Composite component with an electrically conductive base element and method for carrying out a leak test with the composite component

Abstract

The invention relates to a composite component (1) with an electrically conductive base element (2), wherein the surface of the electrically conductive base element (2) is provided with a sheath (3) made of an insulating material for electrical insulation, and wherein the base element (2) has at least two spaced-apart, sheath-free free regions (5, 6), each of which is located in the interior of a chamber (7, 8) connected to the sheath. According to the invention, at least two free regions (5, 6) located within different chambers (7, 8) are connected to one another in a fluid-conducting manner by means of a fluid-conducting structure (9).

Description

Technical area

[0001] The invention relates to a composite component with an electrically conductive base element. Furthermore, the invention relates to a method for conducting a leak test with such a composite component. State of the art

[0002] DE 199 46 825 C1 discloses a housing with a pressure compensation device. DE 101 03 594 A1 discloses a pressure compensation device for a housing of a control unit. DE 10 2017 129 061 B3 discloses a leak testing device for a charging socket for supplying electrical energy to an energy storage device. Description of the invention

[0003] A composite component with an electrically conductive base element, which is partially covered with a sheath made of an insulating material for electrical insulation, represents a complex and technically sophisticated component. This type of component is required in a wide variety of applications where both reliable electrical conductivity and safe insulation are required.

[0004] Examples of this can be found in electrical engineering and electronics. Such composite components are particularly important in the automotive industry and modern vehicle technology. Here, they are frequently used in areas where electrical and electronic components must operate under extreme conditions. A typical example is their use in bus systems or battery systems in electric vehicles, where a reliable electrical connection and secure insulation are crucial.

[0005] The central element of the composite component is the electrically conductive base element. This can be made of various materials with good electrical conductivity, such as copper, aluminum, or various alloys. The base element is preferably mechanically stable and dimensionally stable to meet the structural requirements of the application. Furthermore, it must offer a surface suitable for subsequent encasing with insulating material.

[0006] Encasing the base element with an insulating material provides electrical insulation and is crucial for the functionality of the composite component. Insulating materials can exhibit a variety of properties, which are specifically selected depending on the application. Commonly used materials are plastics such as PVC, polyethylene, or special insulating varnishes, which possess good insulating properties and high resistance to environmental influences.

[0007] A special feature of such composite components are spaced-apart, sheath-free areas on the surface of the base element. These free areas are deliberately left open to create specific electrical contact points or to keep certain functional areas of the component accessible. For example, to ensure the structural integrity and tightness of the sheath, these free areas can be enclosed or surrounded by chambers that are part of the sheath. These chambers are designed so that the free areas are located within the interior of the respective chamber. This protects the exposed areas from external influences and mechanical damage, while simultaneously ensuring electrical insulation of the remaining areas.

[0008] The design and manufacture of these chambers represents a significant technical challenge. One of the greatest difficulties with such composite components is conducting leak tests. The unencased open areas must be reliably protected against the ingress of moisture, dust, and other contaminants to ensure the long-term functionality and reliability of the component. Leak testing is often difficult to perform, especially if it is to be performed precisely and without subsequent machining of the composite component. Therefore, performing a leak test often requires subsequent machining of the composite component. This is not only time-consuming but often results in the destruction of the structure or certain areas of the component.

[0009] In addition, it is often necessary to maintain a uniform pressure in the various chambers of a composite component, for example, to ensure the stability and functionality of the chambers themselves or to avoid pressure differences that could lead to damage or malfunctions. Such uniform pressure can only be achieved by using additional pressure equalization elements in each chamber.

[0010] In contrast, it is the object of the present invention to provide a composite component with an electrically conductive base element by means of which functional tests, such as a leak test and / or pressure equalization, can be carried out in a particularly simple and, in particular, non-destructive manner.

[0011] This problem is solved by the features of the independent patent claims. Advantageous embodiments are specified in the description, the figures, and the dependent claims.

[0012] According to the invention, a composite component is provided with an electrically conductive base element, wherein the surface of the electrically conductive base element is provided, at least in some regions, with a sheath made of an insulating material for electrical insulation, and wherein the base element has at least two spaced-apart, sheath-free free regions, each located in the interior of a chamber connected to the sheath. According to the invention, at least two free regions of the base element located within different, for example, spaced-apart, chambers are fluidly connected to one another by means of a fluid-conducting structure.

[0013] In other words, the invention relates to a composite component comprising an electrically conductive base element provided with a sheath. The sheath comprises chambers above or around the sheath-free free areas, creating free areas on the inside of the chambers, i.e., those located inside the chambers. These free areas on the inside of two different chambers are fluidically connected to one another by a fluid-conducting structure. This enables a reproducible fluid exchange between two or more chambers in the finished component, for example, to conduct a leak test between two or more chambers or to create a simple pressure equalization option between two or more chambers, without the composite component itself having to be reworked for such functional tests.

[0014] The fluid guidance structure according to the invention for flow connection between multiple chambers thus offers the advantage of effective and reliable leak testing, as a test fluid can circulate smoothly between the chambers. This advantageously eliminates the need for complicated post-processing of the composite component. Furthermore, such a fluid guidance structure can also ensure continuous and automatic pressure equalization between the chambers, for example, when pressure differences arise due to temperature fluctuations or operational loads.

[0015] In the present context, the term “fluid” is to be understood explicitly and comprehensively and includes not only gases, such as air, but also liquids.

[0016] In automotive engineering, bus structures are regularly used for the electrical and electronic networking of vehicle systems. A typical bus structure consists of bus tracks made of conductive materials such as copper or aluminum and often encased in an insulating layer. These bus tracks serve as power rails that conduct electrical power to the various components in the vehicle. Electronic control units (ECUs) are connected to the bus tracks and monitor and control various functions such as engine management, braking, and infotainment. The ECUs communicate over the bus using specific protocols such as CAN (Controller Area Network) for reliable communication, LIN (Local Interconnect Network) for less critical applications, and FlexRay for safety-critical systems. Ethernet is increasingly being used for data-intensive applications.These bus tracks are often also equipped with special connectors that ensure a secure electrical connection to the ECUs. These connectors or plug elements can, for example, be formed by the electrically conductive base element used in the context of the present invention, which is then placed with one of its free areas, for example, in at least one correspondingly assigned chamber of a bus structure and electrically connected there to a connection element. While a free area of ​​the electrically conductive base element located in another, further chamber is then typically used to connect to another electrical component or system. This could, for example, be another control unit (ECU), a sensor, an actuator, or another electrical component that is part of the electrical circuit.Accordingly, according to a particularly preferred specific embodiment, the electrically conductive base element can be electrically conductively connected to a connection element in at least one of the chambers. This connection element can then be formed, for example, by a current-carrying rail sheathed with an insulating material, for example, by a current-carrying rail of a bus track sheathed with an insulating material, as described above.

[0017] Particularly in connection with a leak test, it is particularly advantageous if at least one of the chambers is designed as a fluid-tight, i.e. in the present context gas-tight and / or liquid-tight, closed chamber, in particular as a hollow chamber, which is suitable and designed to be pressurized with a fluid such that the fluid flows via the fluid conducting structure to at least one further chamber. In this context, it is preferably further provided that the electrical connection element with a connection region is guided in a fluid-tight manner from the outside through a chamber wall into the fluid-tight closed chamber. In order to be able to insert the connection element in a fluid-tight manner from the outside through the chamber wall into the second chamber, a sealing element, for example a sealing clip or the like, can be provided in the wall-side feed-through region.This makes it particularly easy to check whether leaks are occurring in the area of ​​this chamber and whether the fluid is actually flowing completely from this fluid-tight chamber forming a first chamber into the additional chamber forming a second chamber. For example, the test fluid can be supplied via the chamber wall, for example, where the electrical connection element is routed through the chamber wall into the interior of the chamber.

[0018] In this context, it is further particularly advantageous if the at least one further chamber is suitable and designed to be coupled to a measuring device for measuring the amount of fluid flowing into the at least one further chamber. The at least one further chamber can be either fluid-tight and closed or open, as long as in the latter case it is also ensured that the incoming amount of fluid is fed to the measuring device in its entirety. Since no fluid can escape uncontrollably in a fluid-tight, closed chamber, the measuring device can be connected directly to the chamber so that all of the fluid entering the chamber is fed to the measuring device. In an open chamber, on the other hand, the chamber is not completely closed and can therefore communicate openly with the environment.In this case, it must be ensured that the entire incoming fluid volume reaches the measuring device without any part of it escaping.

[0019] With a structure as described above, a method according to the invention for carrying out a leak test can be carried out in a functionally reliable manner in which the at least one fluid-tight closed chamber, in particular a hollow chamber, is supplied with a fluid in such a way that a defined initial quantity of the fluid flows via the fluid guide structure to at least one further chamber, which is coupled to a measuring device for detecting the quantity of fluid flowing into the at least one further chamber, wherein an evaluation device is provided which assesses the tightness of the flow path, preferably the tightness of the at least one fluid-tight closed chamber and / or the fluid guide structure up to the at least one further chamber, based on a comparison of the initial quantity of the fluid with the inflowing quantity of fluid.

[0020] According to a specific further development, the free area located in the further chamber is suitable and designed to be coupled to a further connection element, for example a further electrical and / or electronic component.

[0021] The chambers can, in principle, have any geometry, for example, a round or square outer and / or inner geometry. Furthermore, the chambers can be designed, for example, as an upwardly open chamber that can be sealed fluid-tight by means of a lid, for example, by plastic welding in the case of a plastic material.

[0022] According to a particularly preferred embodiment, which is easy to manufacture, for example, in conjunction with an injection molding process, the chambers can be an integral part of the casing and can be connected to it, at least in some areas, using the same material and / or in one piece. Alternatively, the chambers could also be formed by separate components that are integrated into the casing as part of the same during production.

[0023] According to a particularly preferred specific embodiment, which is also simple to manufacture, the fluid conducting structure is formed in the region between the upper side of the base element facing the casing and the underside of the casing facing the base element. As a result, as is the case according to a further particularly preferred optional embodiment, the fluid conducting structure can be formed in a simple and functionally reliable manner by at least one channel-like depression introduced into the surface of the base element, which opens into the associated free areas. Deeper conducting structures that lie inside the material of the base element and are very complex to manufacture, such as tubular fluid conducting channels, can thus advantageously be avoided, although these can of course also be realized in principle if desired.

[0024] For a particularly preferred flow connection, it is also advantageous if the fluid guide structure is formed by a plurality of spaced-apart channel-like depressions which open into the associated free areas.

[0025] The fluid-conducting structure can, in principle, be incorporated into the surface of the base element in various ways, for example, by cutting it. However, it is particularly preferred that the fluid-conducting structure be embossed into the surface of the base element. Embossing is understood here as the creation of patterns, reliefs, structures, or a texture on a surface, preferably by pressure or deformation. The particular advantage of embossing is that, in the case of an electrically conductive base element produced by an embossing process, this can be done simultaneously with the manufacturing process of the base element.

[0026] For unhindered flow guidance, it is also advantageous if the at least one channel-like depression is formed by an elongated and / or rectilinear and / or upwardly open flow channel.

[0027] In order not to impair the functionality of the flow connection formed by the fluid-conducting structure between the fluid-conductingly interconnected chambers, it is advantageous if the casing has and / or forms a defined covering region that covers and / or covers the at least one channel-like recess so that it is inaccessible from the outside. Particularly in conjunction with a casing applied by casting, such as injection molding, it must be ensured that the covering region exposes the at least one channel-like recess at least in some areas, in particular such that the covering region has a projection that projects into the at least one channel-like recess at a gap spacing from the channel base and / or the channel side walls.This is achieved in a particularly advantageous and functionally reliable manner with a structure in which the casing is made of a castable, in particular injection-moldable, material which shrinks upon curing and is suitable and designed to form a covering region after the base element has been encased, for example by overmolding, which covering region (again) exposes the at least one channel-like depression at least in regions as a result of shrinkage, and preferably has or forms a projection after curing and shrinkage which projects into the respectively assigned channel-like depression at a gap distance from the channel base and / or the channel side walls. With such a material, a defined and targeted shrinkage process is thus brought about or achieved after the base element has been encased or overmolding.accepted in order to create a “leakage” which, in conjunction with the at least one channel-like depression, enables a reproducible and targeted fluid exchange between individual chambers.

[0028] The insulating material can be any suitable insulating material. However, an insulating material made of a plastic material is particularly preferred and especially suitable for injection molding. Character description

[0029] The invention is explained in more detail below using a concrete embodiment which is merely an example.

[0030] They show: Fig. 1a a schematic and perspective top view of an exemplary embodiment of a composite component according to the invention, Fig. 1b the composite component according to Fig. 1a as a grid model, Fig. 2a the not yet coated electrically conductive base model without fluid conduction structure, Fig. 2b the not yet coated electrically conductive base element according to Fig. 2a with fluid conduction structure, Fig. 3a a schematic sectional view along the line AA of the Fig. 1b, Fig. 3b the detail C of the Fig. 3a, Fig. 4 a schematic sectional view along the line BB of the Fig. 1b.

[0031] In the Fig. Figure 1a shows a schematic and perspective top view of an exemplary embodiment of a composite component 1 according to the invention. The composite component 1 has an electrically conductive base element 2, which, as can be seen in particular from the lattice model Fig. 1b, is provided with a sheath 3 made of a plastic material serving as an insulating material for electrical insulation. For this purpose, the base element 2, which is made of an electrically conductive metal material, for example, is overmolded, for example by injection molding.

[0032] As this is particularly evident from the overview of Fig. 1a and Fig. 1b with the Fig. 2a and Fig. 2b, which show the base element 2 without the casing 3, the base element 2 in the example shown here has two spaced-apart, casing-free free areas 5, 6, each of which is located in the interior 4 of a chamber 7, 8 connected to the casing 3. Specifically, in the example shown here, a first free area 5 is located in a first chamber 7, while a second free area 6 is located in a second chamber 8.

[0033] The two free areas 5, 6, each located in different chambers 7, 8, are connected by means of a Fig. 1b and Fig. 2b are connected to each other in a fluid-conducting manner. Fig. 2a shows the base element 2 before the introduction of the fluid conducting structure 9, while the Fig. 2b shows the base element 2 with the fluid conduction structure 9 incorporated. Fig. 2b, those areas which are to form the two free areas 5, 6 after the production of the casing 3 are only dashed and schematically marked with the reference numerals 5, 6.

[0034] The base element 2 can be produced, for example, by an embossing process, so that the fluid conducting structure 9, according to a particularly preferred embodiment, is also embossed into the surface 11 of the base element 2 in conjunction with this embossing process.

[0035] The fluid guide structure 9 is formed here, for example, by several spaced-apart, here further exemplary parallel aligned, elongated and straight channel-like depressions 10, which form upwardly open flow channels. This is particularly evident from the section along the line AA of the Fig. 1b showing Fig. 3a in conjunction with detail C of the Fig. 3b.

[0036] From the Fig. 3a it is further clearly evident that the base element 2 is completely surrounded by the sheath 3 except for the free areas 5, 6 and is thus electrically insulated, whereby the sheath 3, which is particularly clear from the Fig. 3a, has or forms a cover region 12 which covers or covers the channel-like depressions 10 in an inaccessible manner from the outside, so that the fluid conducting structure 9 is formed in the region between the upper side or surface 11 of the base element 2 facing the casing 3 and the underside of the casing 3 facing the base element 2.

[0037] The casing 3 is preferably formed from a castable material that shrinks upon curing, for example, a plastic material. Although this material initially fills the channel-like recesses 10 of the fluid conducting structure 9 substantially completely, it shrinks after curing and thereby partially exposes the channel-like recesses 10, as can be seen in particular from the Fig. 3b. This Fig. 3b shows that after curing and shrinkage, a projection 13 remains, which projects into the respective associated channel-like recess 10 with a gap distance 14 to the channel base 15 or to the channel side walls 16, 17.

[0038] With such a composite component 1 it is achieved that the base element 2 is completely encased in the insulating material except for the defined free areas 5, 6 which are located in the area of ​​the two chambers 7, 8, whereby the two chambers 7, 8, however, as can be seen in particular from the section along the line BB Fig. 4, are flow-connected via the fluid guide structure, which flows into the associated free areas 5, 6.

[0039] As this is particularly evident from the overview of Fig. 1a, Fig. 1b and Fig. 4, the second chamber 8 can, for example, be designed as a fluid-tight, closed chamber. In the example shown here, this is done purely by way of example in that the second chamber 8, which forms an integral part of the casing 3, as well as the first chamber 7, which forms an integral part of the casing 3, are initially designed as upwardly open chambers which are connected to the casing 3 in one piece and of the same material. To produce a closed chamber, the second chamber 8 is then closed by means of a cover 18 in a fluid-tight, i.e. gas- and liquid-tight manner, for example by plastic welding. The first chamber 7, on the other hand, remains open with its associated first free area 5, which serves, for example, for the plug-in connection with a further electrical connection element, although this is not shown here.

[0040] As this further becomes clear, particularly from the overview of Fig. 1b and Fig. 4, in the example shown here, an electrical connection element 19 with a connection area 20 is guided in a fluid-tight manner from the outside through a chamber wall 21 into the fluid-tightly closed second chamber 8 and there is electrically conductively connected to the second free area 6 of the base element 2. In order to be able to insert the connection element 19 in a fluid-tight manner from the outside through the chamber wall into the second chamber 8, a sealing clip (not shown here) can be provided in the wall-side feed-through area.

[0041] How this continues to be good from the Fig. As can be seen from Figure 4, the connecting element 19, which is formed, for example, by a current-carrying rail or a bus track, is provided or sheathed with an insulation 22.

[0042] With such a structure, an advantageous leak test can be carried out by, for example, supplying the second chamber 8 with a defined initial quantity of a fluid, for example air, such that the fluid flows via the fluid guide structure 9 to the first chamber 7, which is coupled to a measuring device 23, which is shown here only very schematically and in dashed lines, with which the quantity of fluid flowing into the first chamber 7 is recorded. This measuring device 23 is coupled to an evaluation device 24, which is also shown only very schematically and by way of example, which assesses the tightness of the flow path, preferably in the present example the tightness of the second chamber 8 and / or the fluid guide structure 9 up to the first chamber 7, based on a comparison of the initial quantity of fluid with the quantity of fluid flowing in there. LIST OF REFERENCE SYMBOLS 1 composite component 2 Basic element 3 Sheathing 4 Interior 5 Open area, first 6 Open area, second 7th chamber, first 8th chamber, second 9 Fluid conduction structure 10 recesses 11 Surface 12 Coverage area 13 lead 14 gap distance 15 Canal bottom 16 Channel side wall 17 Channel side wall 18 lids 19 Connection element 20 Connection area 21 Chamber wall 22 Insulation 23 Measuring device 24 Evaluation device

Claims

[1] Composite component with an electrically conductive base element, wherein the surface of the electrically conductive base element (2) is provided with a sheath (3) made of an insulating material for electrical insulation, wherein the base element (2) has at least two spaced-apart, casing-free free areas (5, 6), each of which is located in the interior of a chamber (7, 8) connected to the casing (3), wherein at least two free areas (5, 6) located within different chambers (7, 8) are fluidly connected to one another by means of a fluid conducting structure (9), characterized by , that the fluid conducting structure (9) is formed by at least one channel-like depression (10) introduced into the surface (11) of the base element (2), which opens into the associated free areas (5, 6), and / or that the fluid conducting structure (9) is embossed into the surface (11) of the base element (2). [2] Composite component according to claim 1, characterized by that the electrically conductive base element (2) can be electrically conductively connected to a connection element (19) in at least one of the chambers (8). [3] Composite component according to claim 1 or 2, characterized by that at least one of the chambers (8) is designed as a fluid-tight closed chamber which is suitable and designed to be supplied with a fluid in such a way that the fluid flows via the fluid guide structure (9) to at least one further chamber (7). [4] Composite component according to claims 2 and 3, characterized by that the electrical connection element (19) with a connection area (20) is guided fluid-tight from the outside through a chamber wall (21) into the fluid-tight closed chamber (8). [5] Composite component according to claim 3 or 4, characterized bythat the at least one further chamber (7) is suitable and designed to be coupled to a measuring device (23) for measuring the amount of fluid flowing into the at least one further chamber (7) and / or that the free area (5) located in the further chamber (7) is suitable and designed to be coupled to a further connection element. [6] Composite component according to one of the preceding claims, characterized by that the chambers (7, 8) are an integral part of the casing (3) and are connected to it at least in regions in a uniform material and / or in one piece. [7] Composite component according to one of the preceding claims, characterized by that the fluid conducting structure (9) is formed in the region between the upper side of the base element (2) facing the casing (3) and the underside of the casing (3) facing the base element (2). [8] Composite component according to one of the preceding claims, characterized by that the at least one channel-like recess (10) is formed by an elongated and / or rectilinear and / or upwardly open flow channel. [9] Composite component according to one of the preceding claims, characterized by that the casing (3) has and / or forms a covering region (12) which covers and / or covers the at least one channel-like recess (10) in an inaccessible manner from the outside. [10] Composite component according to claim 9, characterized by that the cover region (12) exposes the at least one channel-like depression (10) at least in regions, wherein it is preferably provided that the cover region (12) has a projection (13) which projects into the at least one channel-like depression (10) with a gap distance (14) from the channel base (15) and / or from the channel side walls (16, 17). [11] Composite component according to claim 9 or 10, characterized byin that the casing (3) is formed from a castable material which shrinks upon curing and is suitable and designed to form a covering region (12) after the casing (3) of the base element has been produced, which covering region (12) exposes the at least one channel-like depression (10) at least in regions after curing and shrinking, preferably having a projection (13) after curing and shrinking which projects into the respectively assigned channel-like depression (10) at a gap distance (14) from the channel base (15) and / or from the channel side walls (16, 17). [12] Method for carrying out a leak test with a composite component (1) according to one of the preceding claims, in which at least one of the chambers (8) is designed as a fluid-tightly closable or closed chamber which is supplied with a fluid in such a way that a defined initial quantity of the fluid flows via the fluid guide structure (9) to at least one further chamber (7) which is coupled to a measuring device (23) for detecting the quantity of fluid flowing into the at least one further chamber (7), wherein an evaluation device (24) is provided which assesses the tightness of the flow path, preferably the tightness of the at least one fluid-tightly closable or closed chamber (8) and / or the fluid guide structure (9) up to the at least one further chamber (7), based on a comparison of the output quantity of the fluid with the inflowing fluid quantity.

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