to form the composite component 50. This is in Fig. 3B illustrates.

[0038] Fig. Figure 3C shows the finished composite component 50 with its layer structure, in particular the two glass fiber-containing cover layers 12, 12a and the intervening plastic layer 44. The contact plate 10, which is incorporated into the composite component and is positively and materially bonded, is also visible. Furthermore, it shows Fig. 3C simplifies a connecting element 46, for example a screw or a bolt, which is designed to enable an electrical connection to the contact plate 10 incorporated in the composite component 50 and thus to the sensor wire 24.

[0039] Fig. Figure 3C also illustrates, by way of example, the positive-locking connection between the plastic layer 44 and the contact plate 10 when the plastic 44 at least partially enters or passes through the through-openings 26 and hardens therein. It should also be noted that the contact plate 10 may have further, not shown, hole-like or groove-like connecting sections into which the plastic material 44 can enter, in order to enable an improved positive-locking connection between the plastic and the contact plate 10.

[0040] The contact plate 10 shown here can be used, for example, for an underbody protection element (composite component 50) of a motor vehicle. The contact plate 10, which is connected, for example, via the Fig.Since the connecting element 46 shown in Figure 3C is connected to a control unit of the motor vehicle, changes in the electrical resistance in the sensor wire 24 can be detected in order to draw conclusions about deformation, impact, or even damage to the underbody protection element. Such an underbody protection element made of a fiber composite material is used particularly in electrically powered motor vehicles and protects a high-voltage battery located above the vehicle.

Claims

[1] Contact plate (10) which is configured to be connected to a sensor wire (24) and pressed into a fiber composite material (12), wherein the contact plate (10) has a plate-like base body (14), characterized by , that the contact plate (10) has an embossed recess (20) which is provided in an edge region (18) of the contact plate (10) so that a trough-like recess (20) is formed which is open on one side and which is designed to accommodate a material-locking connection (22) with the sensor wire (24). [2] Contact plate (10) according to claim 1, characterized by , that it has at least one through-opening (26) which is arranged such that an imaginary connecting line between the recess (20) and the through-opening (26) runs parallel to an edge (16) of the contacting plate (10) on which no recess is provided. [3] Contact plate (10) according to claim 1 or 2, characterized by , that in addition to the at least one through-opening (26) it has groove-like or hole-like connecting sections which are designed to form a positive connection with a plastic compound (44). [4] Contact plate (10) according to any one of the preceding claims, characterized by , that it has a predefined contact area (32) which is provided outside the recess (20). [5] Textile semi-finished product (12) with at least one contact plate (10) according to one of the preceding claims and a sensor wire (24) which is materially connected to the contact plate (10) in the area of ​​the recess (20), wherein the contact plate (10) and the sensor wire (24) are fixed to the textile semi-finished product (12) by embroidery, wherein the contact plate (10) is fixed to the semi-finished product (12) in such a way that the recess (20) of the contact plate (10) faces away from the semi-finished product (12). [6] Textile semi-finished product (12) according to claim 5, insofar as referring to claim 2, wherein the contacting plate (10) is connected to the semi-finished product (12) by embroidery in the area of ​​its at least one through-opening (26). [7] Method (500) for manufacturing an underbody protection element for a motor vehicle, comprising the steps: Providing (S501) a first textile semi-finished product (12) with integrated sensor wire (24); Providing (S502) a contact plate (10) according to one of claims 1 to 4; Preliminary fixing (S503) of the contact plate (10) to the semi-finished product (12); Material-locking connection (S504) of the sensor wire (24) with the contact plate (10) in the area of ​​the recess (20) formed on the contact plate (10); Providing (S505) a second textile semi-finished product (12a); Arranging (S506) the first textile semi-finished product (12) and the second textile semi-finished product (12a) in a molding tool (42) such that a cavity (40) is formed between the two semi-finished products (12, 12a), wherein the first textile semi-finished product (12) is arranged in the molding tool (42) such that the material-locking connection (22) in the area of ​​the recess (20) of the contacting plate (10) faces the cavity (40); Filling (S507) the cavity (40) with a plastic molding compound (44) and pressing (S508) the two semi-finished products (12, 12a) with the plastic molding compound (44) to form the underbody protection element. [8] Method (500) according to claim 7, wherein the preliminary fixing (S503) of the contacting plate (10) to the semi-finished product (12) is carried out by means of an embroidery connection (28, 30). [9] Method (500) according to claim 7 or 8, wherein the material-jointed connection (22) between sensor wire (24) and contact plate (10) is made by soldering. [10] Underbody protection element for a motor vehicle, with a first fiber composite layer (12); a second fiber composite layer (12a); a plastic layer (44) arranged between the fiber composite layers (12, 12a), wherein the fiber composite layers (12, 12a) and the plastic layer (44) are pressed together, wherein the first fiber composite layer (12) has at least one sensor wire (24), characterized by , that in the first fiber composite layer (12) at least one contact plate (10) is materially connected to a relevant sensor wire (24) according to one of claims 1 to 4. [11] Electrically powered motor vehicle with an underbody protection element according to claim 10.

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