Method for adapting at least one optical transmission element to at least one routing path, adaptation device for carrying out the method, optical transmission element and vehicle

Abstract

Method for adapting at least one optical conductor element (1, 2) to at least one routing path (3, 4), in particular in a vehicle (5), wherein the optical conductor element (1, 2) is subjected to heat treatment, wherein the optical conductor element (1, 2) is deformed after the heat treatment according to the routing path (3, 4), wherein the optical conductor element (1, 2) is at least partially made of at least one thermoplastic.

Description

[0001] The invention relates to a method for adapting at least one optical line element to at least one installation path, particularly in a vehicle. Furthermore, the invention relates to a corresponding optical line element and a corresponding vehicle. Furthermore, the invention also relates to an adaptation device.

[0002] Optical cable elements are known from the prior art. These optical cable elements are typically not adaptable to the routing paths within a vehicle. As a result, the optical cable elements are exposed to high mechanical stress, which can cause damage that could lead to functional failure of the optical cable elements.

[0003] JP 2004-133005 A shows a fiber optic cable comprising a glass fiber covered by sheaths. The sheaths comprise inner coatings made of a soft thermoplastic resin and outer coatings made of a thermoplastic resin that is harder than the inner coatings. The inner coatings have a plurality of annular grooves with the inner coating exposed circumferentially. When the fiber optic cable is bent, the edges of the outer coatings on both sides, which are adjacent to each other across the intervening annular grooves, come into contact with each other, preventing the cable from being bent to the specified bending diameter or less.

[0004] US 2015 / 0129126 A1 discloses a bonding method and a bonding tool that enable fast and reliable bonding of an optical fiber to a structural body using a simple process, as well as a method for manufacturing a structural body. In an optical fiber, a strand is coated with a coating portion made of a thermoplastic resin. At least a portion of the coating portion is heated and melted by a heater. The portion of the optical fiber in which the thermoplastic resin is melted and a surface of the structural body are brought into contact with each other in a state in which the thermoplastic resin is melted. A molding roller bonds the optical fiber to the surface of the structural body using pressure. The thermoplastic resin is then cooled and cured, so that the optical fiber is bonded to the structural body.

[0005] A method is proposed for adapting at least one optical line element to at least one installation path, particularly in a vehicle. The optical line element is subjected to heat treatment. Following the heat treatment, the optical line element is deformed according to the installation path. The optical line element is formed at least partially from at least one thermoplastic.

[0006] The optical conduction element is preferably intended for use in a vehicle. The optical conduction element is preferably intended for use in an electric vehicle. An “electric vehicle” should be understood in particular to mean a vehicle that includes an electric drive. In particular, the electric vehicle is driven at least partially by at least one electric drive motor. The electric vehicle can be designed in particular as a hybrid vehicle, in particular as a plug-in hybrid vehicle or as a gas hybrid vehicle, as a battery-electric vehicle, as a fuel cell vehicle, in particular as a hydrogen vehicle, or as another vehicle that appears appropriate to a person skilled in the art. “Intended” should be understood in particular to mean specially programmed, specially equipped and / or specially designed.The fact that an object is intended for a function should be understood in particular to mean that the object performs the function in at least one operating state.

[0007] The vehicle can, in particular, be designed as an automated vehicle. An "automated vehicle" is understood to mean, in particular, a vehicle with one of the automation levels 1 to 5 of the SAE J3016 standard. In particular, the automated vehicle has technical equipment required for these automation levels. The technical equipment includes, in particular, environmental detection sensors, such as radar sensors, lidar sensors, cameras and / or acoustic sensors, control units, or the like. The automated vehicle is preferably designed as a land vehicle. The automated vehicle can, in particular, be designed as a passenger car, preferably as a passenger transport vehicle, as a truck, as a construction vehicle, as an agricultural vehicle, or as another vehicle that a person skilled in the art deems appropriate.The automated vehicle can alternatively be designed as an aircraft, for example as a drone, as an airplane, as a helicopter, as a vertical take-off and landing aircraft or the like, or as a watercraft, in particular as a ship, as a boat or the like.

[0008] The optical line element is preferably intended for data transmission. In particular, the optical line element is intended to connect vehicle components, such as control units, sensors, power electronic components, or the like, for data transmission purposes. Data transmitted by the optical line element can, in particular, be control or regulation signals, sensor data, diagnostic data, navigation data, or other data deemed appropriate by a person skilled in the art. In particular, the optical line element is intended to transmit data using light signals. The optical line element is designed, in particular, as a light guide. The optical line element is preferably designed as an optical waveguide, for example, as an optical cable.

[0009] The optical guide element is at least partially formed from at least one thermoplastic. In particular, the optical guide element can have a multi-layer structure. For example, the optical guide element can comprise an optical fiber that is enclosed by an inner cladding, which is enclosed by an outer cladding. In particular, at least the optical fiber is at least partially, preferably completely, formed from at least one thermoplastic. A thermoplastic is in particular a plastic that can be deformed, in particular reversibly, within a certain temperature range. The thermoplastic can in particular be a polyamide, a polymethyl methacrylate, a polycarbonate, a polyethylene, a polypropylene, a polyetheretherketone or another thermoplastic that appears appropriate to a person skilled in the art.

[0010] The optical line element is intended to be arranged, in particular laid, along a laying path in the vehicle. The laying path can in particular run between two components that the optical line element connects for data transmission purposes. The laying path can be predetermined, for example, by cable ducts, cable holders, cable channels, space restrictions in the vehicle, the routing of high-voltage cables, or the like. In particular, the laying path can be non-linear, for example, bypassing other components. In particular, an optical line element that is not adapted to the laying path can be bent and thus damaged during laying along the laying path, or it cannot be laid due to the complex course of the laying path.Through heat treatment and deformation, the optical cable element can be adapted to the installation path, in particular to enable it to be laid smoothly along the installation path.

[0011] Preferably, the optical guide element is heated during the heat treatment to a temperature at which it is deformable, particularly plastically. The optical guide element can be heated during the heat treatment, for example, to a temperature between 100°C and 300°C. In particular, the thermoplastic is converted into a thermoplastic state by the heat treatment. The optical guide element can be subjected to the heat treatment, particularly in an oven, by means of a radiant heater, or by means of another device deemed appropriate by a person skilled in the art.

[0012] Preferably, the optical guide element is deformed according to the installation path while the thermoplastic is in the thermoplastic aggregate state, particularly immediately after the heat treatment. Alternatively, it is conceivable for the optical guide element to be deformed during the heat treatment. In particular, a shape of the optical guide element is adapted to a course of the installation path. The deformation of the optical guide element can, in particular, take place as free deformation over a tool, as thermoforming, or the like.

[0013] The inventive design of the method advantageously allows an optical line element to be adapted to a routing path. Advantageously, an optical line element with high transmission quality can be provided, enabling uncomplicated integration into a vehicle.

[0014] Furthermore, it is proposed that the deformed optical guide element is cooled in order to establish a shape. Preferably, the optical guide element is cooled following the deformation according to the installation path. In particular, the thermoplastic is converted into a solid state by cooling. In particular, after cooling, the optical guide element retains the shape established by the deformation at least until further heating, in particular until the thermoplastic is converted into a thermoelastic, thermoplastic, or flowable state. The optical guide element can be cooled in particular passively, for example by terminating the heat treatment, or actively, for example by means of a cooling device. In particular, the optical guide element can be cooled while it is located in a mold.Advantageously, the achieved shape of the optical guide element can be permanently fixed.

[0015] It is further proposed that the optical guide element is brought into a shape other than a rectilinear shape by deformation.

[0016] In particular, the optical guide element is formed into a shape other than rectilinear in order to be adapted to a routing path that has a course other than rectilinear. In particular, the optical guide element is formed into a shape that corresponds to the course of the routing path. The optical guide element can, in particular, be formed into an arcuate shape, such as a C-shape, an angular shape, such as an L-shape, or another shape deemed appropriate by a person skilled in the art. Advantageously, an optical guide element optimally adapted to non-reciprocal routing paths can be provided.

[0017] It is further proposed that the optical line element be deformed to bypass damaged areas, in particular mechanical ones, along the installation path. Damaged areas are in particular areas along the installation path that have a negative effect on the optical line element. In particular, damaged areas can have a mechanical effect on the optical line element, in particular damaging the optical line element. Damaged areas can in particular be corners or edges of the installation path. The damaged areas can in particular be formed by components arranged along the installation path, by a chassis of the vehicle, by a body of the vehicle, by a cable duct in which the optical line element is guided, or the like. The optical line element is preferably deformed in such a way that it can be arranged along the installation path without contact with the damaged areas or at least without bending at the damaged areas.Advantageously, the optical cable element can be laid along the installation path without damage.

[0018] It is also proposed that the installation path be defined by at least one cable duct through which the optical line element can be guided. The cable duct is preferably provided to protect the optical line element from mechanical and / or electrical influences. The cable duct can be designed, for example, as a corrugated pipe. The cable duct preferably has a path other than a straight line. The installation path preferably runs within the cable duct. In particular, the optical line element is deformed according to the path of the cable duct. Advantageously, the optical line element can be effectively protected from damage.

[0019] Furthermore, it is proposed that the optical guide element be formed at least partially from at least one polymeric optical fiber. In particular, the optical guide element is designed as a plastic optical waveguide. Preferably, the optical guide element is designed at least partially as a step-index mode fiber, in particular as a step-index multimode fiber, or as a gradient index fiber. Advantageously, a moldable optical guide element with high transmission quality can be provided.

[0020] Furthermore, an optical line element is proposed. In a method according to the invention, the optical line element is adapted to at least one installation path, in particular in a vehicle. Advantageously, an optical line element can be provided that can be easily and damage-free integrated into a vehicle.

[0021] Furthermore, a vehicle is proposed. The vehicle comprises at least one optical line element according to the invention. The optical line element is arranged along at least one installation path to which the optical line element is adapted. In particular, at least one wiring harness of the vehicle can comprise the optical line element. Preferably, the vehicle comprises a plurality of optical line elements. In particular, at least some of the optical line elements can be installed, at least in sections, along the same installation path, in particular have the same shape. In particular, at least some of the optical line elements can be installed, at least in sections, along different installation paths, in particular have different shapes. Advantageously, a particularly operationally safe, reliable, and weight-efficient vehicle can be provided.

[0022] In addition, an adaptation device for carrying out a method according to the invention is proposed. The adaptation device comprises at least one heating unit for subjecting at least one optical guide element to a heat treatment. The adaptation device comprises at least one shaping unit for deforming the optical guide element following the heat treatment according to at least one laying path. The adaptation device can be designed, in particular, as a manually operable and / or an automatic adaptation device. In particular, the units of the adaptation device can be operated manually and / or carry out at least part of the method according to the invention in an automated manner. The heating unit can be designed, in particular, as an oven, as a radiant heater, or as another heating unit that appears appropriate to a person skilled in the art.The molding unit can be designed, in particular, as a molding tool, a thermoformer, or any other molding unit deemed appropriate by a person skilled in the art. Alternatively or in addition to the molding unit, it is conceivable for the optical guide element to be manually shaped according to the installation path. Advantageously, an adjustment device can be provided that enables efficient adjustment of the optical guide element to the installation path.

[0023] Furthermore, it is proposed that the adaptation device comprise at least one cooling unit for cooling the deformed optical guide element in order to establish a shape. The cooling unit can be designed, in particular, as a cooling device, as a cooling chamber, or as another cooling unit deemed appropriate by a person skilled in the art. Advantageously, a cooling unit can be provided with which the achieved shape of the optical guide element can be permanently fixed.

[0024] The invention is illustrated by an exemplary embodiment in the following figures. They show: Fig. 1 a vehicle according to the invention in a schematic representation, Fig. 2 an optical line element in a schematic representation, Fig. 3 the optical line element from Fig. 2 before adaptation to at least one installation path in a schematic representation, Fig. 4 a method according to the invention in a schematic representation, Fig. 5 the optical line element from Fig. 2 and Fig. 3 after adaptation to at least one laying path in a schematic representation, Fig. 6 a flow diagram of the method according to the invention Fig. 4 in a schematic representation, Fig. 7 shows a further optical line element before adaptation to at least one further installation path in a schematic representation, Fig. 8 a method according to the invention in a schematic representation and Fig. 9 the further optical line element from Fig. 7 after adaptation to at least one further installation path in a schematic representation.

[0025] Fig. 1 shows a vehicle 5 in a schematic representation. The vehicle is designed, for example, as an electric vehicle 5. The vehicle 5 is designed, for example, as a land vehicle, in particular as a passenger car. The vehicle 5 comprises at least one optical line element 1, 2. In the present exemplary embodiment, the vehicle 5 comprises, for example, a plurality of optical line elements 1, 2. For the sake of clarity, Fig. 1 shows two optical line elements 1, 2, and the following description is limited to the two optical line elements 1, 2, in particular one optical line element 1 and another optical line element 2. The optical line elements 1, 2 have different shapes. The optical line element 1 has, for example, an arcuate shape, in particular a C-shape. The further optical line element 2 has, for example, an angular shape, in particular a Z-shape.

[0026] The optical line elements 1, 2 are arranged along laying paths 3, 4 to which the optical line elements 1, 2 are adapted (cf. Fig. 5 and Fig. 9). In the present exemplary embodiment, the optical line elements 1, 2 are laid along different laying paths 3, 4, for example. The optical line element 1 is arranged along a laying path 3. The further optical line element 2 is arranged along a further laying path 4. The optical line elements 1, 2 are provided for data transmission. The optical line elements 1, 2 are provided for connecting components of the vehicle for data transmission purposes (not shown here). The optical line elements 1, 2 are formed at least partially from at least one thermoplastic.

[0027] Fig. Figure 2 shows the optical line element 1 in a schematic representation. The optical line element 1 is designed as an optical waveguide, in particular as an optical cable. The optical line element 1 is formed at least partially from at least one polymer optical fiber 14. The optical line element 1 has a multi-layer structure. The optical line element 1 comprises the polymer optical fiber 14. The polymer optical fiber 14 is formed from a thermoplastic. The polymer optical fiber 14 is encased by an inner cladding 20. The inner cladding 20 is encased by an outer cladding 21. For the sake of clarity, Fig. 2, the inner sheath 20 and the outer sheath 21 are partially masked. The further optical line element 2 is constructed analogously to the optical line element 1.

[0028] Fig. 3 shows the optical line element 1 from Fig. 2 before adaptation to at least one installation path 3 in a schematic representation. The installation path 3 is defined by at least one cable duct 12 through which the optical line element 1 can be guided. The cable duct 12 has a course that differs from a straight line, in particular an arcuate course. The installation path 3 runs within the cable duct 12. The optical line element 1 that is not adapted to the installation path 3 abuts against the cable duct 12 at damaged areas 6, 7, 8, in particular mechanical ones. The damaged areas 6, 7, 8 can have a mechanical effect on the optical line element 1, in particular damage the optical line element 1. In the present exemplary embodiment, the damaged areas 6, 7, 8 are formed, for example, by edges of the installation path 3, in particular of the cable duct 12.

[0029] Fig. 4 shows a method for adapting the optical line element 1 to the at least one laying path 3, in particular in the vehicle 5, in a schematic representation. Fig. 4 also shows an adaptation device 15 for carrying out the method. In a first method step 22, the optical line element 1 is subjected to a heat treatment. The optical line element 1 is subjected to the heat treatment by means of at least one heating unit 16 of the adaptation device 15. The heat treatment is Fig. 4 by thermal radiation 25. During the heat treatment, the optical guide element 1 is heated to a temperature at which the optical guide element 1 is deformable, in particular plastically. The thermoplastic is converted into a thermoplastic aggregate state by the heat treatment.

[0030] In a second method step 23, the optical guide element 1 is deformed following the heat treatment according to the installation path 3. Following the heat treatment, the optical guide element 1 is deformed according to the at least one installation path 3 by means of at least one molding unit 17 of the adaptation device 15. While the thermoplastic is in the thermoplastic aggregate state, in particular immediately following the heat treatment, the optical guide element 1 is deformed according to the installation path 3. A shape of the optical guide element 1 is adapted to a course of the installation path 3.

[0031] The optical line element 1 is deformed into a shape other than a straight line. The optical line element 1 is formed into a shape that corresponds to the course of the installation path 3. The optical line element 1 is deformed to bypass the damaged areas 6, 7, 8, particularly mechanical ones, along the installation path 3.

[0032] In a third method step 24, the deformed optical guide element 1 is cooled to establish a shape. The deformed optical guide element 1 is cooled by means of at least one cooling unit 19 of the adaptation device 15 to establish the shape. Following the deformation, the optical guide element 1 is cooled according to the installation path 3. The thermoplastic is converted into a solid state by cooling. After cooling, the optical guide element 1 retains the shape established by the deformation at least until it is heated again, in particular until the thermoplastic is converted into a thermoelastic, thermoplastic, or flowable state. In the present exemplary embodiment, the optical guide element 1 is cooled, for example, while it is located in the molding unit 17.

[0033] Fig. 5 shows the optical line element 1 from Fig. 2 and Fig. 3 after adaptation to the at least one installation path 1 in a schematic representation. The optical line element 1 is arranged along the installation path 3. The optical line element 1 is guided through the cable duct 12. The optical line element 1 is shaped in such a way that the damaged areas 6, 7, 8 are bypassed.

[0034] Fig. 6 shows a flowchart of the process from Fig. 4 in a schematic representation. In Fig. 6 is a sequence of Fig. 4 shown process steps 22, 23, 24 are shown.

[0035] Fig. 7 shows the further optical line element 2 before adaptation to the at least one further installation path 4 in a schematic representation. The further installation path 4 is defined by at least one further cable duct 13 through which the further optical line element 2 can be guided. The further cable duct 13 has a course that differs from a straight line, in particular an angular course. The further installation path 4 runs within the further cable duct 13. The further optical line element 2 that is not adapted to the further installation path 4 abuts against the further cable duct 13 at further, in particular mechanical, damaged points 9, 10, 11. The further damaged points 9, 10, 11 can have a mechanical effect on the further optical line element 2, in particular damaging the further optical line element 2.In the present embodiment, the further damaged areas 9, 10, 11 are formed, for example, by corners of the further laying path 4, in particular of the further cable duct 13.

[0036] Fig. 8 shows a method for adapting the further optical line element 2 to the further installation path 4 in a schematic representation. Fig. 8 also shows the adaptation device 15 for carrying out the method. In a first method step 22', the further optical line element 2 is subjected to a heat treatment. The further optical line element 2 is subjected to the heat treatment by means of the heating unit 16. The heat treatment is in Fig. 8 by thermal radiation 25. During the heat treatment, the further optical guide element 2 is heated to a temperature at which the further optical guide element 2 is deformable, in particular plastically. The thermoplastic is converted into a thermoplastic aggregate state by the heat treatment.

[0037] In a second method step 23', the further optical line element 2 is deformed following the heat treatment according to the further installation path 4. The further optical line element 2 is deformed following the heat treatment according to the at least one further installation path 4 by means of at least one further forming unit 18 of the adaptation device 15. The further optical line element 2 is deformed according to the further installation path 4 while the thermoplastic is in the thermoplastic aggregate state, in particular immediately following the heat treatment. A shape of the further optical line element 2 is adapted to a course of the further installation path 4.

[0038] The additional optical line element 2 is formed into a shape other than a rectilinear shape by deformation. The additional optical line element 2 is formed into a shape that corresponds to a course of the additional installation path 4. The additional optical line element 2 is deformed to bypass the additional, particularly mechanical, damaged areas 9, 10, 11 along the additional installation path 4.

[0039] In a third method step 24', the deformed further optical line element 2 is cooled in order to establish a shape. The further deformed optical line element 2 is cooled by means of the cooling unit 19 in order to establish the shape. Following the deformation, the further optical line element 2 is cooled according to the further laying path 4. The thermoplastic is converted into a solid state by cooling. After cooling, the further optical line element 2 retains the shape established by the deformation at least until it is heated again, in particular until the thermoplastic is converted into a thermoelastic, thermoplastic, or flowable state. In the present exemplary embodiment, the further optical line element 2 is cooled, for example, while it is located in the further forming unit 18.

[0040] Fig. 9 shows the further optical line element 2 from Fig. 7 after adaptation to the at least one further installation path 4 in a schematic representation. The further optical line element 2 is arranged along the further installation path 4. The further optical line element 2 is guided through the further cable duct 13. The further optical line element 2 is shaped such that the further damaged areas 9, 10, 11 are bypassed. Reference symbol 1 optical line element 2 optical line element 3 Installation route 4 Installation route 5 vehicle 6 Damaged area 7 Damaged area 8 Damaged area 9 Damaged area 10 Damaged area 11 Damaged area 12 cable duct 13 Cable duct 14 polymer optical fiber 15 Adjustment device 16 Heating unit 17 Forming unit 18 mold unit 19 Cooling unit 20 inner jacket 21 outer shell 22 Process step 23 Process step 24 process steps 25 Thermal radiation

Claims

[1] Method for adapting at least one optical line element (1, 2) to at least one laying path (3, 4), in particular in a vehicle (5), wherein the optical line element (1, 2) is subjected to a heat treatment, wherein the optical line element (1, 2) is deformed following the heat treatment in accordance with the laying path (3, 4), wherein the optical line element (1, 2) is at least partially formed from at least one thermoplastic. [2] The method according to claim 1, wherein the deformed optical guide element (1, 2) is cooled to establish a shape. [3] Method according to claim 1 or 2, wherein the optical line element (1, 2) is brought into a shape other than a rectilinear shape by the deformation. [4] Method according to one of the preceding claims, wherein the optical line element (1, 2) is deformed to bypass, in particular mechanical, damaged areas (6, 7, 8, 9, 10, 11) along the laying path (3, 4). [5] Method according to one of the preceding claims, wherein the laying path (3, 4) is defined by at least one cable duct (12, 13) through which the optical line element (1, 2) can be guided. [6] Method according to one of the preceding claims, wherein the optical line element (1, 2) is formed at least partially from at least one polymeric optical fiber (14). [7] Optical line element adapted to at least one laying path (3, 4), in particular in a vehicle (5), in a method according to one of the preceding claims. [8] Vehicle comprising at least one optical line element (1, 2) according to claim 7, which is arranged along at least one laying path (3, 4) to which the optical line element (1, 2) is adapted. [9] Adaptation device for carrying out a method according to one of claims 1 to 6, comprising at least one heating unit (16) for subjecting at least one optical line element (1, 2) to a heat treatment, and at least one forming unit (17, 18) for deforming the optical line element (1, 2) following the heat treatment according to at least one laying path (3, 4). [10] Adaptation device according to claim 9, comprising at least one cooling unit (19) for cooling the deformed optical guide element (1, 2) to establish a shape.

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